2011 RANGER RZR / RZR S / RZR 4 SERVICE MANUAL PN 9923142
011 RANGER RZR / RZR S / RZR 4 SERVICE MANUAL FOREWORD The information printed within this publication includes the latest product information at time of print. The most recent version of this Service Manual is available in electronic format at www.polarisdealers.com. This Service Manual is designed primarily for use by certified Polaris Master Service Dealer technicians in a properly equipped shop and should be kept available for reference.
UNDERSTANDING MANUAL SAFETY LABELS AND DIRECTIONS Throughout this manual, important information is brought to your attention by the following symbols: WARNING SAFETY ALERT WARNING indicates a potential hazard that may result in severe injury or death to the operator, bystander or person(s) inspecting or servicing the vehicle. CAUTION SAFETY ALERT CAUTION indicates a potential hazard that may result in minor personal injury or damage to the vehicle.
GENERAL INFORMATION 1 MAINTENANCE 2 ENGINE 3 ELECTRONIC FUEL INJECTION 4 BODY / STEERING / SUSPENSION 5 CLUTCHING 6 FINAL DRIVE 7 TRANSMISSION 8 BRAKES 9 ELECTRICAL 10
GENERAL INFORMATION CHAPTER 1 GENERAL INFORMATION 1 MODEL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 MODEL IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 ENGINE DESIGNATION NUMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 VIN IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GENERAL INFORMATION MODEL INFORMATION Model Identification The machine model number must be used with any correspondence regarding warranty or service. Model Year Designation } } } } Machine Model Number Identification R 11 VH 76 AD Emissions & Model Option Basic Chassis Designation Engine Designation Engine Designation Number 1204276 RZR800HO-11 ................................................................... Twin Cylinder, Liquid Cooled, OHV 4 Stroke, Electric Start VIN Identification World Mfg.
GENERAL INFORMATION VEHICLE INFORMATION 1 Publication Numbers Model Model No. Owner’s Manual Parts Manual 2011 RANGER RZR R11VH76AA, AD, AF, AH 9922973 9922974 2011 RANGER RZR EPS R11VY76AO 9922973 9922974 2011 RANGER RZR S R11VE76AC, AD, AW 9922973 9923141 2011 RANGER RZR S EPS INT’L R11VM76FX 9922973 9922977 2011 RANGER RZR 4 R11XH76AW 9923148 9923149 2011 RANGER RZR 4 EPS R11XY76AA 9923148 9923149 NOTE: When ordering service parts be sure to use the correct parts manual.
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. / 196 cm Ground Clearance 10 in. / 25.4 cm Dry Weight 945 lbs. / 429 kg Gross Vehicle Weight 1727 lbs. / 783 kg Front Storage Capacity Cargo Box Dimension 25 lbs. / 11.3 kg 42 in. x 22 in. / 107 cm x 56 cm Cargo Box Capacity 300 lbs.
GENERAL INFORMATION MODEL: 2011 RANGER RZR / EPS MODEL NUMBER: R11VH76AA, AD, AF, AH MODEL NUMBER: R11VY76AO ENGINE NUMBER: 1204276 Drivetrain Transmission Type Polaris Automatic PVT Drive Ratio - Front 3.82:1 Drive Ratio - Final 3.70:1 Engine Shift Type In Line Shift - H / L / N / R / P Polaris Demand Drive Plus 6.75 oz. (200 ml) Platform H.O. Domestic Twin Cylinder, Liquid Cooled, 4-Stroke Front Gearcase Fluid Type / Capacity Engine Number 1204276 Engine Displacement 760cc H.O.
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. / 32 cm Dry Weight 1000 lbs. / 454 kg Gross Vehicle Weight 1782 lbs. / 808 kg Front Storage Capacity Cargo Box Dimension 25 lbs. / 11.3 kg 42 in. x 22 in. / 107 cm x 56 cm Cargo Box Capacity 300 lbs.
GENERAL INFORMATION MODEL: 2011 RANGER RZR S / EPS INT’L MODEL NUMBER: R11VE76AC, AD, AW MODEL NUMBER: R11VM76FX ENGINE NUMBER: 1204276 Drivetrain Transmission Type Polaris Automatic PVT Drive Ratio - Front 3.82:1 Drive Ratio - Final 3.70:1 Engine Shift Type In Line Shift - H / L / N / R / P Polaris Demand Drive Plus 6.75 oz. (200 ml) Platform H.O. Domestic Twin Cylinder, Liquid Cooled, 4-Stroke Front Gearcase Fluid Type / Capacity Engine Number 1204276 Engine Displacement 760cc H.O.
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. / 29 cm Dry Weight 1255 lbs. / 569 kg Gross Vehicle Weight 2155 lbs. / 978 kg Front Storage Capacity Cargo Box Dimension 25 lbs. / 11.3 kg 42 in. x 22 in. / 107 cm x 56 cm Cargo Box Capacity 300 lbs.
GENERAL INFORMATION MODEL: 2011 RANGER RZR 4 / EPS MODEL NUMBER: R11XH76AW MODEL NUMBER: R11XY76AA ENGINE NUMBER: 1204276 Drivetrain Transmission Type Polaris Automatic PVT Drive Ratio - Front 3.82:1 Drive Ratio - Final 3.70:1 Engine Shift Type In Line Shift - H / L / N / R / P Polaris Demand Drive Plus 6.75 oz. (200 ml) Platform H.O. Domestic Twin Cylinder, Liquid Cooled, 4-Stroke Front Gearcase Fluid Type / Capacity Engine Number 1204276 Engine Displacement 760cc H.O.
GENERAL INFORMATION MISC. SPECIFICATIONS AND CHARTS Conversion Table °C to °F: 9/5(°C + 32) = °F °F to °C: 5/9(°F - 32) = °C 1.10 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
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 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
GENERAL INFORMATION SAE Tap / Drill Sizes Decimal Equivalents Metric Tap / Drill Sizes 1.12 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
GENERAL INFORMATION Glossary of Terms ABDC: After bottom dead center. ACV: Alternating current voltage. Alternator: Electrical generator producing voltage alternating current. ATDC: After top dead center. BBDC: Before bottom dead center. BDC: Bottom dead center. BTDC: Before top dead center. 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).
GENERAL INFORMATION NOTES 1.14 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
MAINTENANCE CHAPTER 2 MAINTENANCE PERIODIC MAINTENANCE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3 BREAK-IN PERIOD / MAINTENANCE CHART KEY . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3 PRE-RIDE - 25 HOUR MAINTENANCE INTERVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4 50 - 500 HOUR MAINTENANCE INTERVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5 MAINTENANCE QUICK REFERENCE . . . . . . . . . . . . . . .
MAINTENANCE SUSPENSION (STANDARD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.31 SPRING PRELOAD ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.31 SUSPENSION (FOX™). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.31 SPRING PRELOAD ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.31 SHOCK COMPRESSION ADJUSTMENT . . . . . .
MAINTENANCE PERIODIC MAINTENANCE CHART Periodic Maintenance Overview Inspection, adjustment and lubrication of important components are explained in the periodic maintenance chart. Inspect, clean, lubricate, adjust and replace parts as necessary. When inspection reveals the need for replacement parts, use genuine Pure Polaris parts available from your Polaris dealer. NOTE: Service and adjustments are critical.
MAINTENANCE Pre-Ride - 25 Hour Maintenance Interval Maintenance Interval (whichever comes first) Item Hours Calendar Miles (KM) Steering - Pre-Ride - Front Suspension Rear Suspension - Pre-Ride - - Pre-Ride - - Pre-Ride - Tires Remarks Brake Fluid Level Brake Pedal Travel - Pre-Ride - - Pre-Ride - Brake Systems - Pre-Ride - Wheels / Fasteners - Pre-Ride - Frame Fasteners - Pre-Ride - Engine Oil Level - Pre-Ride - Air Filter - Pre-Ride - Inspect; r
MAINTENANCE 50 - 500 Hour Maintenance Interval Maintenance Interval (whichever comes first) Item Remarks Hours Calendar Miles (KM) Throttle Cable / Throttle E Pedal 50 H 6M 300 (500) Inspect; adjust; lubricate; replace if necessary Throttle Body Air Intake Ducts / Flange 50 H 6M 300 (500) Inspect ducts for proper sealing / air leaks 50 H 3M 500 (800) Lubricate all fittings, pivots, cables, etc.
MAINTENANCE Maintenance Quick Reference III. # Item Lube Rec. Method Frequency* 1 Engine Oil Polaris PS-4 Plus Performance Synthetic 4-Cycle Engine Oil Add oil to proper level on dipstick Change after 1st month or first 25 hours of operation, 100 hours thereafter; Change more often (25 hours) in severe duty conditions or short trip cold weather operation 2 Engine Coolant Polaris 60/40 Coolant Maintain coolant level in coolant reservoir bottle.
MAINTENANCE Maintenance Quick Reference, Continued..... III. # Item Lube Rec.
MAINTENANCE Grease Lubrication Points There are grease fittings at each A-arms pivot point, each front or rear stabilizer bushing, and on the front propshaft yoke. Apply grease until all traces of water have been purged out at each of these areas. Item Recommended Lube Method Frequency Polaris Premium U-Joint Grease Grease fittings every 500 miles (800 km). Grease before long periods of storage, and after thoroughly washing or submerging the vehicle.
MAINTENANCE LUBRICANTS / SERVICE PRODUCTS Polaris Lubricants, Maintenance and Service Products NOTE: Each item can be purchased separately at your local Polaris dealer. Part No. Description Additives / Sealants / Thread Locking Agents / Misc. Part No. Description Engine Lubricant 2870791 Fogging Oil (12 oz. Aerosol) 2876244 PS-4 Plus Synthetic 4-Cycle Engine Oil (Quart) 2876245 PS-4 Plus Synthetic 4-Cycle Engine Oil (Gallon) 2 2871950 Loctite™ Threadlock 242 (6 ml.
MAINTENANCE GENERAL VEHICLE INSPECTION AND MAINTENANCE 1. Locate the shift cable in the rear LH wheel well area. Clevis Pin Shift Cable Mount Pre-Ride / Daily Inspection Perform the following pre-ride inspection daily, and when servicing the vehicle at each scheduled maintenance.
MAINTENANCE FUEL SYSTEM AND AIR INTAKE Fuel Pump / Fuel Filters Fuel System The RZR 800 EFI engine uses a serviceable, high-volume, highpressure, fuel pump that includes a preliminary filter and an internal fine filter located before the pump regulator. WARNING 2 Fuel Pump Asm Gasoline is extremely flammable and explosive under certain conditions. Always stop the engine and refuel outdoors or in a well ventilated area.
MAINTENANCE Throttle Pedal Inspection 3. Remove the (2) push rivets retaining the air intake box and remove the box from the frame. 4. Loosen the hose clamp retaining the PVT intake duct and remove the duct from the vehicle to access the throttle cable freeplay adjustment. 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.
MAINTENANCE NOTE: While adjusting, lightly move the throttle pedal in and out. 7. Re-tighten the jam nut after final adjustment is made. 8. Apply a small amount of grease to the inside of the boot and slide it over the cable adjuster to its original position. 9. Reinstall the PVT intake duct and tighten the hose clamp. NOTE: If the filter has been soaked with fuel or oil it must be replaced. Seal 2 Air Filter 10. Reinstall the air intake box and (2) push rivets. 11.
MAINTENANCE Air Box / Air Filter Exploded View Front Foam Seal Air Intake Duct Intake Box Foil Primary Foam Seal Seal Breather Hose Intake Seal Breather Filter Fitting Boot Clip (3) Filter Ring Cap Air Box Can Clamps Seal Air Filter 2.14 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
MAINTENANCE ENGINE 6. Engine Oil Level NOTE: Make certain the dipstick is inserted all the way into the filler tube to keep the angle and depth of dipstick consistent. The twin cylinder engine is a wet-sump engine, meaning the oil is contained in the bottom of the crankcase. To check the oil level follow the procedure listed below: 1. Position vehicle on a level surface. 2. Place the transmission in Park (P). 3. Be sure the machine has sat for awhile before removing the dipstick. 7.
MAINTENANCE Engine Oil and Filter Service Always change engine oil and filter at the intervals outlined in the Periodic Maintenance Chart. Always change the oil filter whenever changing the engine oil. WARNING Personal injury can occur when handling used oil. Hot oil can cause burns or skin damage. NOTE: The sealing surface on the drain plug should be clean and free of burrs, nicks or scratches. 8. Reinstall drain plug and torque to 16 ft. lbs. (22 Nm). 9. Place shop towels beneath oil filter.
MAINTENANCE Engine Breather Hose Inspection Exhaust - Spark Arrestor The engine is equipped with a breather hose. Inspect the breather hose for possible kinks or wear. The hose is form fitted for a proper fit. Follow the breather hose from the side of the airbox to the engine valve cover. WARNING Do not clean spark arrestor immediately after the engine has been run, as the exhaust system becomes very hot. Serious burns could result from contact with the exhaust components.
MAINTENANCE TRANSMISSION AND GEARCASES Transmission / Gearcase Specification Chart GEARCASE LUBRICANT CAPACITY FILL PLUG TORQUE DRAIN / LEVEL CHECK PLUG TORQUE Transmission (Main Gearcase) AGL Plus Gearcase Lubricant 24 oz. (710 ml) 40-50 ft. lbs. (54-68 Nm) 30-45 in. lbs. (3-5 Nm) Transmission (Transfer Case) AGL Plus Gearcase Lubricant 14 oz. (414 ml) 40-50 ft. lbs. (54-68 Nm) 30-45 in. lbs. (3-5 Nm) Front Gearcase Demand Drive Plus 6.75 oz. (200 ml) 8-10 ft. lbs. (11-14 Nm) 8-10 ft.
MAINTENANCE Main Gearcase - Lubricant Level Check: 5. The fill plug is located on the side of the gearcase just below the shift lever bell crank. Maintain the fluid level even with the bottom of the fill plug hole. Add the recommended fluid through the fill plug hole until it begins to flow out the level plug hole. Do not overfill. 6. Reinstall the level check plug and torque to 30-45 in. lbs. (3-5 Nm). 1. Position vehicle on a level surface. 7. 2.
MAINTENANCE Front Gearcase Lubrication 1. Position vehicle on a level surface. The front gearcase lubricant level should be checked and changed in accordance with the maintenance schedule. 2. Remove the fill plug and check the fluid level. 3. Add the recommended fluid as needed. Maintain the lubricant level even with the bottom threads of the fill plug hole. 4. Reinstall the fill plug and torque to 8-10 ft. lbs. (11-14 Nm).
MAINTENANCE Rear Gearcase Lubrication Lubricant Change: The rear gearcase lubricant level should be checked and changed in accordance with the maintenance schedule. The drain plug is located on the bottom right side of the rear gearcase. • Be sure vehicle is positioned on a level surface when checking or changing fluid. • Check vent hose to be sure it is routed properly and unobstructed. 1. Remove the fill plug. 2. Place a drain pan under the drain plug. 3.
MAINTENANCE COOLING SYSTEM 4. Cooling System Overview The engine coolant level is controlled, or maintained, by the recovery system. The recovery system components are the recovery bottle, radiator filler neck, radiator pressure cap and connecting hose. NOTE: If overheating is evident, allow system to cool completely and check coolant level in the radiator and inspect for signs of trapped air in system.
MAINTENANCE Cooling System Pressure Test 2. Carefully straighten any bent radiator fins. Refer to Chapter 3 for cooling system pressure test procedure. 3. Remove any obstructions with compressed air or low pressure water. Cooling System Hoses 1. CAUTION Inspect all hoses for cracks, deterioration, abrasion or leaks. Replace if necessary. 2 Washing the vehicle with a high-pressure washer could damage the radiator fins and impair the radiators effectiveness.
MAINTENANCE FINAL DRIVE / WHEEL AND TIRE Radiator Removal 1. Remove the front bumper (see Chapter 5). 2. Remove the upper engine outlet hose and recovery hose from the top of the radiator. 3. Wheel and Hub Torque Table Remove the (2) upper radiator retaining bolts and the (4) bolts retaining the lower radiator mount bracket. Remove the bracket from the frame. Item Nut Type Specification Aluminum Wheels (Cast) Lug Nut #1 30 ft. lbs.
MAINTENANCE 6. 7. Torque the wheel nuts and/or hub nut to the proper torque specification listed in the torque table at the beginning of this section. Tread Depth 1/8" (3 mm) If hub nut was removed, install a new cotter pin after the hub nut has been tightened. 2 Use a new cotter pin Note Tire Rotation (RZR Only) Hub Nut Tire Pressure CAUTION Wheel Nuts (4) Valve stem facing outward CAUTION If wheels are improperly installed it could affect vehicle handling and tire wear.
MAINTENANCE ELECTRICAL AND IGNITION SYSTEM Battery Removal Battery Maintenance 1. Keep battery terminals and connections free of corrosion. If cleaning is necessary, remove the corrosion with a stiff wire brush. Wash with a solution of one tablespoon baking soda and one cup water. Rinse well with tap water and dry off with clean shop towels. Coat the terminals with dielectric grease or petroleum jelly. Remove the driver’s seat to access the battery.
MAINTENANCE Battery Installation IMPORTANT: Using a new battery that has not been fully charged can damage the battery and result in a shorter life. It can also hinder vehicle performance. Follow the battery charging procedure in Chapter 10 “Electrical” before installing the battery. 1. Ensure the battery is fully charged. 2. Place the battery in the battery holder and secure with holddown strap. 3. Coat the terminals with dielectric grease or petroleum jelly. 4.
MAINTENANCE 10. Apply anti-seize compound to the spark plug threads. 11. Install spark plugs and torque to specification. Recommended Spark Plug: Champion RC7YC3 Spark Plug Torque: 18 ft. lbs. (24 Nm) 12. Install the plug caps to the appropriate cylinder by referencing the MAG and PTO spark plug cap decals. STEERING Steering Inspection The steering components should be checked periodically for loose fasteners, worn tie rod ends, ball joints, and damage.
MAINTENANCE Tie Rod End / Wheel Hub Inspection • To check for play in the tie rod end, grasp the steering tie rod, pull in all directions feeling for movement. • Replace any worn steering components. Steering should move freely through entire range of travel without binding. • Elevate front end of machine so front wheels are off the ground. Check for any looseness in front hub/wheel assembly by grasping the tire firmly at top and bottom first, and then at front and rear.
MAINTENANCE Wheel Toe Adjustment If toe alignment is incorrect, measure the distance between vehicle center and each wheel. This will tell you which tie rod needs adjusting. • IMPORTANT: When tightening the tie rod end jam nuts, the rod ends must be held parallel to prevent rod end damage and premature wear. Damage may not be immediately apparent if done incorrectly. • After alignment is complete, torque jam nuts to specification. =T Tie Rod Jam Nut Torque: 12-14 ft. lbs.
MAINTENANCE SUSPENSION (STANDARD) SUSPENSION (FOX™) Spring Preload Adjustment Spring Preload Adjustment The front and rear shock absorber springs are adjustable by rotating the adjustment cam to change spring tension preload. The front and rear shocks have a preload adjustment. Suspension spring preload may be adjusted to suit different riding conditions or vehicle payloads.
MAINTENANCE Factory Preload Setting 4.2 in. (10.7 cm) Shock Compression Adjustment The compression damping adjustment is located on top of the shock ‘Piggyback’ reservoir of each shock. Decrease Preload Increase Preload 1 Use a flat blade screwdriver to make damping adjustments. NOTE: When the adjuster screw is turned clockwise until it stops, the damping is in the fully closed position. Turn the clicker clockwise to increase compression damping.
MAINTENANCE SUSPENSION (WALKER EVANS™) Shock Spanner Wrench Spring Preload Adjustment The front and rear shocks have a preload adjustment. Suspension spring preload may be adjusted to suit different riding conditions or vehicle payloads. WARNING 2 Shock Compression Adjustment The compression damping adjustment is located on top of the shock reservoir of each shock. Uneven adjustment may cause poor handling of the vehicle, which could result in an accident and serious injury or death.
MAINTENANCE BRAKE SYSTEM Brake Pad / Disc Inspection Brake Fluid Inspection 1. Check the brake pads for wear, damage, or looseness. Always check the brake pedal travel and inspect the brake fluid reservoir level before each operation. If the fluid level is low, add DOT 4 brake fluid only. 2. Inspect the brake pad wear surface for excessive wear. 3. Pads should be changed when the friction material is worn to .040” (1 mm). Brake fluid should be changed every two years.
MAINTENANCE MAINTENANCE LOG Service Date Hours / Miles (km) Service Performed / Comments Dealer / Technician 2 2.35 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
MAINTENANCE NOTES 2.36 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
ENGINE CHAPTER 3 ENGINE ENGINE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.2 CRANKCASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.2 OIL PUMP / GEARS / ENGINE COVER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3 STATOR COVER / STARTER / WATER PUMP / LUBRICATION SYSTEM . . . . . . . . . . 3.4 CYLINDER / CYLINDER HEAD / PISTON . . . . . .
ENGINE ENGINE SPECIFICATIONS Crankcase Exploded Views 3.2 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
ENGINE Oil Pump / Gears / Engine Cover Exploded View 3 3.3 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
ENGINE Stator Cover / Starter / Water Pump / Lubrication System Exploded View 3.4 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
ENGINE Cylinder / Cylinder Head / Piston Exploded View 3 3.5 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
ENGINE Engine EFI Sensors / Valve Cover / General Components Exploded View NOTE: See chapter 4 for more information on the EFI System 3.6 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
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 ± 1 (13 ± 1.35) Coolant Bleed Screw 6 mm 70 ± 10 (7.9 ± 1.15) - 3/8 NPT 120 (13.5) - Counterbalance Gear 8 mm - 22 ± 2 (30 ± 3) Crankcase Bolts 8 mm - * 22 ± 2 (30 ± 3) Crankcase Breather 5 mm 84 ± 8 (9.5 ± 0.
ENGINE 800 EFI Engine Service Specifications Cylinder Head - Engine Specifications Main Component: Cylinder Head 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" 0.00039" (42 0.010 mm) Camshaft Journal Outer Diameter - Center 1.634" 0.00039" (41.50 0.010 mm) Camshaft Journal Outer Diameter - PTO 1.614" 0.00039" (41 0.010 mm) Camshaft Journal Bore Inner Diameter - Mag 1.656" 0.00039" (42.07 0.
ENGINE Cylinder / Piston - Engine Specifications Main Components: Cylinder / Piston / Connecting Rod Cylinder Lifter Piston Piston Pin RZR800HO-11 (PN 1204276) Cylinder - Surface warp limit (mating with cylinder head) 0.004" (0.10 mm) Cylinder Bore - Standard 3.1495" (80 mm) Cylinder Taper Limit 0.00031" (0.008 mm) Cylinder Out of Round Limit 0.00030" (0.0075 mm) Cylinder to Piston Clearance .0015" .00059" (.040 .015 mm) Lifter Outer Diameter Standard 0.84245" 0.00025" (21.39 8 0.
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 WATER PUMP MECHANICAL SEAL INSTALLER PU-45543 UNIVERSAL DRIVER HANDLE PA-45483 MAIN SEAL INSTALLER PU-45658 CRANKSHAFT MAIN SEAL SAVER PA-45401 WATE
ENGINE ENGINE COOLING SYSTEM WARNING Cooling System Specifications Room Temperature 68F (20C) Thermostat Closed 175° F (79° C) Thermostat Open 180° F (82° C) Fan Off 194F (90C) Thermostat Full Open Lift 202° F (94° C) Fan On 205F (96C) Engine Temperature Overheat Indicator Engine Protection Ignition Misfire Engine Protection Shutdown Never remove pressure cap when engine is warm or hot. The cooling system is under pressure and serious burns may result.
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 Coolant Flow Diagram Filler Neck Engine Water Pump Engine Cylinder Head Bypass Recovery Bottle Engine Thermostat Housing 3.
ENGINE Cooling System Bleeding Procedure WARNING 3. Remove pressure cap and top off coolant. 4. Remove recovery bottle cap and fill bottle to the full line. Recovery Bottle Always wear safety glasses and proper shop clothing when performing the procedures in this manual. Failing to do so may lead to possible injury or death. Pressure Cap 3 CAUTION Use caution when performing these procedures. Coolant may be hot and may cause severe injury or burns.
ENGINE 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. GENERAL ENGINE SERVICE Engine Lubrication Specifications WARNING = Be sure to install the pressure cap before shutting off the engine. Coolant may spit out of the radiator. 11. Stop the engine and let cool, top off the radiator filler neck with coolant.
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. At this point, the oil is supplied to the main oil galley through a crankcase passage.
ENGINE Engine Removal 8. Remove the (2) screws from the rear of the center console (RZR / RZR S only). 9. Remove the rear seat base assembly from the vehicle: 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. IMPORTANT: Some engine repair procedures can be performed without removing the engine assembly from the vehicle.
ENGINE 11. Remove the (2) push rivets and remove the intake box from the vehicle. IMPORTANT: Mark or note which ignition coil wire goes to which cylinder and ignition coil post. The engine will misfire if the spark plug wires are installed incorrectly. The spark plug wires are marked with PTO and MAG from the factory and should be installed to the corresponding cylinder and ignition coil post. 17.
ENGINE 20. Remove the (4) fasteners retaining the stabilizer bar and bracket and remove the assembly from the vehicle. 24. Remove the remaining bolt attaching the airbox to the frame (see photo). Standard RZR Shown 21. Remove the engine breather hose from the valve cover. 22. Loosen the hose clamp between the throttle body and intake adaptor. Loosen Clamp 25. Remove the airbox and throttle body from the vehicle as an assembly. Take care in not allowing the throttle cable to bend excessively or kink.
ENGINE 27. Disconnect the fuel line from the fuel injector rail by slightly squeezing the lock tabs and gently pushing the connector lock out. To separate the lines, pull the fuel line from the tank strait down. NOTE: If the upper jam nut is moved, shift cable adjustment will be required during engine installation (see Chapter 2 “Shift Cable Inspection / Adjustment”). Squeeze locking tabs together Push lock outward 30. Disconnect the transmission gear indicator switch harness.
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. Cam Phase Connector 37. Pivot the A-arms upward and rear hub carriers downward and remove the drive shafts from the hub carriers. Hub Carrier 35. Remove the castle nuts from both rear wheel hubs. 38.
ENGINE 39. Disconnect the engine coolant temperature (ECT) sensor harness and the bypass coolant hose. 45. Remove RH engine mount fastener. ECT Connector 3 Coolant Bypass 40. Loosen the hose clamp and remove the lower coolant hose from the water pump cover inlet and drain coolant into a suitable container. 46. Remove the (2) lower bolts that retain the LH transmission mount to the frame. Remove (2) Lower Bolts 47.
ENGINE 48. Using an engine hoist, hook a chain between the engine / transmission mounting plate and the transmission / rear gearcase mounting plate. Standard RZR Shown 50. Remove propshaft from the transmission output shaft. 51. Then move assembly towards the front of the vehicle while lifting it out to allow the rear gearcase to clear the rear portion of the frame. 52. Then lift assembly high enough to clear vehicle frame and completely remove it from the vehicle to a work bench.
ENGINE Engine / Transmission Separation 4. 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. Use the following procedure to separate the engine from the assembly. 1. Remove the drive belt, drive clutch and driven clutch (see Chapter 6). 2.
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 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
ENGINE Rocker Arms 5. 1. Remove the valve cover. 2. Mark or tag rocker arms in order of disassembly to keep them in order for reassembly. If the push rod (A) is visibly bent, it should be replaced. A 3 Cylinder Head Removal 3. Inspect the wear pad at the valve end of the rocker arm for indications of scuffing or abnormal wear. If the pad is grooved, replace the rocker arm. NOTE: Do not attempt to true this surface by grinding. 4.
ENGINE Cylinder Head Inspection Valve Seal / Spring Service (On Engine) Thoroughly clean cylinder head surface to remove all traces of gasket material and carbon. NOTE: The following procedure is only for servicing the top end of the valve train when replacing valve springs or replacing valve seals. CAUTION Use care not to damage sealing surface. In some cases the valve train can be serviced while the cylinder head is still on the engine.
ENGINE Cylinder Head Disassembly 4. 1. 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. Carefully remove the cylinder components. 5. Remove valve guide seals. Mark the valves with a white pen. Remove the valves from the cylinder head. This will ensure that the valves are properly placed during engine reassembly. 3 Mark the Valves 2.
ENGINE Valve Inspection 1. Remove all carbon from valves with a soft wire wheel or brush. = In. / mm. 2. Check valve face for runout, pitting, and burnt spots. To check for bent valve stems, mount valve in a drill or use “V” blocks and a dial indicator. Valve Stem Diameter: Intake: 0.2356" 0.00039" (5.985 0.01 mm) Exhaust: 0.2351" 0.00039" (5.972 0.01 mm) 5. Measure valve guide (C) inside diameter at the top middle and end of the guide using a small hole gauge and a micrometer.
ENGINE Combustion Chamber 1. Clean all accumulated carbon deposits from combustion chamber and valve seat area with carbon cleaner and a soft plastic scraper. IMPORTANT: Do not use a wire brush, metal scraper, or abrasive cleaners to clean the bottom of the cylinder head. Extensive damage to the cylinder head may result. Wear safety glasses during cleaning. Combustion Area NOTE: Valve seat width and point of contact on the valve face is very important for proper sealing.
ENGINE 4. Inspect the cut area of the seat: * If the contact area is less than 75% of the circumference of the seat, rotate the pilot 180 and make another light cut. NOTE: When using an interference angle, the seat contact point on the valve will be very narrow, and is a normal condition. Look for an even and continuous contact point all the way around the valve face (A). B * If the cutter now contacts the uncut portion of the seat, check the pilot. Look for burrs, nicks, or runout.
ENGINE 9. Lubricate the valve guides with clean engine oil, and apply oil or water based lapping compound to the face of the valve. NOTE: Lapping is not required with an interference angle valve job. 10. Insert the valve into its respective guide and lap using a lapping tool or a section of fuel line connected to the valve stem. Cylinder Head Reassembly NOTE: Assemble the valves one at a time to maintain proper order. 1. Apply engine oil to valve guides and seats. 2.
ENGINE Valve Sealing Test Valve Lifter Removal / Inspection 1. 1. Remove the valve lifters by reaching into the crankcase and pushing the lifter up through the lifter bore by hand. 2. Thoroughly clean the lifters in cleaning solvent and wipe them with a clean, lint-free cloth. 3. Mark the lifters with a white pen if using the lifters for reassembly. This will ensure that the lifters are properly placed during engine reassembly. Clean and dry the combustion chamber area (A).
ENGINE Piston Removal 1. Remove the circlip. Mark the piston with a white pen to ensure proper orientation (if reused) during assembly. 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 a locating tab on the end which fits into a notch (B) in the upper oil ring land of the piston. To Remove: A) Remove the top rail first followed by the bottom rail. B) Remove the expander.
ENGINE Cylinder Inspection 4. 1. Remove gasket material from cylinder sealing surfaces. 2. Inspect the top of the cylinder (B) for warp using a straight edge (A) and feeler gauge (C). Refer to Ill. 1 and Ill. 2. A Inspect cylinder for taper and out of round with a telescoping gauge or a dial bore gauge. Measure in two different directions, front to back and side to side, on three different levels (1/2, down from top, in the middle, and 1/ 2, up from bottom). Record measurements.
ENGINE Cylinder Hone Selection and Honing Procedure Cylinders may be wet or dry honed depending upon the hone manufacturer’s recommendations. Wet honing removes more material faster and leaves a more distinct pattern in the bore. If cylinder wear or damage is excessive, it will be necessary to replace the cylinder. The cylinders are lined with a nicasil coating and are not repairable. Hone only enough to de-glaze the outer layer of the cylinder bore.
ENGINE Piston-to-Cylinder Clearance 2. 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. Subtract this measurement from the maximum cylinder bore measurement obtained during the “Cylinder Inspection” procedure.
ENGINE 4. Measure piston ring to groove clearance by placing the ring in the ring land and measuring with a thickness gauge. Replace piston and rings if ring-to-groove clearance exceeds service limits. 3. If the bottom installed gap measurement exceeds the service limit, replace the rings. If ring gap is smaller than the specified limit, file ring ends until gap is within specified range. NOTE: Always check piston ring installed gap after re-boring a cylinder or when installing new rings.
ENGINE 6. Inspect gear teeth on starter drive (A). Replace starter drive if gear teeth are cracked, worn, or broken. 7. Inspect the bendix bushing (C) in the mag cover for wear. Replace as needed. C 2871043 4. A Use caution when removing the wire holddown (B) and the stator assembly (D). Do not tap or bump the gear /stator housing cover or the stator. This could cause the seal around the gear/stator housing cover and the crankcase to break, causing a leak. Flywheel / Stator Removal / Inspection 1.
ENGINE 2. Remove the nut (C), washer (D) and water pump impeller (E). Remove part of the water pump seal behind the impeller. 5. Remove the starter bendix (G), wire holddown plate (H), and the woodruff key (I) from the crankshaft. The stator does not have to be removed at this point. E I 3 G H D C 6. 3. Remove flywheel nut and washer. 4. Install Flywheel Puller (PN 2871043) and remove flywheel (F).
ENGINE 8. Use a white pen to accent the timing marks on the following gears: camshaft gear (K), crankshaft gear (M), or counterbalance gear (N) This will ensure proper gear alignment and timing during reassembly of the gears. K Water Pump Gear Timing Marks CAUTION Wear safety glasses at all times. Use caution when working with the top gear. The springs could cause injury or become lost should they pop out. 12. Remove all three springs using one of the tapered pins from the Tapered Pins (PU-45497-1).
ENGINE 14. Inspect the gear teeth and the three tabs on the gears for wear. Inspect Teeth & Tabs To Assemble: • Hold the spring with one finger. • Start the pointed end of the tapered pin into the cam gear hole. Slowly push the dowel through the hole until the end of the dowel is almost flush with the spring. • Perform this procedure with all three tapered pins. • Do not push the pins too far through or the springs will pop out. NOTE: Do not remove the tapered pins at this time. 17.
ENGINE 19. Once the gears are pressed together, firmly hold the gears together with one hand. Carefully remove the Tapered Pins (PU-45497-1) by pulling them out one at a time with the other hand. 21. To remove the balance shaft gear, the flat side of the camshaft (P) must face the balance shaft gear. To rotate the camshaft, use the Cam Spanner Wrench (PU-45498) to rotate the camshaft so the flat side of the camshaft faces the balance shaft gear. PU-45498 P 20.
ENGINE 23. Inspect the crankshaft gear (Q) for broken or worn teeth. If the crankshaft gear does not need to be replaced, it does not need to be removed. If the crankshaft gear is damaged, remove the crankshaft gear with the Flywheel Puller (PN 2871043). 26. Rotate the water/oil pump gear (S), so that all four bolts are visible though the gear. Remove the four bolts with a hex wrench. Pull out the pump. S Q 24. Install the two puller bolts (R).
ENGINE 29. Remove the oil pressure relief. The oil pressure relief consists of a bolt, washer, spring, and valve (dowel). Inspect the valve (dowel) for signs of possible obstructions. Use compressed air to blow out any debris. 31. Carefully press the gear off the assembly while supporting the housing assembly. Press Off Gear CAUTION 30. Reinstall the valve (dowel chamfered end first). Install the spring, washer, and bolt. Torque to specification. 22 ± 2 ft. lbs. (30 ± 3 Nm).
ENGINE 34. Press shaft into the new bearing. 37. Remove thrust plate (U). U Press On Bearing 3 35. Press the bearing/shaft assembly using the bearing's outer race. Do not use the shaft to press the assembly into the housing, as bearing damage may result. Install retaining ring. Press Bearing / Shaft Assembly using outer race only 38. Remove PTO end engine mount. Remove crankcase bolts. Tap on the reinforced areas on the cases using soft hammer. Carefully separate the two crankcase halves.
ENGINE 39. Remove and clean oil pick up (V) and oil baffle weldment (W). W Camshaft Inspection 1. Thoroughly clean the cam shaft. 2. Visually inspect each cam lobe for wear, chafing or damage. 3. Measure height of each cam lobe using a micrometer. Compare to specification. V 40. Remove balance shaft and crankshaft. Cam Lobe Height = In. / mm. Cam Lobe Height Intake (Std): 1.357” (34.477 mm) 41. Remove and inspect crankshaft main journal bearings for abnormal wear.
ENGINE 4. Measure camshaft journal outside diameters (O.D.). ENGINE REASSEMBLY 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”). C B A NOTE: Before assembly, clean the bolts and bolt holes with Primer N (PN 2874275) to remove any debris. This will ensure proper sealing when installing bolts. 1. Install oil pick up (A), if removed.
ENGINE NOTE: Always install new balance shaft bearings. 4. 7. Apply assembly lube to cam journals and balance shaft bearing surfaces of the MAG case halve. Install camshaft and balance shaft. Assemble the crankcase halves. Apply LocTite™ 242 (PN 2871949) to the threads and pipe sealant to the bolt flanges. Torque bolts to specification following torque pattern at beginning of this chapter. =T Crankcase Bolt Torque: 22 2 ft. lbs. (30 3 Nm) Torque in sequence 8.
ENGINE 10. Lubricate connecting rods with PS-4 PLUS synthetic engine oil. 13. Install piston assemblies into cylinder aligning the piston pin holes, to ensure proper alignment of the pistons to the connecting rods upon assembly. Partially install the piston pins into the pistons. 3 11. Install new cylinder gasket on crankcase. Align gasket on the dowel pins for proper gasket alignment.
ENGINE NOTE: While installing in piston circlips, cover all engine passages. The clip could fall into the engine during installation. 17. Assemble rotors as marked when disassembled. Use a cleaner to remove the marks previously made on the rotors. Line Up Marks 18. Apply assembly lube or oil to the rotors on the oil pump shaft. 16. Install camshaft thrust plate (G) with new bolts. Torque bolts to specification.
ENGINE 20. Install oil pump housing bolts (H). The new bolts contain patch lock, so Loctite is not needed on the new bolts. Torque bolts to specification and follow the torque sequence at beginning of the chapter. 22. Before installing the crankshaft gear (I), heat the crankshaft gear to 250 F (121C) on a hot plate (J). J I H 3 CAUTION NOTE: Occasionally spin the oil pump when installing bolts to check for binding of the rotors. =T Oil Pump Bolt Torque: 84 8 in. lbs. (9.50 0.
ENGINE 25. Install counter balance shaft gear (J) with new key, aligning timing marks with crankshaft gear (I). Install washer and bolt. Use the Gear Holder (PU-45838). Torque to specification. J NOTE: Cam Spanner Wrench (PU-45498) is only needed to rotate the camshaft when the entire valve train is assembled. PU-45498 I PU-45838 27. Reinstall the camshaft gear; so the timing marks are properly aligned. Install the washer and bolt. Torque to specification.
ENGINE 28. Before installing the gear / stator housing, replace the seals in the cover. Install a new water pump seal (N) into the gear / stator housing. Use the Water Pump Mechanical Seal Installer (PA-44995) to properly install the seal to the correct depth in the cover. NOTE: Install the crankshaft seal (P) with the seal lip facing out (towards the crankcase). P PA-44995 PA 99 -4 4 3 5 N Seal lip goes towards the crankcase. 30.
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. With the tools installed, carefully place the gear/ stator housing cover over the protection tools. 36. Secure the gear / stator housing cover to the crankcase with the cover bolts.
ENGINE NOTE: Before assembly, clean the bolts and bolt holes with Primer N (PN 2874275) to remove any debris. This will ensure proper sealing when installing bolts. 39. Install water pump cover (R) with new O-ring seal. Torque bolts to specification in proper sequence (see Page 3.4). Install the O-ring dry No lubricants 37. Install shaft seal with ceramic surface facing inward. R 3 96 ± 3 in. lbs. (10.85 ± 1.35 Nm) =T 38. Install water pump impeller (P).
ENGINE Flywheel / Stator Installation =T NOTE: Before assembly, clean the bolts and bolt holes with Primer N (PN 2874275) to remove any debris. This will ensure proper sealing when installing bolts. 1. Install stator assembly (S) and bolts. Torque bolts to specification. 2. Install the wire hold down bracket (T). Install two new wire hold down bolts. New bolts contain patch-lock. Torque bolts to specification, following the proper bolt torque sequence.
ENGINE 2. Install cylinder head on cylinder. 3. Lubricate threads and top of washers underside of bolt head with engine oil. Install head bolts (C) and torque to specification in sequence. 4. Lubricate push rods (D) and install into lifters. D C 3 5. Lubricate rockers (E) with engine oil. E 6. Verify pushrods are engaged in lifters. 7. Install rockers. Be sure that tab of fulcrum (F) is seated in head stand-off. Torque bolts to specification.
ENGINE 8. Install breather reed (G) into rocker cover (H). Lightly apply black RTV sealant to the outer edges of the breather reed. The reed has a tab and will assemble one-way only. Torque the breather bolts to specification. 11. Install thermostat (J), new O-ring, and thermostat housing. Torque to specification. K 20 ± 5 in. lbs. (2.5 ± .55 Nm) 17 ± 2 ft. lbs. (23 ± 3 Nm) H G I L 120 in. lbs. (13.5 Nm) J 84 ± 8 in. lbs. (9.5 ± 0.9 Nm) =T =T Breather Bolt Toque: 20 ± 5 in. lbs. (2.5± 0.
ENGINE 1. After the engine is completely assembled and ready for installation, the engine must be properly primed with Polaris PS-4 PLUS Synthetic Engine Oil (PN 2876244). Fill the oil filter three-quarters full with Polaris PS-4 PLUS Synthetic Engine Oil (PN 2876244). Let the oil soak into the filter for 8-10 minutes. Install the filter onto the engine. ENGINE INSTALLATION Engine Assembly and Installation Use the following procedure to reinstall the engine assembly.
ENGINE • Install engine / transmission / rear gearcase mounting hardware and torque to specification. Engine Break-In Period The break-in period consists of the first 25 hours of operation, or the time it takes to use 14 gallons (53 liters) of fuel. Careful treatment of a new engine and drive components will result in more efficient performance and longer life for these components. CAUTION 30 ft. lbs. (41 Nm) Use only Polaris PS-4 PLUS Synthetic Engine Oil. Never substitute or mix oil brands.
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 • Incorrect spark plug heat range or gap • PVT system calibrated incorrectly/ components worn or mis-adjusted • Fuel quality poor (old) or octane too high • Air box removed (reinstall all intake components) • Incorrect ignition timing • Restricted exhaust system 3 • Cam worn excessively • Low compres
ENGINE Excessive Smoke and Carbon Buildup • Excessive piston-to-cylinder clearance Cooling System 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 • Wrong type/mix of coolant • Restricted breather • Faulty pressure cap or system leaks • Air filter dirty or contaminated • Restricted system (mud or debris in radiator fins causing restriction to air flow, passages blocked in radiator, lines
ELECTRONIC FUEL INJECTION CHAPTER 4 ELECTRONIC FUEL INJECTION GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2 SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2 SERVICE NOTES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.4 EFI SYSTEM EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . .
ELECTRONIC FUEL INJECTION GENERAL INFORMATION WARNING Throttle Position Sensor (TPS) Tester - 2201519-A This tester allows the use of a digital multi-meter to test TPS function as well as perform the TPS adjustment procedure. * Gasoline is extremely flammable and explosive under certain conditions. * EFI components are under high pressure. Verify system pressure has been relieved before disassembly. * Never drain the fuel system when the engine is hot. Severe burns may result. * Do not overfill the tank.
ELECTRONIC FUEL INJECTION TPS Tester Regulator - 547927 This tester regulator is part of 2201519-A. It regulates the 9 volt battery voltage to a 5 volt reference input, required when using the TPS Tester Wire Harness (PU-47466). Fuel Pressure Gauge Adaptor - PV-48656 Adaptor works with PU-43506-A Disconnect here and connect in-line w/fuel pump outlet NOTE: You may already have this regulator (marked 4010264) as part of another TPS Tester Kit.
ELECTRONIC FUEL INJECTION Digital Wrench™ - Diagnostic Connector Located under the dash connected to a sealed plug. Service Notes • For more convenient and accurate testing of EFI components, it is recommended dealers utilize the Digital Wrench™ Diagnostic Software (dealer only), or testing may be done manually using the procedures provided. • 80% of all EFI problems are caused by wiring harness connections.
ELECTRONIC FUEL INJECTION EFI System Exploded View 1. Electronic Control Unit (ECU) 2. Temperature / Manifold Absolute Pressure Sensor (T-MAP) 3. Crankshaft Position Sensor (CPS) 4. Fuel Injectors 5. Fuel Filter 6. Fuel Pump / Regulator / Fuel Level Sender (located in fuel tank) 7. Fuel Rail 8. Engine Coolant Sensor (ECT) 9. Throttle Position Sensor (TPS) 10. Throttle Body 11. Ignition Coil 12. Spark Plugs 13. Spark Plug Wires 14. Idle Air Control (IAC) 15.
ELECTRONIC FUEL INJECTION EFI System Component Locations 1. 3. Electronic Control Unit (ECU) - Located behind the driver’s seat (RZR / RZR S) or under the left rear passenger seat (RZR 4). Crankshaft Position Sensor (CPS) - Located in the magneto cover between the engine and transmission, just in front of the rear gear case. CPS ECU RZR / RZR S 4. Fuel Injectors / Fuel Rail - Attached to the fuel rail located in the intake track of the cylinder head. Fuel Rail ECU Fuel Injectors RZR 4 2.
ELECTRONIC FUEL INJECTION 9. Located in Fuel Tank Camshaft Phase Sensor - 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 Connection ECT Fuel Pump Camshaft Phase Sensor 4 Preliminary Filter 6. Throttle Body - Located between the rubber air box boot and rubber cylinder head adaptor. 7.
ELECTRONIC FUEL INJECTION FUEL TANK Exploded View Fuel Flow Fuel Rail Fuel Tank Pressure Regulator Fuel Filters Fuel Pump Assembly Quick Connect Fuel Line 4.8 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
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: 1. Place a shop towel around the fuel line to catch any dripping fuel. Squeeze the connector tabs together and push the locking slide back.
ELECTRONIC FUEL INJECTION 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), engine temperature, speed (RPM), camshaft position and throttle position. These primary signals are compared to the programming in the ECU computer chip, and the ECU adjusts the fuel delivery and ignition timing to match the values.
ELECTRONIC FUEL INJECTION RANGER RZR 800 EFI RPM Limit: Max RPM Limit - Injector and ignition suppression. • RZR: 6600 RPM (All Gears) TEMP / MANIFOLD ABSOLUTE PRESSURE SENSOR (T-MAP) Operation Overview • RZR S / RZR 4: 6750 RPM (All Gears) Mounted on the throttle body intake manifold, the T-MAP sensor performs two functions in one unit. ECU Service Never attempt to disassemble the ECU. It is sealed to prevent damage to internal components.
ELECTRONIC FUEL INJECTION 7. Install the sensor by inserting it with a twisting motion to properly seat the grommet. Torque to Specification T-MAP Bolt The two-tooth gap creates an “interrupt” input signal, 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 during the first two revolutions each time the engine is started.
ELECTRONIC FUEL INJECTION 4. 5. If the resistance is correct. - Test the main harness circuit between the sensor connector terminals and the corresponding pin terminals at the ECU (see wiring diagram). - Check the sensor mounting, air gap, flywheel ring gear for damage or runout, and flywheel key. Follow the “CPS Replacement” procedure to inspect CPS and flywheel ring gear for damage. 5. Remove the bottom bolt that attaches the bracket to the rear gearcase through the hole in the frame support as shown.
ELECTRONIC FUEL INJECTION 8. Lift the mounting bracket straight up and out from the vehicle. Remove Bracket Installation IMPORTANT: When reinstalling the transmission to rear gearcase mount bracket, it is extremely important to torque all (7) fasteners to specification. Refer to the following procedure. NOTE: Special tool (PA-48873) will be required to torque the mounting bracket fasteners when the transmission and rear gearcase are installed in the vehicle. Special Tool PA-48873 9.
ELECTRONIC FUEL INJECTION 4. Using special tool (PA-48873), torque the (3) bolts that retain the front portion of the mounting bracket to the transmission. 5. Remove the special tool and attach an extension to the torque wrench. Torque the bottom bolt that attaches the bracket to the rear gearcase through the hole in the frame support. Upper Transmission Bolt Bottom Rear Gearcase Bolt NOTE: Special Tool is not required for this torque. 4 Torque with an extension Middle Transmission Bolt 6.
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. Fuel Injectors 7. Torque the remaining bolt that attaches the bracket to the front side of the rear gearcase.
ELECTRONIC FUEL INJECTION Fuel Injector Service Fuel Injector Test Injector problems typically fall into three general categorieselectrical, dirty / clogged, or leakage. An electrical problem usually causes one or both of the injectors to stop functioning. Several methods may be used to check if the injectors are operating. NOTE: The harness connector and locking spring is bonded to the fuel injectors with an epoxy. DO NOT attempt to disconnect the connector from the fuel injectors.
ELECTRONIC FUEL INJECTION Fuel Injector Replacement 1. Be sure the engine has cooled enough to work on. 2. Remove the seats and rear service panel: (see chapter 5) • RZR / RZR S: Remove both driver and passenger seats • RZR 4: Remove both rear passenger seats 3. Remove the rear cargo box (see chapter 5). 4. Place a suitable container below the quick connect plug at the end of the fuel rail. Hold a shop rag over the plug and remove it to depressurize the fuel system.
ELECTRONIC FUEL INJECTION FUEL PUMP The ECU switches off the pump preventing the continued delivery of fuel in these instances: Operation Overview An electric fuel pump assembly is used to transfer fuel to the EFI system from inside the fuel tank. This assembly includes the fuel pump, fuel filters, regulator and fuel gauge sender. The pump is rated for a minimum output of 25 liters per hour at 45 +/- 2 psi and has two non-serviceable fuel filters.
ELECTRONIC FUEL INJECTION Fuel Pump Test If a fuel delivery problem is suspected, make certain the fuel pump filters are not plugged, that the pump is being activated through the ECU, all electrical connections are properly secured, the fuses are good, and a minimum of 7.0 volts is being supplied. If during starting the battery voltage drops below 7.0 volts, the ECU will fail to operate the system. Normal Fuel Pressure: 45 +/- 2 psi.
ELECTRONIC FUEL INJECTION Fuel Pump Replacement 5. WARNING 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. Clean this area Always wear safety goggles when working with high pressure or flammable fluids. Failure to do so could result in serious injury or complications. 1. Remove the passenger seat to access the fuel pump. 2.
ELECTRONIC FUEL INJECTION 7. Carefully lift the fuel pump out of the fuel tank. As the fuel pump assembly is being removed, be aware of float arm and pump pre-filter. Hold the float arm to the pump body as you lift and tilt the pump to ensure that the float arm is not bent when removed from the tank. 8. Transfer old fuel pump to a suitable container capable of safely holding fuel. The fuel pump will retain some fuel. 9. Inspect the inside of the fuel tank for debris (may require flashlight and mirror).
ELECTRONIC FUEL INJECTION 13. Install fuel pump into fuel tank, hold float arm to the pump body and tilt assembly to ensure float arm does not get caught or bent during installation. 17. Torque PFA nut to specification using the Fuel Pump Service Tool (PU-50326) and a calibrated torque wrench. 14. Gently push down on fuel pump flange ensuring flange is centered. 70 ± 5 ft. lbs. (95 ± 7 Nm) 15.
ELECTRONIC FUEL INJECTION Fuel Tank Removal (RZR / RZR S) 5. Remove the fuel tank vent hose clamp with a suitable pliers and remove the vent line from the tank vent fitting. 6. Remove the rear seat base assembly from the vehicle by removing the (2) fasteners retaining the rear seat base. 7. Remove the shift knob and center console from the vehicle. 8. Remove the push rivets and screws retaining the RH rocker panel and remove panel from the vehicle (see Chapter 5).
ELECTRONIC FUEL INJECTION 9. Remove the lower bolt retaining the seat belt mechanism near the rear RH portion of the fuel tank. Once removed, place the mechanism in the rear cargo box to keep it out of the way. Set bracket by shift lever Do not cut plastic strap 12. Remove the (2) tank bracket fasteners that retain the fuel tank in the chassis. Swing the tank brackets clear of the fuel tank for removal. 10.
ELECTRONIC FUEL INJECTION Fuel Tank Removal (RZR 4) 5. Remove the lower bolt retaining the seat belt mechanism near the rear RH portion of the fuel tank. Once removed, place the mechanism in the rear cargo box to keep it out of the way. 6. Remove the (3) Torx fasteners and (2) push rivets from the rear RH panel divider. Remove the panel divider from the vehicle (see Chapter 5). IMPORTANT: Syphon as much fuel from the tank as possible before attempting to remove it from the vehicle.
ELECTRONIC FUEL INJECTION 7. Remove the rear seat support by removing the 5/16” fastener and 7/16” fastener retaining the right side of the rear seat support. Remove the 7/16” fastener from the left side of the rear seat support. Remove the rear seat support from the vehicle. 9. Disconnect the fuel pump electrical harness. Disconnect Here Remove Remove Do Not Remove 10. Remove the fuel tank vent hose clamp with a suitable pliers and remove the vent line from the tank vent fitting.
ELECTRONIC FUEL INJECTION 12. Lift the rear of the fuel tank up first and carefully lift the fuel tank up and out from the vehicle. Fuel Tank Installation 1. Carefully reinstall the fuel tank assembly. 2. Reinstall the (2) fuel tank brackets and fasteners. 3. Reinstall the (3) shift lever support bracket fasteners (RZR / RZR S). 4. Reinstall the rear RH fender well and secure with fasteners (RZR / RZR S only). Reinstall the rear RH panel divider and secure with fasteners (RZR 4). 5.
ELECTRONIC FUEL INJECTION IDLE AIR CONTROL (IAC) IAC Replacement Operation Overview 1. Remove the seats, rear service panel and the rear cargo box (see Chapter 5). The Idle Air Control (IAC) is used to stabilize the idle quality of the engine at cold start-up and after warm-up operations. 2. Loosen the hose clamps retaining the throttle body. 3. Remove the throttle body from the intake track and plug the intake boots with a clean shop towel.
ELECTRONIC FUEL INJECTION THROTTLE POSITION SENSOR (TPS) TPS Resistance Tests Operation Overview The TPS is a non-serviceable item. If it is faulty, it must be replaced. It can be tested using the following method: The throttle position sensor (TPS) is used to indicate throttle plate angle to the ECU.
ELECTRONIC FUEL INJECTION Verify TPS Tester Reference Voltage 3. A 5 volt reference voltage from the TPS Tester harness is required for the TPS test to be accurate. Refer to the instructions provided with the TPS Tester (2201519-A) or follow the bullet point steps below to check reference voltage. Remove the throttle body from the intake track and plug the intake boots with a clean shop towel. Reference Voltage Test: • Insert black voltmeter probe into the test port as shown.
ELECTRONIC FUEL INJECTION 3. Loosen the TPS mounting screws (see Figure 4-31). TPS Adjustment Using TPS Tester (PN 2201519-A): 1. If Digital Wrench™ is unavailable, assemble the TPS Tester according to the instructions. Refer to “TPS Tester / Regulator” for proper set-up and testing. Verify the 9 volt tester battery is new. 2. Plug the TPS Tester harness into the new TPS. 3. Set your voltmeter to read DC Volts. Insert the red and black voltmeter probes into the test ports as shown. Figure 4-31 4.
ELECTRONIC FUEL INJECTION CAMSHAFT PHASE SENSOR Operation Overview Mounted on the engine crankcase, the Cam Phase Sensor provides camshaft position information to the ECU to be used along with the crankshaft position data to allow for sequential fuel injection. ECT Cam Phase Sensor Replacement 1. Access the sensor through the right rear wheel well. 2. Disconnect vehicle harness from the sensor. 3. Remove the retaining bolt and remove the sensor from the engine. 4.
ELECTRONIC FUEL INJECTION ENGINE COOLANT TEMPERATURE SENSOR (ECT) Refer to Chapter 10 for additional ECT sensor information. Polaris dealers can test the sensor by using the Digital Wrench™ Diagnostic Software (dealer only). Operation Overview ECT Sensor Resistance Readings Mounted on the cylinder head, the engine temperature sensor measures coolant temperature. The engine temperature sensor is a Negative Temperature Coefficient (NTC) type sensor, as the temperature increases the resistance decreases.
ELECTRONIC FUEL INJECTION IGNITION COIL Ignition Coil Tests Operation Overview The ignition coil can be tested by using an ohm meter. Use the following illustration and specification table to test the ignition coil resistance. The ignition coil is used to provide high voltage to fire the spark plugs. When the ignition key is on, DC voltage is present in primary side of the ignition coil windings.
ELECTRONIC FUEL INJECTION EFI DIAGNOSTICS 3. A set of three numbers will appear in the information area. • The first number (located far left) can range from 0 to 9. This number represents the total number of trouble code present (example: 2 means there are 3 codes present). Instrument Cluster Trouble Code Display NOTE: The diagnostic mode is accessible only when the check engine MIL has been activated. • The second number (located top right) can be 2 to 6 digits in length.
ELECTRONIC FUEL INJECTION DIAGNOSTIC TROUBLE CODE TABLE Component Condition SPN FMI Digital Wrench™ P-Code P0563 Voltage Too High 3 C1063 System Power (Battery Potential / Power Input) 168 P0562 Voltage Too Low 4 C1064 Engine Speed (This is applicable when the EPS module gets the engine speed from the ECM) Received Engine Speed Has Error 190 19 C1066 Gear Sensor Signal Voltage Too Low 523 4 P0916 ECU Memory EEPROM: Read/Write Failure 628 12 C1073 Crankshaft Position Sensor (CPS) Pl
ELECTRONIC FUEL INJECTION DIAGNOSTIC TROUBLE CODE TABLE Component Condition SPN FMI Digital Wrench™ P-Code Steering Torque Partial Failure Condition Exists 520223 31 C1052 Steering Torque Full Failure Condition Exists 520224 31 C1053 16 C1054 0 C1055 Greater than 110° C (230° F) EPS Inverter Temperature 520225 Greater than 120° C (248° F) EPS CAN Communications Receive Error No RX Message for 2 Seconds 520226 2 U0100 EPS CAN Communications Transmit Error No TX Message for 2 Second
ELECTRONIC FUEL INJECTION EFI Troubleshooting Poor Idle Fuel Starvation / Lean Mixture Symptom: Idle Too High (If greater than 1300 RPM when engine is warm). Symptoms: Hard start or no start, bog, backfire, popping through intake / exhaust, hesitation, detonation, low power, spark plug erosion, engine runs hot, surging, high idle, idle speed erratic.
ELECTRONIC FUEL INJECTION DIGITAL WRENCH™ OPERATION Digital Wrench™ Diagnostic Software Overview 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.
ELECTRONIC FUEL INJECTION Digital Wrench™ - Diagnostic Connector Digital Wrench™ Version and Update ID Located under the dash connected to a sealed plug. Knowing what Digital Wrench™ version and update is installed will help determine which updates are required. NOTE: Versions and updates are subject to change. 1. Open the Digital Wrench™ software. Locate the version ID shown on the lower right side of the Digital Wrench™ start-up screen. Version: 3.
ELECTRONIC FUEL INJECTION Digital Wrench™ Updates 6. If the update file date listed is newer than your current version and update (see “Digital Wrench™ Version and Update ID”), download the file. 7. Click on the link shown above, save the file to your hard disk and then double-click the icon to start the update process. Updates are released for Digital Wrench™ via the Internet at: http://polaris.diagsys.com. The Digital Wrench™ website can also be accessed through the dealer website at: www.
ELECTRONIC FUEL INJECTION Digital Wrench™ Feature Map 4 4.43 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
ELECTRONIC FUEL INJECTION Engine Controller Reprogramming (Reflash) • KNOW THE PROCESS: If you are not familiar with the entire reprogramming process, review the HELP section of the diagnostic software before you attempt reprogramming. Click on the ? on the tool bar or press F11. The information in the on-line help is the most current and complete information available. This should be your first step until you are familiar with the process.
ELECTRONIC FUEL INJECTION 2. Connect the SmartLink Module cables to the PC and vehicle. See “Digital Wrench™ - Diagnostic Connector” on page 4.41. 3. Open the Digital Wrench™ program. 4. Select the model year, product line and vehicle description by selecting the “Change Vehicle Type” icon. 5. 6. Select “Engine Controller Reprogramming”. 7. Select the file you want to load into the ECU then click the “Continue” icon to proceed to the Integrity Check. 8.
ELECTRONIC FUEL INJECTION 9. Copy (CTRL+C) the Request Code that will be required on the dealer website in the next step. DO NOT CLOSE Digital Wrench™ or the Request Code will be invalid. NOTE: All characters are letters; there are no numbers in a request code. 12. Select the same file type from the list that you selected previously while in Digital Wrench™. Enter the VIN along with the customer’s name and address. When completed, click the Authorize button once to proceed.
ELECTRONIC FUEL INJECTION 15. At this point the reflash process will begin. Do not touch the vehicle or PC during the process. 4 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. 4.47 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
ELECTRONIC FUEL INJECTION EFI SYSTEM ELECTRICAL OPERATION Block Diagram 4.48 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
BODY / STEERING / SUSPENSION CHAPTER 5 BODY / STEERING / SUSPENSION TORQUE SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CAB FRAME (RZR / RZR S) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CAB FRAME (RZR 4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BODY / STEERING / SUSPENSION REAR A-ARMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.36 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.36 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.37 EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BODY / STEERING / SUSPENSION TORQUE SPECIFICATIONS SPECIAL TOOLS ITEM TORQUE VALUE TOOL DESCRIPTION PART NUMBER RZR 37 ft. lbs. (50 Nm) Gas Shock Recharging Kit 2200421 Front LH/RH Upper / Lower A-Arm Bolt 2201640 40 ft. lbs. (54 Nm) Shock Shaft Seal Protector .625" Diameter RZR IFP Tool PS-45908 Shock Spanner Wrench 2871095 Shock Spanner Wrench (Walker Evans and Fox Shocks) 2870803 38 ft. lbs.
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. 1. 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. Tighten screws to 25-28 ft. lbs. (34-38 Nm). 2. Place the assembled cab frame onto the vehicle and align the rear mount holes.
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. Assemble at the coupler joint and secure with (3/8-16 x 1 1/4) bolts and (3/8-16 Nyloc) nuts. Tighten bolts to 25-28 ft. lbs.
BODY / STEERING / SUSPENSION BODY EXPLODED VIEWS Side Safety Nets 5.6 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
BODY / STEERING / SUSPENSION Dash Instruments / Controls / Glovebox A 5 F D E A. Instrument Cluster / Speedo B B. Headlight Switch C. AWD/2WD or AWD/2WD/TURF Switch C G D. 12 Volt Accessory Receptacle E. Key Switch F. Hazard Switch (INT’L) G. Switch; Turn, Lights, Horn (INT’L) 5.7 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
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 T27 Screws 5.8 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
BODY / STEERING / SUSPENSION Front Bumper Front Bumper Support T30 Screws Radiator Screen Front Bumper O-Ring Bulb T25 Screw 5 T27 Screw Headlight Winch Pocket Cover Rear Bumper LH Tail Light T27 Screw RH Tail Light Speed Nuts T25 Screws Rear Bumper T27 Screws 5.9 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
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 Cap 41-57 in. lbs. (4.6-6.4 Nm) 41-57 in. lbs. (4.6-6.4 Nm) Grommets Seat Belts / Mounting (RZR / RZR S) Driver Seat Passenger Seat 3 Point Seat Belt 40 ft. lbs. (54 Nm) 40 ft. lbs. (54 Nm) 3 Point Seat Belt 3 Point Seat Belt 40 ft. lbs. (54 Nm) Latch Plunger 40 ft. lbs. (54 Nm) 40 ft. lbs. (54 Nm) 5.
BODY / STEERING / SUSPENSION Seat Belts / Mounting (RZR 4) Rear Seats 40 ft. lbs. (54 Nm) 3 Point Seat Belts 5 Rear Seat Base Front Seats 40 ft. lbs. (54 Nm) 40 ft. lbs. (54 Nm) 40 ft. lbs. (54 Nm) Rubber Bumpers 40 ft. lbs. (54 Nm) 40 ft. lbs. (54 Nm) 40 ft. lbs. (54 Nm) Rear Seat Support Rubber Bumpers Latch Plunger Front Seat Base 40 ft. lbs. (54 Nm) 3 Point Seat Belts 40 ft. lbs. (54 Nm) 5.11 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
BODY / STEERING / SUSPENSION Floor / Rocker Panels (RZR / RZR S) Self-Tapping Screw LH Rocker Rear Support Bracket Push Rivets Self-Tapping Screws T27 Screws Console Cover Front Support Bracket Rear Support Bracket Self-Tapping Screw T27 Screws T27 Screw T27 Screws Push Rivets Upper Floor Torx Screws Plastic Dart T27 Screws RH Rocker Front Support Bracket Self-Tapping Screws Lower Floor 5.12 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
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 T27 Screw T27 Screw 5 Torx Screws Rear Support Bracket T27 Screw Lower Floor Self-Tapping Screw Front Support Bracket U-Type Nuts Self-Tapping Torx Screws Self-Tapping Screw RH Rocker T27 Screw Front Support Bracket Self-Tapping Screws Upper Floor 5.
BODY / STEERING / SUSPENSION Rear Cargo Box / Fenders (RZR / RZR S) Rear Rack Extender Rear LH Rack Extender Torx Screw & Nut T27 Screws Rear RH Rack Extender Rear LH Fender Flair T27 Screws Push Rivets Tie Down Bracket Rear LH Fender Torx Screw & Nut Rear Cargo Box T25 Screws Tie Down Bracket Torx Screws Rear RH Fender 1/4 Turn Latch Rear RH Fender Flair T27 Screws Rear LH Panel Divider Grommet T25 Screws Rear Main Service Panel Push Rivets Bolts Sound Foam Foil Cover Heat Shield Rear RH
BODY / STEERING / SUSPENSION Rear Cargo Box / Fenders (RZR 4) Rear LH Fender Flair Tie Down Bracket T27 Screws Rear LH Fender Tie Down Bracket Torx Screw & Nut Rear Cargo Box Torx Screw & Nut T25 Screws T27 Screw Torx Screws 5 Rear RH Fender U-Type Nuts Push Rivet Cover T25 Screws 1/4 Turn Latch Grommet Rear LH Floor Rear Console Cover T27 Screws T27 Screws Bolts Rear RH Fender Flair Torx Screws Push Rivet Foil Rear RH Floor Cargo Box Supports Heat Shield 5.
BODY / STEERING / SUSPENSION Chassis / Main Frame (RZR / RZR S) 15 ft. lbs. (20 Nm) Bolt-In Brace Rear Bumper Support Main Frame 15 ft. lbs. (20 Nm) 17 ft. lbs. (23 Nm) Skid Plate Washer 6-8 ft. lbs. (8-11 Nm) 5.16 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
BODY / STEERING / SUSPENSION Chassis / Main Frame (RZR 4) 15 ft. lbs. (20 Nm) Bolt-In Brace 17 ft. lbs. (23 Nm) Nylok Nuts 15 ft. lbs. (20 Nm) Main Frame Rear Bumper Support Plug 5 17 ft. lbs. (23 Nm) Rear Skid Plate 38 ft. lbs. (52 Nm) Fuel Tank Skid Plate Front Frame Bracket Self-Tapping Screws Washers Front Skid Plate Coupler 6-8 ft. lbs. (8-11 Nm) 5.17 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
BODY / STEERING / SUSPENSION BODY COMPONENT REMOVAL Rear Console Cover (RZR 4) Seats 1. Remove the rear passenger seats. 1. 2. Turn both latches 1/4 turn to disengage the cover. 3. Pull out on the top while pressing on the center of the lower portion of the cover to free it from the vehicle. 4. Lift the cover upward and towards the front of the vehicle to remove it. To remove any of the seats, lift upward on the latch lever located behind the seat bottom. Latch Lever 2.
BODY / STEERING / SUSPENSION Rear Bumper Front Body / Dash Removal 1. 1. Remove the hood as previously described. 2. Remove the front bumper (see “BODY COMPONENT REMOVAL - Front Bumper”). 3. Remove the front portion of the cab frame assembly to allow dash removal. Refer to appropriate “CAB FRAME Assembly / Removal” procedure for assembly torque specifications. Remove the (4) Torx screws retaining the upper portion of the rear bumper to the cargo box. Remove 2.
BODY / STEERING / SUSPENSION 6. Disconnect all electrical dash components noting their location and wire routing. 7. Remove the dash assembly from the vehicle. Front Fender Flair Removal 1. 2. If dash is installed, remove the (2) push rivets that attach the lower portion of the fender flair to the rocker panels. Remove the (6) push rivets (RZR) or (8) T27 Torx screws (RZR-S/RZR-4) and remove fender flairs from the dash assembly. Standard RZR Shown 4.
BODY / STEERING / SUSPENSION Rocker Panels, Console and Floor Rear Floor Removal (RZR 4) Rocker Panel Removal 1. Remove all four seats and both rocker panels (see “Rocker Panel Removal”). 2. Remove the T27 screws retaining the console to the floor. 3. Remove the shift handle knob and remove the console. 4. Disconnect the battery and remove it from the vehicle. 5. Remove the (8) fasteners that retain the lower portion of the mid cab frame to the main frame. 6.
BODY / STEERING / SUSPENSION STEERING ASSEMBLY Exploded View (Non-EPS Models) Cap Spacer Thick Washers Thin Washer Thin Washer Steering Wheel 25-31 ft. lbs. (34-42 Nm) Thick Washer Thin Washer Steering Shaft Pivot Tube Spacer Bearing 7 ft. lbs. (10 Nm) Bushing 42.5 ft. lbs. (58 Nm) 23 ft. lbs. (31 Nm) 27-33 ft. lbs. (37-45 Nm) Bushing 23 ft. lbs. (31 Nm) Bearing Oil Locking Shock Asm. 12 ft. lbs. (16 Nm) LH Boot Gear Box Asm. 12-14 ft. lbs. (16-19 Nm) RH Boot 42.5 ft. lbs. (58 Nm) Boot 17 ft.
BODY / STEERING / SUSPENSION Steering Wheel Removal (Non-EPS Models) CAUTION Steering Shaft Removal (Non-EPS Models) 1. Steering Shaft This procedure should NOT be used on EPS models. Using this procedure on an EPS model can permanently damage the EPS unit and cause a Power Steering Fault. 1. Remove the steering wheel cap. 2. Loosen the nut and back it half way off the steering shaft. 3. With a glove on your hand, place it under the steering wheel.
BODY / STEERING / SUSPENSION Steering Shaft Bearing Replacement 9. IMPORTANT: Replacement pivot tube assembly comes with new upper and lower bearings installed. Use this procedure if replacing just the bearings only. 10. Install the steering wheel and hand tighten the nut. 1. Perform the “Steering Shaft Removal” procedure. 2. Remove the steering wheel cap and retaining nut. 3. Press steering shaft out of the steering wheel and pivot tube. 4.
BODY / STEERING / SUSPENSION ELECTRONIC POWER STEERING ASSEMBLY Exploded View (EPS Models) 25-31 ft. lbs. (34-42 Nm) Spacer Thick Washer Cap Thin Washer Thick Washers Thin Washer Thin Washer Upper Steering Shaft Bearing Steering Wheel 7 ft. lbs. (10 Nm) Pivot Tube Spacer 15 ft. lbs. (20 Nm) 23 ft. lbs. (31 Nm) Power Steering Unit Bushing Mounting Bracket Bushing Oil Locking Shock Asm. 23 ft. lbs. (31 Nm) Bearing 12 ft. lbs. (16 Nm) 20-24 ft. lbs. (27-33 Nm) Collar 15-19 ft. lbs.
BODY / STEERING / SUSPENSION Upper Steering Shaft Removal (EPS Models) 1. 4. 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 5. 2. Remove the steering shaft, pivot tube and steering wheel from the vehicle as an assembly. Remove the pinch bolt retaining the upper steering shaft to the power steering unit. Remove as an assembly 6. 3.
BODY / STEERING / SUSPENSION Steering Wheel Removal (EPS Models) 1. 5. Using a large bronze drift and hammer, strike the steering shaft nut to pop the steering wheel off the shaft taper. Remove the upper steering shaft, pivot tube and steering wheel as an assembly before attempting to remove the steering wheel. Refer to “Upper Steering Shaft Removal (EPS Models)”.
BODY / STEERING / SUSPENSION 3. Remove the pinch bolt retaining the lower steering shaft to the power steering unit. If replacing the power steering unit, remove the (4) bolts that retain the power steering unit to the mount bracket. Remove Remove 4. 6. While supporting the power steering unit, remove the (4) nuts from the mount bracket. WARNING Electronic Power Steering (EPS) units are programmed to be vehicle specific and are not interchangeable between product lines. Remove 5.
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 point straight ahead. 1. 2. Locate the lower steering shaft through the left front wheel well. Mark the lower steering shaft, gear box stub shaft and gear box to aid installation. If the power steering unit was removed from the mount bracket, reinstall it prior to vehicle installation. Torque the mounting bolts to specification.
BODY / STEERING / SUSPENSION 6. Torque the (4) mount bracket nuts to specification. 1. 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 =T 2. Install the pivot tube and torque fasteners to specification. Power Steering Unit Mount Bracket Nuts: 17 ft. lbs. (23 Nm) 7. =T Reinstall the throttle pedal return spring. Pivot Tube Fasteners: 23 ft. lbs. (31 Nm) 3.
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. 20. Insert new A-arm bushings and pivot tube into new A-arm. 1. Elevate and safely support the front of the vehicle and remove the front wheel. 21.
BODY / STEERING / SUSPENSION Exploded View (RZR) Exploded View (RZR S / RZR 4) Upper Fastener Bushings Pivot Tube Upper A-arm Upper A-arm Upper Fastener Pivot Tube Grease Zerk Ball Joint Ball Joint Grease Zerk Lower Fastener Pivot Tube Bushings Lower Fastener Bushings Pivot Tube Bearing Carrier Bearing Carrier Lower A-arm Lower A-arm Grease Zerk Pinch Bolts Grease Zerk Bushing Pinch Bolts Ball Joint CV Shield CV Shield Screws Ball Joint 5.
BODY / STEERING / SUSPENSION BALL JOINT SERVICE 4. Removal IMPORTANT: Do not reuse a ball joint if it has been removed for any reason. If removed, it must be replaced. Use this removal procedure only when replacing the ball joint. 1. Use a press and correct size driver to remove the ball joint from the A-arm. Correct Driver Placement The A-arm must be removed to perform this procedure (see “FRONT A-ARMS - Removal / Replacement”). The driver must fit the inside diameter of the A-arm end.
BODY / STEERING / SUSPENSION Installation 1. 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 is properly seated. Press into the A-arm in this direction FRONT STABILIZER BAR (RZR / RZR S INT’L) Sway Bar Linkage Removal 1. Elevate and safely support the front of the vehicle. 2.
BODY / STEERING / SUSPENSION 5. Remove the (4) bolts retaining the lower radiator mount bracket and remove the bracket from the frame. 9. 6. Allow radiator to sag down to allow access to recovery bottle retaining screws and filler neck retaining screws. 10. Inspect the stabilizer bar for straightness. Inspect the bushings and replace if needed. 7.
BODY / STEERING / SUSPENSION REAR A-ARMS WARNING Removal The locking agent on the existing bolts was destroyed during removal. DO NOT reuse old hardware. Serious injury or death could result if fasteners come loose during operation. The following procedure details upper and lower A-arm removal and replacement on one side of the vehicle. Repeat the following steps to remove the A-arm(s) from the opposite side. NOTE: Use the exploded view in this section as a reference during the procedure (see page 5.
BODY / STEERING / SUSPENSION 6. If not replacing the A-arm, thoroughly clean the A-arm and pivot tubes. 6. If not replacing the A-arm, thoroughly clean the A-arm and pivot tubes. 7. Insert new A-arm bushings and pivot tubes into new A-arm. 7. Insert new A-arm bushings and pivot tubes into new A-arm. Lower A-arm Removal (RZR S / RZR 4) Installation 1. 1. Install lower A-arm assembly onto vehicle frame. Torque new fasteners to specification. 2. Attach lower A-arm to bearing carrier.
BODY / STEERING / SUSPENSION Exploded View (RZR) Exploded View (RZR S / RZR 4) Upper Fastener Pivot Tube Upper Fastener Pivot Tube Upper A-arm Upper A-arm Grease Zerk Bushings Grease Zerk Upper Fastener Pivot Tube Bushings Lower Fastener Bushings Lower Fastener Bushings Pivot Tube Lower A-arm Pivot Tube Upper Fastener Bushings Pivot Tube Lower A-arm Bushings Bearing Carrier Pivot Tube Lower Fastener Screws CV Shield Bearing Carrier Pivot Tube Lower Fastener 5.
BODY / STEERING / SUSPENSION REAR STABILIZER BAR (RZR) 4. 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 NOTE: The exhaust silencer can be removed through the side of the vehicle after the exhaust pipe is detached from the header pipe. 2. Remove the retaining nut from the upper portion of the stabilizer bar linkage bushing on each side of the vehicle. 5.
BODY / STEERING / SUSPENSION REAR STABILIZER BAR (RZR S / RZR 4) Removal / Installation 1. 4. Remove the exhaust pipe and exhaust silencer from the vehicle. Remove the stabilizer bar from the bracket (bracket can remain attached to the frame). Leave bracket attached to frame. Remove Fasteners RZR S Shown NOTE: The exhaust silencer can be removed through the side of the vehicle after the exhaust pipe is detached from the header pipe. 2. 5. Inspect the stabilizer bar for straightness.
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. Be sure the area to be flame treated is clean and free of gasoline or flammable residue. WARNING Do not flame treat components that are installed on the vehicle.
BODY / STEERING / SUSPENSION Exploded View (RZR 4) Shock Replacement 1. Using a spring compressor, compress the shock spring far enough to remove the spring retainer. Shock Spring Compressor Tool 2870623 Retainer gap should be 180° from spring end 2. Remove the spring and adjusting cam from the existing shock and install components onto the new shock. 3. Compress the shock spring and install the spring retainer.
BODY / STEERING / SUSPENSION FOX™ SHOCK EXPLODED VIEWS FOX™ PODIUM X ‘Piggyback’ Shock (RZR S) 18 ft. lbs. (24 Nm) 5 Preload Ring 10 ft. lbs. (14 Nm) Ref. Qty Description Ref. Shaft 15. Qty Description 1 Preload Ring 1. 1 2. 1 Body 16. 1 Preload Ring 3. 1 Body Cap Asm. 17. 1 Lock Nut 4. 1 Reservoir 18. 1 Bearing, External 5. - Shock Oil (2870995) 19. 1 Bearing, External 6. 1 Decal 20. 2 Retaining Ring, Wire 7. 2 Bearing, Spherical 21. 1 Spring Guide 8.
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. lbs. (14 Nm) Ref. Qty Description Ref. Qty Description 1. 1 Body Cap Asm. 16. 1 Screw Asm. 2. 1 Body Cap 17. 1 Reservoir End Cap Asm. 3. 1 Body 18. 1 Retaining Ring 4. 1 Eyelet 19. 1 Pellet Retainer Set Screw, Air Valve 5. 1 Shaft 20. 1 Nylon Ball, Air Valve 6.
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 • Every 500 hours or Annually - Change shock oil and replace seals Front Shock Service Information (RZR S) Front Shock Service Information (RZR 4) 5 SHOCK DESIGN DETAILS SHOCK DESIGN DETAILS Travel 6.22” Travel 6.
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 Gas Shock Oil 2870995 (qt.) Gas Shock Oil 2870995 (qt.) SHOCK VALVING COMPRESSION SHOCK VALVING REBOUND COMPRESSION REBOUND 1.300 x 0.012 1.250 x 0.010 1.600 x 0.015 1.
BODY / STEERING / SUSPENSION FOX™ Shock Rebuild Information When performing maintenance on FOX™ shocks, use the Gas Shock Recharging Kit (PN 2200421), as it contains the necessary valves, pressure gauge, and fittings to deflate and pressurize shocks.
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 working on shock absorbers. NOTE: Clean the entire shock assembly with soapy water. Try to remove as much dirt and grime as possible by scrubbing with a soft bristle brush.
BODY / STEERING / SUSPENSION 12. Clamp the body cap of the shock securely in vise with shaft side up. 13. Gently tap the reservoir end cap with a rubber mallet to expose the wire retaining ring. Locate the end of the ring and push inward with fingertip. Remove the retaining ring. A scribe or dental pick can also be used for this step, but use extreme caution not to scratch the bore of the reservoir tube (Fig. 4). 17.
BODY / STEERING / SUSPENSION Figure 9 Figure 7 24. Slide bearing assembly off of shaft. Use extreme caution not to scratch inside of the bearing assembly when passing it over the threads at end of shaft. 2. Thoroughly clean the bearing housing, and piston assembly with solvent. Dry with compressed air in a well ventilated area. If compressed air is not available, dry parts using clean, lint free paper towels and let sit in a well ventilated area to allow the remaining solvent to evaporate.
BODY / STEERING / SUSPENSION 7. Install the scraper in the bearing housing. Check for proper orientation of the scraper in the bearing. The stepped side of the scraper should be visible. 8. Install the new, well greased O-ring onto the IFP. 9. Replace the IFP bleed screw O-ring. 8. 10. Install the new, well greased O-rings into the reservoir end cap. Fill the reservoir to the retaining ring groove with the recommended oil. You should see bubbles rising to oil surface.
BODY / STEERING / SUSPENSION 12. Fill shock body to the bottom of bearing threads with oil. 13. Using the IFP Depth Setting Tool, slowly pull the IFP up to the mid point of the reservoir. Then push it down to the bottom again (Fig. 14). Be careful not to pull the IFP out completely. Also, be careful that the oil level in the shock body does not disappear below the bottom of the body and into the reservoir.
BODY / STEERING / SUSPENSION 34. Continue charging with gas as you pull the reservoir away 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™ air valve, a popping sound should be heard. Figure 17 Figure 19 28. Install IFP bleed screw and tighten using the 1/8” hex tool. Remove the IFP depth setting tool.
BODY / STEERING / SUSPENSION WALKER EVANS™ SHOCK EXPLODED VIEW Walker Evans™ Compression Adjuster Reservoir Shock (RZR L.E.) Ref. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. Qty 1 1 1 1 1 1 1 1 2 1 1 1 1 2 1 2 1 Description Piggyback Body Seal, Head Seal, Head Bushing, Shaft O-Ring Seal Wiper, D-Type O-Ring Shaft Piston Nut, Crimp Loop, Shaft Bearing Piston Screw Stud, Clicker Ref. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31. 32. 33. 34.
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 • Every 500 hours or Annually - Change shock oil and replace seals Front Shock Service Information Rear Shock Service Information 5 SHOCK DESIGN DETAILS SHOCK DESIGN DETAILS Travel (Stroke) 5.313” Travel (Stroke) 5.
BODY / STEERING / SUSPENSION Walker Evans™ Shock Rebuild Information When performing maintenance on Walker Evans™ shocks, use the Gas Shock Recharging Kit (PN 2200421), as it contains the necessary valves, pressure gauge, and fittings to deflate and pressurize shocks. Special Tools Special Tools PART NUMBER DESCRIPTION 2200421 Gas Shock Recharging Kit 2201640 Shock Shaft Seal Protector .
BODY / STEERING / SUSPENSION Walker Evans™ Shock Disassembly 5. Using a snap ring pliers, remove the retaining ring from the reservoir. 6. Carefully remove the cap from the reservoir body. IMPORTANT: To prevent damage or marks to the shock, the use of soft jaws on a vise is recommended. WARNING Walker Evans™ shocks contain high pressure nitrogen gas. Extreme caution must be used while handling and working with Walker Evans™ shocks and related high pressure service equipment.
BODY / STEERING / SUSPENSION 8. Slowly lift up and remove the shock rod assembly from the shock body. IMPORTANT: Seal kits are available and should be installed at this time if seals or O-rings are damaged or worn. 12. Place the shock rod in a vise so the threaded part is facing up. Using an 11/16" socket, remove the nut retaining the valve stack and piston. 9. Remove the used oil from the shock body. IMPORTANT: Keep the rebound and compression valve stacks in the order they were removed.
BODY / STEERING / SUSPENSION 16. Using a 9/16" socket w/extension, remove the fastener retaining the clicker valve stack. Place the valve stack on a clean shop towel in order of removal. 4. Place a new lock nut onto the shock rod. Torque the new lock nut to specification. IMPORTANT: Do not over torque the nut or damage to the valve stack can occur. =T Remove Lock Nut Torque: 14 ft. lbs. (19 Nm) NOTE: Make sure “Top-Out” washers are orientated as shown.
BODY / STEERING / SUSPENSION 6. Turn the compression adjuster knob counter-clockwise (soft) until it stops, so damping is in the full open position. 7. Secure the shock body in a vise by its lower mount. 8. Fill the shock body and remote reservoir 1/2 full of the recommended gas shock oil. 9. Using a 3/32" Allen wrench, remove the IFP bleed screw. 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 submerged.
BODY / STEERING / SUSPENSION 13. Pull the IFP up until its top is approximately 1" (2.54 cm) from the top of the reservoir and remove the IFP Tool. Using a 3/32" Allen wrench, install the IFP bleed screw. NOTE: During installation, some shock oil will over flow. Wrap a shop cloth around the shock body to catch any oil overflow. 17. Pull the damping piston up until it is just below the surface of the oil. 18. Hold the rod eyelet with one hand.
BODY / STEERING / SUSPENSION 25. Install the reservoir cap. Push down on the reservoir cap using even pressure until the retaining ring groove is exposed. 26. Install the retaining ring and check to make sure retaining ring is seated properly. 27. Push the shock rod assembly completely into the shock body. It should go all the way down smoothly without interference. If it does not, disassemble and reassemble per this procedure. 28. Secure the shock body in a vise by its lower mount. 29.
CLUTCHING CHAPTER 6 CLUTCHING SPECIAL TOOLS AND SUPPLIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.2 TORQUE SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.2 PVT SYSTEM OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.2 GENERAL OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.
CLUTCHING SPECIAL TOOLS AND SUPPLIES TOOL DESCRIPTION PART NUMBER Drive Clutch Puller (Short) PA-48595 Clutch Holding Wrench 9314177 Clutch Holding Fixture 2871358-A Drive Clutch Spider Removal and Installation Tool 2870341 Roller Pin Tool 2870910 Clutch Bushing Replacement Tool Kit 2871226 Piston Pin Puller 2870386 Clutch Compression Tool 8700220 Clutch Bushing Replacement Tool Kit 2871025 PVT SYSTEM OVERVIEW General Operation WARNING All PVT maintenance or repairs should be performed b
CLUTCHING Driven Clutch Operation Maintenance / Inspection Driven clutches primarily sense torque, opening and closing according to the forces applied to it from the drive belt and the transmission input shaft. If the torque resistance at the transmission input shaft is greater than the load from the drive belt, the drive belt is kept at the outer diameter of the driven clutch sheaves. Under normal use the PVT system will provide years of trouble free operation.
CLUTCHING Overheating / Diagnosis During routine maintenance, or whenever PVT system overheating is evident, it’s important to check the inlet and outlet ducting for obstructions. Obstructions to air flow through the ducts will significantly increase PVT system operating temperatures. The vehicle should be operated in Low when plowing or pulling heavy loads, or if extended low speed operation is anticipated.
CLUTCHING PVT SYSTEM SERVICE PVT Covers and Ducting Components Clutch Inlet Duct Push Rivets Clamps Boot Clutch Outlet Duct Boot Cover Screws Clamp Clamps Bolt & Washer Inner Clutch Cover Retainer Screws 6 Outer Cover Seal Outer Clutch Cover 6.5 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
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. 1. Remove the driver’s seat (RZR / RZR S only). 2. Remove the passenger seat(s) and rear service panel to gain access to the outer clutch cover (see Chapter 5). 3. Remove the (2) screws from the rear of the center console (RZR / RZR S only). Seat Base 5.
CLUTCHING 10. Install the Drive Clutch Holder (PN 9314177) (A). PVT Assembly 11. Remove drive clutch retaining bolt and remove drive clutch using the Drive Clutch Puller (PA-48595) (B). 1. Inspect inner clutch cover. Replace if cracked or damaged. 2. Inspect the seal on the transmission input shaft. Replace if damaged. 3. Apply RTV silicone sealant to the back side of the inner clutch cover to ensure a water tight fit between the engine and inner clutch cover.
CLUTCHING 11. Clean end of taper on crankshaft and the taper bore inside drive clutch. 12. Install drive clutch and torque retaining bolt to specification. 13. Reinstall drive belt noting direction of belt rotation (see “DRIVE BELT - Belt Installation”). If a new belt is installed, install so numbers can be easily read. Clutch Offset Procedure If the vehicle exhibits drive clutch drag or hard shifting while at idle speed, a clutch offset adjustment is required.
CLUTCHING 4. Reinstall the driven clutch and drive belt. Torque the driven clutch retaining bolt to 17 ft. lbs. (23.5 Nm). Be sure to rotate the driven clutch counterclockwise several times to ensure the belt is tight and riding at the proper height in the clutch. Proper Height 8. Install the outer clutch cover and torque the cover screws to 45-50 in. lbs. (5-5.6 Nm). 9. Install the clutch cover outlet duct and tighten the clamps. 10. Sit in the driver’s seat, apply the brake and start the engine.
CLUTCHING DRIVE BELT 3. Belt Removal 1. Remove outer clutch cover as described in the “PVT Disassembly” section. 2. Mark the drive belt direction of rotation so that it can be installed in the same direction. NOTE: Belt is normally positioned so that the part number can be easily read. 3. 4. Belts with thin spots, burn marks, etc., should be replaced to eliminate noise, vibration, or erratic PVT operation. See the Troubleshooting Chart at the end of this chapter for possible causes.
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 upward in the drive clutch sheaves. This is referred to as drive clutch upshift.
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.
CLUTCHING Clutch Disassembly 1. 5. Using a permanent marker, mark the cover, spider, and moveable and stationary sheaves for reference, as the cast in X's may not have been in alignment before disassembly. Inspect Shaft 6. 2. Mark the stationary sheave and clutch shaft to verify the shaft has not turned in the sheave after tightening the spider during clutch assembly. 3. Remove cover bolts evenly in a cross pattern and remove cover plate. 4. Inspect cover bushing (A).
CLUTCHING NOTE: It is important that the same number and thickness of washers are reinstalled beneath the spider during assembly. Be sure to note the number and thickness of these washers. Roller, Pin, and Thrust Washer Inspection 1. Inspect all rollers, bushings and roller pins by pulling a flat metal rod across the roller. Turn roller with your finger. If you notice resistance, galling, or flat spots, replace rollers, pins and thrust washers in sets of three.
CLUTCHING Button To Tower Clearance Inspection 1. 2. Inspect for any clearance between spider button to tower. If clearance exists, replace all buttons and inspect surface of towers. See “Spider Removal” procedure. Remove shift weight bolts and weights. Inspect the contact surface of the weight. The surface should be smooth and free of dents or gall marks. Inspect the weight pivot bore and pivot bolts for wear or galling. If weights or bolts are worn or broken, replace in sets of three with new bolts.
CLUTCHING Clutch Inspection 5. NOTE: Remove cover, spring, and spider following instructions for drive clutch removal, then proceed as follows: 1. Remove the moveable sheave spacer sleeve (1) and the thrust washer (2). Visually inspect the washer for damage. 2. Measure the thickness and compare to specification. Replace if worn or damaged. Inspect surface of shaft for pitting, grooves, or damage. Measure the outside diameter and compare to specifications.
CLUTCHING Moveable Sheave Bushing Inspection Bushing Service Inspect the Teflon coating (arrow) on the moveable sheave bushing. Inspect both sheaves for signs of wear, grooving or cracking. De-glaze sheave surfaces with a 3M Scotch-Brite Pad if needed. IMPORTANT: Special Tools Required EBS Clutch Bushing Tool Kit - 2201379 Item A, B C D Qty.
CLUTCHING NOTE: Use Bushing Tool PA-47336. CAUTION 8. Install nut (C) onto end of puller rod and hand tighten. Turn puller barrel to increase tension on sheave if needed. Using a hand held propane torch, apply heat around outside of bushing until tiny smoke tailings appear. 9. Turn sheave counterclockwise on puller rod until it comes free. Lift sheave off puller. Clutch components will be hot! In order to avoid serious burns, wear insulated gloves during the removal process.
CLUTCHING Cover Bushing Removal Clutch Assembly 1. NOTE: It is important that the same number and thickness of washers are reinstalled beneath the spider during assembly. The Teflon bushings are self-lubricating. Install main adapter (Item 8) on puller. Removal Tool (3) Nut (C) CAUTION Do not apply oil or grease to the bushings. Adapter Reducer (9) Main Adapter (8) Reassemble the drive clutch in the following sequence.
CLUTCHING 4. Torque spider to specification using the holding fixture and spider tool. Torque with smooth motion to avoid damage to the stationary sheave. =T 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. Inverting the clutch while initially tightening the spider will help position the washers. 5. Install shift weights using new lock nuts on the bolts.
CLUTCHING DRIVEN CLUTCH SERVICE Exploded View Compression Spring Spacer Outer Spring Retainer Stationary Secondary Sheave Inner Spring Retainer Retaining Ring 6 Moveable Secondary Sheave Clutch Disassembly / Inspection CAUTION Wear eye protection when removing snap ring to prevent serious personal injury. Use caution when removing, the snap ring pressure is loaded by the compression spring. 1. Remove driven clutch from the transmission input shaft. 2.
CLUTCHING 4. With the snap ring (A) removed and spring pressure relieved, remove the outer spring retainer (B), compression spring (C), spacer (D), and inner spring retainer (E). D 7. Remove the inner spring retainer from the inner sheave. Inspect for wear and replace as needed. B A E C B Inspect for Abnormal Wear 8. C E Check the rollers in the stationary sheave for wear. If rollers are worn, a new driven clutch assembly may be needed. D 5. Separate the two clutch sheaves.
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 1. Assemble Sheaves Install the inner spring retainer if removed. Do not apply oil or grease to the bearings. 3. Install the spring into the inner retainer. 4. Install the spacer over the shaft. 5.
CLUTCHING TROUBLESHOOTING Situation Engine RPM below specified operating range, although engine is properly tuned. Probable Cause -Wrong or broken drive clutch spring. Remedy -Replace with recommended spring. -Drive clutch shift weight too heavy. -Install correct shift weight kit to match engine application. -Driven clutch spring broken or installed in wrong -Replace spring; refer to proper installation location. helix location. -Drive clutch binding. A.
CLUTCHING Troubleshooting, Continued..... Situation Probable Cause -Plugged air intake or outlet. Remedy -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. Inform operator. overheating (melting) operation. -High vs. low range.
CLUTCHING NOTES 6.26 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
FINAL DRIVE CHAPTER 7 FINAL DRIVE SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.2 TORQUE SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.2 FRONT BEARING CARRIER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.2 BEARING CARRIER INSPECTION / REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.
FINAL DRIVE SPECIAL TOOLS FRONT BEARING CARRIER PART NUMBER TOOL DESCRIPTION 2872608 Roll Pin Removal Tool 8700226 CV Boot Clamp Pliers (earless type) PU-48951 Axle Boot Clamp Tool Bearing Carrier Inspection / Removal 1. 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. Wear eye protection when removing bearings and seals.
FINAL DRIVE 6. Remove the two front brake caliper mounting bolts and remove the caliper from the brake disc (see Chapter 9). CAUTION: Do not hang the caliper by the brake line. Use wire to hang caliper to prevent damage to the brake line. 7. Remove the front wheel hub assembly. 8. Remove the upper and lower ball joint pinch bolts. Bearing Replacement Bearing Removal 1. Remove the outer snap ring. RZR / RZR S Shown Snap Ring RZR / RZR S Shown Pinch Bolts 2. 9.
FINAL DRIVE Bearing Installation 3. 5. 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. 6. Support the bottom of the bearing carrier housing. CAUTION 23 ft. lbs. (31 Nm) Use an arbor and press only on the outer race, otherwise bearing damage may occur. 7. Install pinch bolts and torque to specification.
FINAL DRIVE 9. =T 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: 31-34 ft. lbs. (42-46 Nm) 80 ft. lbs. (108 Nm) CAUTION New bolts have a pre-applied locking agent which is destroyed upon removal. Always use new brake caliper mounting bolts upon assembly. 7. Install the steering tie rod end onto the front bearing carrier.
FINAL DRIVE FRONT DRIVE SHAFT 6. Drive Shaft Removal 1. Remove the upper ball joint pinch bolt. 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. Wear eye protection when removing bearings and seals. 2. Remove the (4) wheel nuts and remove the front wheel. 3. Remove the cotter pin and loosen the front wheel hub castle nut.
FINAL DRIVE Drive Shaft / CV Joint Handling Tips 4. Care should be exercised during drive shaft removal or when servicing CV joints. Drive shaft components are precision parts. Make sure the circlip remains on the shaft and not left in the joint. Discard the circlip as it will be replaced. Circlip Cleanliness and following these instructions is very important to ensure proper shaft function and a normal service life.
FINAL DRIVE 11. Slide the joint onto the drive shaft splines and align the circlip with the lead-in chamfer on the inner race. Inner Plunging Joint / Boot Replacement 1. Remove the front drive shaft from the vehicle (see “FRONT DRIVE SHAFT - Removal”). 2. Remove and discard the boot clamps. 12. Use a soft-faced hammer to tap the CV joint into the splines of the axle. Pull on the joint to ensure it’s securely installed. 13. Add the remaining grease through large end of boot.
FINAL DRIVE 12. Grease the joint with the special joint grease provided in the boot replacement kit. Fill the cavity behind the balls and the splined hole in the joint’s inner race. Pack the ball tracks and outer face flush with grease. Place any remaining grease into the boot. 21. Position the boot lip in its groove. Install and secure the boot with the large clamp using the “earless” clamp pliers.
FINAL DRIVE Drive Shaft Installation 1. 5. Install new spring ring on drive shaft. Apply an anti-seize compound to splines. Install the upper pinch bolt and torque to specification. 23 ft. lbs. (31 Nm) NEW Spring Ring RZR / RZR S Shown Apply Anti-Seize 2. Align splines of drive shaft with front gearcase and reinstall the drive shaft. Use a rubber mallet to tap on the outboard end of the drive shaft if necessary 23 ft. lbs. (31 Nm) RZR 4 Shown =T 3. Ball Joint Pinch Bolts: 23 ft. lbs.
FINAL DRIVE 8. Torque wheel hub nut to specification and install a new cotter pin. Tighten nut slightly if necessary to align cotter pin holes. PROPSHAFT SERVICE Removal / Installation (RZR / RZR S) 1. 80 ft. lbs. (108 Nm) Locate the propshaft roll pin and use the Roll Pin Removal Tool (PN 2872608) to remove the roll pin. NOTE: Front wheel can be removed to gain better access to the propshaft roll pin. NEW Cotter Pin =T Wheel Hub Castle Nut: 80 ft. lbs. (108 Nm) 9.
FINAL DRIVE 6. Remove the fasteners retaining the plastic skid plate and remove the skid plate from the vehicle. 5. Remove the fasteners retaining the center console to access the propshaft support bearing. Cap Torx Screw Screws Torx Screws Cupped Washers Torx Screws Screws 7. Remove the propshaft from the vehicle. 8. Reverse removal steps to reinstall propshaft. Use a NEW Roll Pin (Spring Pin) upon reassembly. 6. Remove the (2) bolts and washers retaining the support bearing.
FINAL DRIVE 9. If removing the rear portion of the propshaft, remove the bearing support (upper & lower half) from the shaft. Support Bearing Replacement (RZR 4) 1. Follow steps 1-8 of the “Removal / Installation (RZR 4)” procedure. 2. Remove the bearing support (upper and lower half) and the retaining ring. Loosen the (2) set screws retaining the bearing to the shaft. 10. Remove the fasteners retaining the front plastic skid plate to allow for propshaft removal. Remove Loosen Remove 3.
FINAL DRIVE 6. Apply Loctite® 242™ to the set screw threads and torque the (2) bearing set screws to specification. PROPSHAFT U-JOINT SERVICE Disassembly 65-75 in. lbs. (7.3-8.4 Nm) 1. Remove internal or external snap ring from bearing caps. CAUTION Always wear eye protection. Retaining Ring =T Bearing Set Screws: 65-75 in. lbs. (7.3-8.4 Nm) 7. Align the front and rear portions of the propshaft as shown below and slide them together.
FINAL DRIVE 3. Support U-joint in vise as shown and drive inner yoke down to remove remaining bearing caps. 4. Force U-joint cross to one side and lift out of inner yoke. 3. Using a suitable arbor, fully seat the bearing cap in one side. Continually check for free movement of bearing cross as bearing caps are assembled. 4. Install snap ring to contain bearing cap just installed. Repeat procedure for other side. 5.
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.
FINAL DRIVE All Wheel Drive Operation The AWD switch may be turned on or off while the vehicle is moving, however, AWD will not enable until the engine RPM drops below 3100. Once the AWD is enabled, it remains enabled until the switch is turned off. Engage the AWD switch before getting into conditions where the front wheel drive may be needed. If the rear wheels are spinning, release the throttle before switching to AWD.
FINAL DRIVE AWD Diagnosis 5. Symptom: AWD Will Not Engage 1. Check the gearcase coil resistance. To test the coil resistance, measure between the Grey and Brown/White wires. The measurement should be within specification. 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 should be seated below the U-shaped insert. The U-shaped insert controls the pole gap.
FINAL DRIVE Gearcase Removal 7. 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. 3. Remove the propshaft (see “PROPSHAFT SERVICE”). 4. Disconnect the wire harness above the front gearcase and remove the harness from the retaining dart. Remove the gearcase from the front LH wheel well area and slide it between the upper and lower A-arm. AWD Harness Gearcase Disassembly / Inspection 5.
FINAL DRIVE 3. Remove the LH output hub assembly from the clutch housing or outer cover plate assembly. 5. Remove the torsion spring retainer and torsion spring from the top of the ring gear. Spring Retainer LH Output Hub Non-serviceable DO NOT Remove Torsion Spring LH Output Hub NOTE: Nylon spacer is non-serviceable and should not be removed. 4. Remove and inspect the armature plate. Refer to “AWD Diagnosis” for detailed inspection process. 6.
FINAL DRIVE 7. Remove the RH output hub assembly from the gearcase housing. 10. Inspect the AWD coil located in the outer cover plate assembly. Refer to “AWD Diagnosis” for detailed inspection process. Replace the cover plate seal and O-ring. Inspect Coil Replace O-Ring & Seal 8. Remove pinion seal, internal retaining ring and pinion gear assembly from the gearcase housing. Inspect and clean the gearcase housing and replace all oil seals and O-rings. Pinion Shaft External Snap Ring Replace Seal 11.
FINAL DRIVE 14. Inspect the roll cage assembly (B) sliding surfaces and Hsprings. The sliding surfaces must be clean and free of nicks, burrs or scratches. If damaged, replace the roll cage assembly. B H-Spring Gearcase Assembly 1. As mentioned during gearcase disassembly section, replace all O-rings, seals and worn components. 2. Install pinion shaft assembly and install internal snap ring.
FINAL DRIVE NOTE: Install the roll cage so that the ring gear grooves line up with the roll cage slots (see below). 8. Check the action of the torsion spring by rotating in both directions to ensure the spring and retainer are installed properly. 9. Be sure the armature plate tabs are fully engaged into the roll cage assembly and are resting on the cut-grooves of the ring gear. Align during installation 6.
FINAL DRIVE 11. Install a new O-ring on the cover plate assembly. Gearcase Installation NOTE: Be sure the square O-ring is placed flat on the cover surface. If the O-ring is twisted fluid leakage may occur. 1. Install the gearcase back into the vehicle through the LH wheel well area, between the upper and lower A-arms. 2. Install the propshaft onto the front gearcase input shaft. Use a NEW spring pin in the front propshaft. 3.
FINAL DRIVE 5. Connect the AWD wire harness. AWD Harness 6. Refer to “FRONT DRIVE SHAFT - Drive Shaft 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) 7 7.25 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
FINAL DRIVE REAR BEARING CARRIER 6. Remove the rear wheel hub assembly. 7. Remove the bolts that attach the rear bearing carrier to the upper and lower A-arms. 8. Remove the bearing carrier from the rear drive shaft. 9. Rotate bearing by hand and check for smooth rotation. Visually inspect bearing for moisture, dirt, or corrosion. Bearing Carrier Inspection / Removal 1. Elevate rear of vehicle and safely support machine under the frame area.
FINAL DRIVE NOTE: Due to extremely close tolerances and minimal wear, the bearings must be inspected visually, and by feel. While rotating bearings by hand, inspect for rough spots, discoloration, or corrosion. The bearings should turn smoothly and quietly, with no detectable up and down movement and minimal movement sideways between inner and outer race. Bearing Installation 5. Thoroughly clean the rear bearing carrier housing and the outer race on the new bearing.
FINAL DRIVE Bearing Carrier Installation 1. 4. Install drive shaft axle through the backside of the bearing carrier. Be sure bushings and pivot tubes are installed. Install rear wheel hub assembly, cone washers, and hand tighten the castle nut. Install washers with domed side out. Cone Washers Wheel Hub Out 5. 2. Install brake caliper mounting bolts and torque to 18 ft. lbs. (24 Nm). Install the fasteners that attach the rear bearing carrier to the upper and lower A-arms.
FINAL DRIVE 6. Torque wheel hub nut to 80 ft. lbs. (108 Nm) and install a NEW cotter pin. Tighten nut slightly if necessary to align cotter pin holes. 3. Remove the cotter pin and loosen the rear wheel hub castle nut. Remove the nut, and (2) cone washers from the rear wheel hub assembly. 80 ft. lbs. (108 Nm) Castle Nut Cone Washers NEW Cotter Pin =T 4. Wheel Hub Castle Nut: 80 ft. lbs. (108 Nm) 7. Cotter Pin Remove the two brake caliper attaching bolts.
FINAL DRIVE 6. Remove the bolt that attaches the rear bearing carrier to the upper A-arm. Outer CV Joint / Boot Replacement 1. Using a side cutters, cut away and discard the boot clamps. 7. Slide the rear drive shaft out of the bearing carrier by pulling the bearing carrier assembly outward and tipping it down to remove the shaft. 2. Remove the large end of the boot from the CV joint and slide the boot down the shaft. 8.
FINAL DRIVE 5. Make sure the circlip is on the shaft and not left in the joint. Circlip NOTE: Shiny areas in ball tracks and on the cage spheres are normal. Do not replace CV joints because parts have polished surfaces. Replace CV joint only if components are cracked, broken, worn or otherwise unserviceable. 9. Clean the splines on the end of the shaft and apply a light coat of grease prior to reassembly. 10.
FINAL DRIVE 13. Slide the joint onto the drive shaft splines and align the circlip with the lead-in chamfer on the inner race of the joint. 19. While pulling out on the CV shaft, slide a straight O-ring pick or a small slotted screw driver between the small end of the boot and the shaft. This will allow the air pressure to equalize in the CV boot in the position that the joint will spend most of its life.
FINAL DRIVE Inner Plunging Joint / Boot Replacement 1. 5. Using a side cutters, cut away and discard the boot clamps. Circlip 6. 2. Make sure the circlip is on the shaft and not left in the joint. Remove the boot from the shaft. Remove the large end of the boot from the plunging joint and slide the boot down the shaft. CAUTION Complete disassembly of the plunging joint is NOT recommended. The internal components are a precision fit and develop their own characteristic wear patterns.
FINAL DRIVE 11. Install a NEW circlip on the end of the shaft. 12. Grease the joint with the special joint grease provided in the boot replacement kit. Fill the cavity behind the balls and the splined hole in the joint’s inner race. Pack the ball tracks and outer face flush with grease. Place any remaining grease into the boot. CAUTION 17. Remove excess grease from the plunging joint’s external surfaces and place the excess grease in the boot. 18.
FINAL DRIVE Drive Shaft Exploded View Drive Shaft Installation 1. REAR SHAFT Install new spring ring on drive shaft. Apply anti-seize compound to splines. NEW Spring Ring RZR RZR S / RZR 4 Spring Ring Plunging Joint Spring Ring Apply Anti-Seize Large Clamp Grease Pack Gear Side Boot Kit 2. Align splines of drive shaft with rear gearcase and reinstall the drive shaft. Use a rubber mallet to tap on the outboard end of the drive shaft if necessary.
FINAL DRIVE 4. Lift bearing carrier into place and install the bolt attaching the bearing carrier to the upper A-arm. Torque fastener to specification. =T Rear Caliper Mounting Bolts: 18 ft. lbs. (24 Nm) CAUTION New bolts have a pre-applied locking agent which is destroyed upon removal. Always use new brake caliper mounting bolts upon assembly. 8. Torque wheel hub nut to 80 ft. lbs. (108 Nm) and install a NEW cotter pin. Tighten nut slightly if necessary to align cotter pin holes.
FINAL DRIVE REAR GEARCASE 4. Remove the (2) rear gearcase mount bracket fasteners and mount bolt and remove bracket from vehicle. 5. Remove the fasteners and bracket that secure the rear gearcase to the transmission. 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” on page 7.29 2. Remove the exhaust pipe and exhaust silencer to allow for gearcase removal. Silencer Remove Remove 3.
FINAL DRIVE 7. 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. 8. Remove the vent line and lift the rear gearcase upward and on its side to remove it from the vehicle.
FINAL DRIVE 5. Inspect the ring gear for chipped, worn, or broken teeth. If damaged, replace the gearcase assembly. 7. Remove the input shaft seal using a seal puller or other suitable method. 8. Inspect the input shaft by rotating the assembly in the gearcase housing while checking for any looseness or roughness. Inspect the pinion gear teeth for chipped, worn, or broken teeth. If damaged, replace the ring gear and pinion gear as a set.
FINAL DRIVE Gearcase Assembly 3. 1. Install a new input shaft seal using a standard seal installer or other suitable method. 2. Install new seals on each side of the gearcase housing using a standard seal installer or other suitable method. Install a new O-ring in the gearcase cover. If removed, install each axle spool bearing race using standard bearing installation tools and an arbor press. WARNING Wear the appropriate safety equipment while installing bearing races to reduce the risk of injury.
FINAL DRIVE 4. Install the shim(s) previously removed onto the appropriate sides of the axle spool. Install the bearings. The bearings are a slip-fit and will slide onto the axle spool. Gearcase Installation 1. Install the rear gearcase by reversing the procedure listed under “REAR GEARCASE - Gearcase Removal” at the beginning of this section. IMPORTANT: When reinstalling the transmission to rear gearcase mount bracket, it is extremely important to torque all (7) fasteners to specification.
FINAL DRIVE Gearcase Exploded View 14 6 9 10 23-27 ft. lbs. (31-37 Nm) 4 5 3 7 6 16 9 1 12 10 2 17 23-27 ft. lbs. (31-37 Nm) 19 21 16 40 ft. lbs. 15 7 18 70-80 ft. lbs. (95-108 Nm) 13 (54 Nm) 23-27 ft. lbs. (31-37 Nm) 20 30-45 in. lbs.
FINAL DRIVE REAR GEARCASE (RZR S INT’L) Shift Yoke General Operation Clutch Gear 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. Unlocking the rear differential makes maneuvering easier and minimizes damage to turf and sensitive terrains.
FINAL DRIVE When the clutch gear is unlocked the rear drive shafts are dependent on the differential allowing tighter turns. When it’s locked it becomes a solid rear axle increasing traction. 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” on page 7.29 2. Remove the exhaust pipe and exhaust silencer to allow for gearcase removal. Silencer Remove Differential Clutch Gear Remove 3.
FINAL DRIVE 5. Disconnect the differential solenoid 2-wire harness. Gearcase Disassembly 6. Remove the fasteners and bracket that secure the rear gearcase to the transmission. IMPORTANT: The pinion gear assembly is NOT intended to be disassembled from the case, as it requires special OEM tooling in order to properly reassemble. If there is any damage to the pinion gear, bearings or case, the entire gearcase assembly must be replaced.
FINAL DRIVE 3. Remove the differential assembly from the housing. 6. Remove the shim(s) from the differential assembly. Be sure to keep the shims together for reassembly. 4. Inspect the ring gear and differential gears for chipped, worn, or broken teeth. 7. Remove the bearing from the lower portion of the differential assembly. Inspect the bearing for smoothness and wear. 8. Remove the shim(s) from the differential assembly. Be sure to keep the shims together for reassembly. Inspect Teeth 5.
FINAL DRIVE 9. Inspect each differential bearing and race for signs of wear or damage. If bearing replacement is required, use standard bearing puller tools to remove the bearing races. 10. Remove the seals from the gearcase housing and cover and replace the O-ring in the gearcase cover. 12. Inspect the pinion shaft by rotating the assembly in the gearcase housing while checking for any looseness or roughness. Inspect the pinion gear for chipped, worn, or broken teeth.
FINAL DRIVE 15. Remove the clutch gear from the gearcase. 16. Inspect the shift lever (A), shift lever spring (B), shift return springs (C), and shift yoke (D) for excessive wear or damage. If disassembly is required, proceed to the next step. If no disassembly is required, proceed to “Gearcase Assembly”. D 18. Carefully remove the shift yoke assembly from the gearcase cover. 19. Inspect the shift lever (A), shift lever spring (B), shift return springs (C), shift yoke (D), and lock pin bushing (E).
FINAL DRIVE Differential Disassembly 1. Use a scribe to mark the differential cover and case. Remove the (10) screws retaining the differential cover. 2. Use a brass punch in the recessed area as shown to remove the differential cover. 4. Use a scribe to mark the ring gear and differential case. Remove the (8) bolts that secure the ring gear to the differential and allow the ring gear to slide down and off. 5. Place the differential assembly upright.
FINAL DRIVE 3. Install the side differential gears and thrust washers and slide the cross pin into position with the hole side facing the hole in the differential case. Differential Assembly 4. Install a new roll pin. 1. 5. Install the upper differential gear and differential cover. Apply Loctite® 271 to the cover screws and torque the screws to specification. 7. Inspect the gears, thrust washers and differential case for excessive wear or damage. Replace components if needed.
FINAL DRIVE Gearcase Assembly 1. Replace all worn components. 2. If removed, install new bearing races using standard bearing installation tools and an arbor press. 5. Install a new pinion shaft seal using a standard seal installer or other suitable method. 6. Install the original shim(s) previously removed onto the appropriate sides of the differential assembly. Install the bearings by hand as they are a slip-fit.
FINAL DRIVE 8. 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 9. Install the shift yoke assembly with the shift return springs (C), facing down in the housing. 12. Assemble the gearcase halves and install the bolts that secure the cover to the housing. Torque the bolts in a crisscross pattern to 23-27 ft. lbs. (31-37 Nm). 23-27 ft. lbs. (31-37 Nm) C 10.
FINAL DRIVE Gearcase Installation 1. Install the rear gearcase by reversing the procedure listed under “REAR GEARCASE - Gearcase Removal” at the beginning of this section. IMPORTANT: When reinstalling the transmission to rear gearcase mount bracket, it is extremely important to torque all (7) fasteners to specification. Refer to the “Installation” procedure listed on page 4.14.
FINAL DRIVE Gearcase Exploded View 70-80 ft. lbs. 20 (95-108 Nm) 35 32 31 33 34 6 16 30 130-155 in. lbs. (15-18 Nm) 18 37 29 30-40 ft. lbs. (41-54 Nm) 27 7 6 4 36 19 5 12 12 3 28 15 23-27 ft. lbs. (31-37 Nm) 10 1 9 17 2 26 8 13 22 23 14 18 40 ft. lbs. 21 24 (54 Nm) 11 23-27 ft. lbs. (31-37 Nm) 30-45 in. lbs.
FINAL DRIVE WHEEL HUBS Front Hub Exploded View Sealed Ball Bearing Bolts Wheel Hub Front Rim (Aluminum) Front Tire Cotter Pin Cone Washers Bearing Carrier Wheel Nuts Retaining Ring 30 ft. lbs. + 90° (1/4 turn) Brake Disc Studs Castle Nut 80 ft. lbs. (108 Nm) Wheel Nuts 27 ft. lbs. (37 Nm) Front Rim (Steel) 7 Rear Hub Exploded View Sealed Ball Bearing Bolts Rear Tire Rear Rim (Aluminum) Wheel Hub Cotter Pin Cone Washers Bearing Carrier Wheel Nuts 30 ft. lbs.
FINAL DRIVE NOTES 7.56 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
TRANSMISSION CHAPTER 8 TRANSMISSION TORQUE VALUES / SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.2 SHIFT LEVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.2 REMOVAL / INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.2 SHIFT CABLE INSPECTION / ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.
TRANSMISSION TORQUE VALUES / SPECIFICATIONS SHIFT LEVER Maintain and check/change these items in accordance with the maintenance schedule in Chapter 2 or during service repairs. Removal ITEM TORQUE VALUE Transmission Fill Plugs 40-50 ft. lbs. (54-67 Nm) Transmission Drain / Level Plugs 30-45 in. lbs. (0.2-0.3 Nm) Transmission Case Screws 23-27 ft. lbs. (31-36 Nm) Shift Cable Lever Screw 15-20 ft. lbs. (20-27 Nm) Detent Sleeve Assembly 40-45 ft. lbs. (54-61 Nm) Outer Detent Screw 23-27 ft.
TRANSMISSION Shift Cable Inspection / Adjustment 4. Adjust the shift cable so there is the same amount of cable travel when shifting slightly past the detents of HIGH (H) gear and PARK (P). 5. Thread the upper or lower jam nut as required to obtain proper cable adjustment. Shift cable adjustment may be necessary if symptoms include: • No AWD or gear position display on instrument cluster • Ratcheting noise on deceleration • Inability to engage a gear 1.
TRANSMISSION TRANSMISSION SERVICE 3. Remove the (7) fasteners retaining the transmission to rear gearcase mount bracket. Transmission Removal / Service Notes Note the number or thickness of shims for reassembly purposes. The engine, transmission and rear differential are bolted together as a unit. Removal of the transmission is not possible without removing the engine and differential. The shift housing cannot be removed without first disassembling the transfer case.
TRANSMISSION 8. After removing the cover, remove the intermediate shaft bearing cup and shims from the cover. Bearing cup is a slipfit. Note and record the number and thickness of shims and set aside. Also note the two alignment dowels (circle) in the cover for installation. 10. Remove the intermediate pinion shaft assembly from the housing. Check bearings and gear teeth for wear or damage and replace as needed. The shaft can be disassembled as shown using a press and standard bearing removal tools.
TRANSMISSION 13. Remove the front output pinion shaft assembly. The shaft can be disassembled as shown using a press and standard bearing removal tools. 15. Remove the lower snap ring from under the gear. 16. Remove the intermediate shaft seal using a seal puller or other suitable method. 14. Remove the upper snap ring from the top side of the 21T main pinion gear and remove the gear. 8.6 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
TRANSMISSION Transfer Case Reassembly 1. 2. 3. Install the shims, bearing cup and alignment dowels into the retaining bracket. 4. Install a new output shaft seal flush with the case. Install the output pinion shaft assembly and bearing cup/bracket assembly as shown. Verify the alignment dowels are seated. Torque the bracket screws evenly to specification. Install the intermediate shaft seal (circled) flush or slightly below the case.
TRANSMISSION 5. Reinstall the intermediate pinion shaft assembly and bearing cup. 7. Install the transfer case cover. Align the dowels (#1 & #7) and insert the cover screws (note position of the longest screw #4). Torque the screws evenly to specification in sequence as shown. 1 4 8 6 3 2 6. 7 5 Assemble the transfer case cover using new components as required. Press in new bearings and a seal using standard installation tools.
TRANSMISSION Transmission Shift Housing Disassembly 2. IMPORTANT: Shift housing repairs are not possible without performing transfer case disassembly. Read and understand all instructions before beginning disassembly. 1. Place the transmission shift housing onto a flat surface as shown. Lift the transmission case half straight up and remove. Verify transmission is in neutral. Remove the (7) shift housing case screws from the front of the transmission and (2) from the backside as shown.
TRANSMISSION 5. 6. Remove the (5) screws retaining the park flange. Inspect the park flange for wear or damage. Replace if needed. Inspect the shaft bearing. Use a standard bearing puller to remove the shaft bearing if required. 8. Remove the input shaft seal and clutch intermediate shaft seal using a seal puller or punch. 9. Remove the (2) screws that attach the gear position sensor to the shift housing. Inspect the O-ring, switch poles and contact pins for wear or damage. Replace parts as required.
TRANSMISSION 10. Remove the spacer, contact pins, springs, drum gear and washer from the shift housing. Replace any worn or damaged components. 13. Pull back fully on gear selector arm to bring shift collar up and disengage the shift collar from the clutch yoke. Lifting on the clutch shaft may aid in shift collar removal. 11. Remove the inner shift detent screws, springs, and balls from the shift housing. 14.
TRANSMISSION 19. Remove the clutch shaft assembly from the housing. The forward gear assembly and bearings will remain on the shaft upon removal. 22. Locate the retaining ring on the shifter assembly and move the retaining ring out of the groove to allow the shifter assembly to slide out. 20. Disassemble the clutch shaft as needed by removing both retaining rings and separating the high and low gears from the clutch shaft. Inspect all parts for wear or damage and replace as required.
TRANSMISSION 26. Remove the screw from the end of the shift cable lever and remove the shifter assembly from the housing. Transmission Shift Housing Reassembly 1. Install a new shift cable lever seal and press it flush with the case. Apply lubricant to the seal lip. 2. Lubricate the shaft of the shifter assembly and install the assembly into the housing with a new retaining ring and washer. Install the shift cable lever (“X” facing out) and torque the retaining screw to specification. 27.
TRANSMISSION 4. Install the input shaft assembly into the transmission housing. =T Pivot Pin Set Screw: 100-125 in. lbs. (11-14 Nm) 5. 7. 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. 8. Install the clutch shaft into the transmission housing. 9. Install the sliding shoes onto the clutch yoke. Install the clutch yoke into the shifter assembly. Align the holes and install clutch yoke pivot pin.
TRANSMISSION 10. Install the shift collar onto the clutch shaft. Pull back fully on gear selector arm to bring the shift yoke arms up and engage the shift shoes onto the center groove of the shift collar. Shifting the clutch shaft position may aid in shift collar installation. Install the park/reverse spacer on top of the shift collar as shown. 11. Install the dent sleeve assembly, ball, spring and outer detent screw. Use new O-rings anytime these screws are removed.
TRANSMISSION 14. Install the reverse idler lower washer, needle bearing, gear, upper washer and retaining ring onto the idler shaft. 17. Install the reverse clutch assembly onto the park flange. Note the orientation of the needle bearing. 15. Install a new shaft bearing (if required). 18. Install the retaining plate and a new retaining ring. 19. Install the input shaft seal and verify it is fully seated. Install the intermediate shaft seal (circled) flush or slightly below the case.
TRANSMISSION 20. Place the transmission shift housing onto a flat surface as shown. Apply a bead of crankcase sealant onto the mating surfaces. Align the dowels and install the transmission case half onto the shift housing while rotating the input shaft, using care not to damage the seal surfaces. 22. Install the (2) shift housing case screws to the backside as shown. Torque to specification. NOTE: Shift cable bracket installation is required. 2871557 Apply Sealant PN 2871557 to Case Mating Surfaces 21.
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 • Loose fasteners on rod ends • Loose fasteners on selector box • Worn rod ends, clevis pins, or pivot arm bushings • Linkage rod adjustment and rod end positioning • Shift selector rail
TRANSMISSION TRANSMISSION EXPLODED VIEW Shift Housing / Transfer Case Exploded View Shift Housing 8 Transfer Case 8.19 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
TRANSMISSION NOTES 8.20 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
BRAKES CHAPTER 9 BRAKES GENERAL SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TORQUE SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BRAKE SYSTEM SERVICE NOTES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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 Front Brake Disc Runout .188" (4.78 mm) .170" (4.32 mm) - .010" (.254 mm) REAR BRAKE SYSTEM Item Standard Service Limit Rear Brake Pad Thickness .298 ± .007" (7.57 ± .178 mm) .180" (4.6 mm) Rear Brake Disc Thickness .188" (4.78 mm) .170" (4.32 mm) - .010" (.
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. • Optional pads are available to suit conditions in your area. Select a pad to fit riding style and environment. • DO NOT over-fill the master cylinder fluid reservoir.
BRAKES HYDRAULIC BRAKE SYSTEM OPERATION The Polaris brake system consists of the following components or assemblies: brake pedal, master cylinder, hydraulic brake lines, brake calipers, brake pads, and brake discs, which are secured to the drive line. When the foot activated brake lever is applied it applies pressure on the piston within the master cylinder.
BRAKES BRAKE SYSTEM EXPLODED VIEW RZR / RZR S / RZR S INT’L LH Rear Line 3 2 1 Cross Fitting Brake Switch LH Front Brake Line Master Cylinder 2 1 Front Calipers 3 2 Rear Calipers 2 1 1 MC Rear Brake Line 1 RH Rear Line 1 Caliper Banjo Style Fittings: 15 ft. lbs. (20 Nm). RH Front Brake Line Master Cylinder Side View All Caliper Bleed Screws: 2 47 in. lbs. (5.3 Nm) All Flare Style Fittings: 15 ft. lbs. (20 Nm) 3 12-15 ft. lbs.
BRAKES MASTER CYLINDER NOTE: Make note of front and rear brake line locations to master cylinder. Removal 1. 4. Locate the master cylinder above the left front tire in the wheel well area. Loosen the brake line banjo bolts (C) and allow fluid to drain. NOTE: Dispose of fluid properly. Do not re-use. 5. Remove the two mounting fasteners (D) that secure the master cylinder to the frame. Installation Master Cylinder 1. Reverse Steps 1-5 for master cylinder installation.
BRAKES BRAKE BLEEDING / FLUID CHANGE 5. Have an assistant slowly pump foot pedal until pressure builds and holds. NOTE: When bleeding the brakes or replacing the fluid always start with the furthest caliper from the master cylinder. 6. Hold brake pedal on to maintain pedal pressure, and open bleeder screw. Close bleeder screw and release foot pedal. NOTE: Do not release foot pedal before bleeder screw is tight or air may be drawn into master cylinder. CAUTION Always wear safety glasses. 7.
BRAKES FRONT BRAKE PADS 6. Push the mounting bracket inward and the slip outer brake pad out between the bracket and caliper body. Pad Removal 1. RZR / RZR S Elevate and support front 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. 2. Remove the wheel nuts, washers and front wheel. 3. Loosen the pad adjuster screw 2-3 turns. RZR 4 4.
BRAKES Pad Inspection Pad Assembly / Installation 1. 1. Measure the thickness of the pad material. Replace pads if worn beyond the service limit. Lubricate mounting bracket pins with a light film of silicone grease and install rubber dust boots. Apply Grease to Each Bracket Pin 2. Compress mounting bracket and make sure dust boots are fully seated. Install pads with friction material facing each other. WARNING If brake pads are contaminated with grease, oil, or liquid soaked do not use the pads.
BRAKES 4. 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. 5. Install the adjustment set screw and turn clockwise until stationary pad contacts disc, then back off 1/2 turn (counterclockwise). 1/2 Turn 6. Verify fluid level in reservoir is up to MAX line inside reservoir and install reservoir cap. Master Cylinder Fluid Up to MAX line inside reservoir 7.
BRAKES FRONT CALIPER SERVICE Caliper Exploded View (RZR / RZR S / RZR S INT’L) Apply Polaris DOT 4 Brake Fluid to Component A C E Apply Silicone Grease 47 in. lbs. (5.3 Nm) B F G D H I D A. Socket Set Screw B. Bleeder Screw C. Caliper Assy. D. Boot E. Square O-ring (thick) F. Square O-ring (thin) G. Piston H. Caliper Mount I. Brake Pads Caliper Exploded View (RZR 4) Apply Polaris DOT 4 Brake Fluid to Components C B 47 in. lbs. (5.3 Nm) Apply Silicone Grease A D E D 9 F G A.
BRAKES Caliper Removal 1. Elevate and safely support the front of the vehicle. 2. Remove the (4) wheel nuts and the front wheel. 5. Loosen brake pad adjustment set screw 2-3 turns to allow brake pad removal after the caliper is removed. 6. Remove the two caliper mounting bolts and remove the caliper assembly from the front hub. CAUTION Use care when supporting vehicle so that it does not tip or fall. Severe injury may occur. 3. Clean caliper area before removal. 4.
BRAKES Caliper Disassembly 1. Remove both brake pads from the caliper (see “FRONT BRAKE PADS - Pad Removal”). 2. Remove mount bracket assembly and dust boots. IMPORTANT: Do not remove the caliper pistons with a standard pliers. The piston sealing surfaces will become damaged if a standard pliers is used. 5. Once the pistons are removed, use a pick to carefully remove the square O-rings from the caliper. O-rings should be replaced during caliper service. 6.
BRAKES Caliper Inspection 1. Inspect caliper body for nicks, scratches, pitting or wear. Measure bore size and compare to specifications. Replace if damaged or worn beyond service limit. = In. / mm. RZR / RZR S: Front Caliper Piston O.D.: Std: 1.002” (25.45 mm) Service Limit: 1.000” (25.4 mm) = In. / mm. RZR 4: Front Caliper Piston O.D.: Std: 1.370” (34.80 mm) Service Limit: 1.368” (34.75 mm) 3. Inspect the brake disc and pads as outlined in this chapter. = In. / mm.
BRAKES Caliper Assembly 1. IMPORTANT: If disc scraper was removed, reinstall it upon caliper installation (RZR 4 Only). Install new O-rings in the caliper body. Be sure the grooves are clean and free of residue or brakes may drag upon assembly. Disc Scraper Seal Grooves 31-34 ft. lbs. (42-46 Nm) RZR 4 Shown New O-Rings =T 2. 3. Coat pistons with clean Polaris DOT 4 Brake Fluid. Install pistons with a twisting motion while pushing inward.
BRAKES 4. Install the adjustment set screw and turn clockwise until stationary pad contacts disc, then back off 1/2 turn (counterclockwise). FRONT BRAKE DISC Disc Runout 1. Mount dial indicator as shown to measure disc runout. Slowly rotate the disc and read total runout on the dial indicator. Replace the disc if runout exceeds specification. 1/2 Turn 5. Perform brake bleeding procedure as outlined earlier in this chapter. 6. Install wheel and torque wheel nuts to specification.
BRAKES CAUTION Brake Disc Thickness New .188” (4.78 mm) Service Limit .170” (4.32 mm) Brake Disc Thickness Variance Service Limit: .002” (.051 mm) difference between measurements Disc Replacement 1. Remove the front brake caliper (see “FRONT CALIPER SERVICE”). 2. Remove wheel hub cotter pin, castle nut and washers. 3. Remove the wheel hub assembly from the vehicle and remove the (4) bolts retaining the disc to the hub. Always use new brake disc mounting bolts.
BRAKES REAR BRAKE PADS 5. Push caliper piston into the caliper bore slowly using a Cclamp or locking pliers with pads installed. Pad Removal 1. 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. 2. Remove the rear wheel. 3. Loosen pad adjuster screw 2-3 turns.
BRAKES Pad Inspection 3. 1. Clean the caliper with brake cleaner or alcohol. 2. Measure the thickness of the pad material. Replace pads if worn beyond the service limit. Install caliper and torque mounting bolts to specification. 18 ft. lbs. (24 Nm) Measure Thickness =T Rear Brake Pad Thickness New .298” ± .007” (7.57 mm ± .178 mm) Service Limit .180” (4.6 mm) Rear Caliper Mount Bolt Torque: 18 ft. lbs. (24 Nm) 4. Slowly pump the brake pedal until pressure has been built up.
BRAKES REAR CALIPER SERVICE Caliper Exploded View Apply Polaris DOT 4 Brake Fluid to Component D 47 in. lbs. (5.3 Nm) Apply Silicone Grease G I K A. Brake Pad B. Mount Bracket C. Piston D. Caliper Assy. E. Square Ring (thick) F. Square Ring (thin) G. Boot, Pin Bushing H. Boot, Pin Seal I. Bleeder Screw K. Set Screw A H E F C B Caliper Removal 1. Elevate and safely support the rear of the vehicle. CAUTION 5.
BRAKES Caliper Disassembly Caliper Inspection 1. Remove brake pad adjustment set screw (K). 1. 2. Push upper pad retainer pin inward and slip brake pads past the edge and remove from the caliper. 3. Remove mounting bracket (B) and dust boots (G) and (H). Inspect caliper body for nicks, scratches or wear. Measure bore size and compare to specifications. Replace if damage is evident or if worn beyond service limit. D G K Pads H E F C B 4. = In. / mm.
BRAKES Caliper Assembly = In. / mm. 1. RZR / RZR S: Rear Caliper Piston O.D. Standard: 1.1875” (30.16 mm) Service Limit: 1.186” (30.12 mm) Install new caliper seals (A) in the caliper body (B). Be sure groove is clean and free of residue or brakes may drag upon assembly. B = In. / mm. RZR 4: Rear Caliper Piston O.D.: Standard: 1.500” (38.10 mm) Service Limit: 1.498” (38.05 mm) 3. D Inspect the brake disc and pads as outlined in this chapter. A 2.
BRAKES Caliper Installation REAR BRAKE DISC 1. Disc Inspection Install the rear caliper with the mounting bolts. Torque mounting bolts to specification. 18 ft. lbs. (24 Nm) 1. Visually inspect disc for scoring, scratches, or gouges. Replace the disc if any deep scratches are evident. 2. Use a 0-1” micrometer and measure the disc thickness at eight different points around the pad contact surface. Replace disc if worn beyond service limit.
BRAKES Disc Replacement TROUBLESHOOTING 1. Remove rear brake caliper (see “REAR CALIPER SERVICE”). Brakes Squeal / Poor Brake Performance 2. Remove wheel hub cotter pin, castle nut and washers. • Air in system 3. Remove the hub assembly from the vehicle and remove the (4) bolts retaining the disc to the hub.
ELECTRICAL CHAPTER 10 ELECTRICAL GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.3 SPECIAL TOOLS / ELECTRICAL SERVICE NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . 10.3 UNDER-DASH COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.3 SWITCHES / CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.3 BRAKE LIGHT SWITCH . . . .
ELECTRICAL STARTING SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.30 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.30 VOLTAGE DROP TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.30 STARTER MOTOR REMOVAL / DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.30 BRUSH INSPECTION / REPLACEMENT . . . . .
ELECTRICAL GENERAL INFORMATION Under-Dash Components Special Tools The following switches and components can be accessed underneath the instrument / dash panel: Part Number • Speedometer Tool Description PV-43568 Fluke™ 77 Digital Multimeter PV-43526 Connector Test Kit 2870630 Timing Light • Digital Wrench Diagnostic Connector • AWD Switch PU-50338 • Headlamp Switch • 12 Vdc Accessory Power Point Battery Hydrometer • Ignition Switch 2460761 Hall Effect Sensor Probe Harness • Fuse / Relay
ELECTRICAL Headlamp Switch Ignition Key Switch 1. Disconnect the headlamp switch harness by depressing the connector locks and pulling on the connector. Do not pull on the wiring. 1. Disconnect the key switch harness by lifting the connector lock and pulling on the connector. Do not pull on the wiring. 2. Test between the 3 sets of outputs (OFF / LOW / HIGH). If any of the tests fail, replace headlamp switch assembly. 2. Test between the 3 sets of outputs (OFF / ON / START).
ELECTRICAL Ignition Key Switch (INT’L) AWD / 2WD Switch 1. Disconnect the key switch harness by lifting the connector lock and pulling on the connector. Do not pull on the wiring. 1. Disconnect the AWD / 2WD switch harness by depressing the connector locks and pulling on the connector. Do not pull on the wiring. 2. Test between the 4 sets of outputs (OFF / ON LIGHTS / ON / START). If any of the tests fail, replace ignition switch assembly. 2. Test between the 2 sets of outputs (AWD / 2WD).
ELECTRICAL AWD / 2WD / TURF Switch (INT’L) Turn Signal Switch (INT’L) 1. Disconnect the AWD / 2WD / TURF switch harness by depressing the connector locks and pulling on the connector. Do not pull on the wiring. 1. Disconnect the Turn Signal switch harness by depressing the connector locks and pulling on the connector. Do not pull on the wiring. 2. Test between the 3 sets of outputs (AWD / 2WD / TURF). If any of the tests fail, replace the switch assembly. 2.
ELECTRICAL Transmission (Gear Position) Switch VEHICLE SPEED SENSOR 1. Speed Sensor Location 2. Disconnect the transmission switch harness by lifting the connector lock and pulling on the connector. Do not pull on the wiring. The speed sensor is located in the transmission transfer case cover and can be accessed through the rear LH wheel well area. Test the transmission switch continuity readings for each gear position and compare to the specification table below.
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.
ELECTRICAL INSTRUMENT CLUSTER Overview The instrument cluster displays critical vehicle information to the user. Reference the following page for display functions and descriptions. 10 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. Certain products, including insect repellents and chemicals, will damage the instrument cluster lens.
ELECTRICAL Rider Information Display 13. Gear Position Indicator - Displays gear selector position. The rider information display is located in the instrument cluster. All segments will light up for 1 second at start-up. H = High NOTE: If the instrument cluster fails to illuminate, a battery over-voltage may have occurred and the instrument cluster may have shut off to protect the electronic speedometer. N = Neutral L = Low R = Reverse P = Park -- = Gear Signal Error (shifter stuck between gears) 1.
ELECTRICAL Trip Meter Engine Hours The trip meter records the miles traveled by the vehicle on each trip. To reset the trip meter: Engine hours are logged anytime the engine is running. Total hours can not be reset. 1. Toggle the MODE button to TRIP 1. Programmed Service Interval 2. To reset to 0, push and hold the MODE button until the distance display changes to 0. Tachometer (RPM) The initial factory service interval setting is 50 hours.
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: The clock displays the time in a 12-hour or 24-hour format. Refer to “Units of Measurement” to change the format (Standard 12-hour / Metric-24 hour). To set the clock, follow these steps: 1. Toggle the MODE button until the odometer is displayed.
ELECTRICAL Under / Over Voltage Diagnostic Mode This warning usually indicates that the vehicle is operating at an RPM too low to keep the battery charged. It may also occur when the engine is at idle and a high electrical load is applied (lights, cooling fan or other accessories). The diagnostic mode is accessible only when the check engine MIL has been activated. If battery voltage drops below 11 volts, a warning screen will display “Lo” and provide the present battery voltage.
ELECTRICAL 4. Use the trouble code reference table in the EFI Chapter for a description of each code. 5. If more than one code exists, press the MODE button to advance to the next trouble code. 6. To exit the diagnostic mode, press and hold the MODE button or turn the ignition key OFF once the codes are recorded. 2. Push the instrument cluster out from the back side of the dash while securely holding the dash and rubber mount.
ELECTRICAL ALL WHEEL DRIVE COIL HEAD LIGHTS Operation Overview Headlight Adjustment • When the AWD switch is “ON”, 12 VDC power is present at the hub coil. The headlight beam is adjustable. 1. Place the vehicle on a level surface with the headlight approximately 25 ft. (7.6 m) from a wall. 2. Measure the distance from the floor to the center of the headlight and make a mark on the wall at the same height. 3. With the machine in Park, start the engine and turn the headlight switch to on. 4.
ELECTRICAL 6. Adjust the beam to desired position. Repeat the procedure to adjust the other headlight. Headlamp Housing Removal 1. Disconnect the wire harness from the headlamp bulb. Be sure to pull on the connector, not on the wiring. 2. Remove the O-rings (A) from the headlamp brackets on both sides of the headlamp. 3. Remove the adjustment screw (B) from the bracket. WARNING Due to the nature of light utility vehicles and where they are operated, headlight lenses become dirty.
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. 1. Remove bulb by turning the rubber base 1/4 turn and pulling the bulb out. Replace it with recommended bulb. Apply Dielectric Grease (PN 2871329).
ELECTRICAL COOLING SYSTEM Cooling System Break-Out Diagram 10.18 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
ELECTRICAL Fan Control Circuit Operation / Testing EFI DIAGNOSTICS Power is supplied to the fan via the Orange/Black wire when the relay is ON. The ground path for the fan motor is through the Brown harness wire. Refer to “RELAYS” later in this chapter for more information on fan functions. EFI Component Testing CAUTION Keep hands away from fan blades during operation. Serious personal injury could result. All EFI component information and diagnostic testing procedures are located in Chapter 4.
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. A separate 20-amp circuit breaker protects the fan motor circuit. 10.
ELECTRICAL Fuse Box Detail 10 10.21 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
ELECTRICAL Relay Operation Located in the fuse box under the dash, the relays assist with component operation like the cooling fan, fuel pump and EFI system, drive system and EPS. NOTE: The Rear Diff Solenoid Relay is mounted separately, attached to the rear plastic LH panel divider behind the driver’s seat.
ELECTRICAL REAR DIFF SOLENOID RELAY (INT’L) provides power to the following system: • Rear Differential Solenoid REAR DIFF SOLENOID RELAY (INT’L) COLOR Red / Dark Green FUNCTION 10-Amp fuse protected 12 Vdc battery voltage. Dark Green / White ECU input to enable relay. Brown Relay coil ground. Red Relay switched power to operate the Rear Diff Solenoid. Blue Ground to energize the Rear Diff Solenoid. 10 10.
ELECTRICAL CHARGING SYSTEM WARNING Current Draw - Key Off Never start the engine with an ammeter connected in series. Damage to the meter or meter fuse will result. Do not run test for extended period of time. Do not run test with high amperage accessories. CAUTION Do not connect or disconnect the battery cable or ammeter with the engine running. Damage will occur to electrical components. Connect an ammeter in series with the negative battery cable. Check for current draw with the key off.
ELECTRICAL NOTE: If there are any significant variations in ohm readings between the three legs it is an indication that one of the stator legs may be weak or failed. Regulator / Rectifier The Regulator / Rectifier is located behind the radiator cooling fan and can be accessed through the front left wheel well. TEST 2: Resistance Value of Each Stator Leg to Ground 1. Measure the resistance value of each of the stator legs to ground: Y1 to Ground, Y2 to Ground, Y3 to Ground.
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. Using a multitester set on D.C. volts, measure the battery open circuit voltage (See earlier test). It should be 12.4 volts or more. Is it? No Remove the battery and properly service. Reinstall the fully charged battery or a fully charged shop battery.
ELECTRICAL BATTERY SERVICE General Battery Information Battery Specifications WARNING RZR / RZR S Battery PN 4011496 Type Polaris / Yuasa YTX20HL-BS Sealed - Maintenance Free Voltage 12 Vdc Nominal Capacity @ 10 HR Rate 18 AH CCA CALIFORNIA PROPOSITION 65 WARNING: Batteries, battery posts, terminals and related accessories contain lead and lead compounds, and other chemicals known to the State of California to cause cancer and birth defects or other reproductive harm. WASH HANDS AFTER HANDLING.
ELECTRICAL Battery Removal / Installation See Chapter 2 “Maintenance” for battery removal and installation procedures. Battery Off Season Storage Whenever the vehicle is not used for a period of three months or more, remove the battery from the vehicle, ensure that it's fully charged, and store it out of the sun in a cool, dry place. Check battery voltage each month during storage and recharge as needed to maintain a full charge.
ELECTRICAL Battery Conductance Analyzer Conductance describes the ability of a battery to conduct current. A conductance tester functions by sending a low frequency AC signal through the battery and a portion of the current response is captured, from this output a conductance measurement is calculated. Conductance testing is more accurate than voltage, specific gravity, or load testing. Authorized Polaris dealers/distributors are required to use the conductance analyzer when testing 12V Polaris batteries.
ELECTRICAL STARTING SYSTEM Voltage Drop Test Troubleshooting The Voltage Drop Test is used to test for bad connections. When performing the test, you are testing the amount of voltage drop through the connection. A poor or corroded connection will appear as a high voltage reading. Voltage shown on the meter when testing connections should not exceed 0.1 VDC per connection or component.
ELECTRICAL NOTE: Note the alignment marks on both ends of the starter motor casing. These marks must align during reassembly. 3. 2. Measure resistance between insulated brush and starter housing. Reading should be infinite (OL). Inspect insulation on brush wires for damage and repair or replace as necessary. 3. Slide positive brush springs to the side, pull brushes out of their guides and remove brush plate. Slide brush end frame off end of starter.
ELECTRICAL Brush Replacement 1. Remove terminal nut with lock washer, flat washer, large phenolic washer, the small phenolic spacers, and sealing O-ring. Inspect O-ring and replace if damaged. 2. Slide positive brush springs to the side, pull brushes out of their guides and remove brush plate. CAUTION Some cleaning solvents may damage the insulation in the starter. Care should be exercised when selecting an appropriate solvent. If the commutator needs cleaning use only electrical contact cleaner. 4.
ELECTRICAL 2. Install O-ring, two small phenolic spacers, large phenolic washer, flat washer, lock washer, and terminal nut. 3. While holding brush springs away from brushes, push brushes back and hold in place. 4. Slide armature into field magnet housing. Release brushes. 5. Lightly grease the drive roller bearing and reinstall drive end frame on armature. Inspect seal for wear or damage. Replace drive end cap if necessary.
ELECTRICAL 2. 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. Make sure the end washer is positioned properly so that it will hold the lock ring in its groove.
ELECTRICAL Starter Exploded View * Indicates - Do not reuse. Replace with new parts. 1. Rubber Ring* 2. Brush Spring 3. Thrust Washer 4. Gear Assembly 5. O-Ring* 6. Brush Complete 7. O-Ring* 8. Thrust Washer 9. Shaft Complete 10. Gear Assembly 11. Through Bolt 12. Cover 13. Stopper 14. Snap Ring 15. Washer 16. Flange Bolt 17. Thrust Washer 18. Flange Bushing 10 10.35 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
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 red lead on the battery positive. Reading should be 12.4 V D. C. or greater. No Remove battery and properly service. Install fully charged shop battery to continue test. Yes Disconnect 2-wire connector at the solenoid.
ELECTRICAL ELECTRONIC POWER STEERING (EPS) EPS 8-Way Wire Harness Connector EPS Operation The 8-way connector, two rows of four pins, does not have a channeled lock on both sides, allowing it to be installed 180° from its intended position. The connector will not positively engage or snap into place while in the wrong position, but can still be installed. If the connector is not installed correctly, the Power Steering Unit will not function.
ELECTRICAL EPS System Breakout 10.38 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
ELECTRICAL EPS Troubleshooting (Power Steering Non-Functional with MIL ON) 10 10.39 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
ELECTRICAL EPS Troubleshooting (Power Steering Non-Functional with MIL OFF) 10.40 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
ELECTRICAL EPS Troubleshooting (Using Digital Wrench™) 10 10.41 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
ELECTRICAL ELECTRICAL SYSTEM BREAKOUTS AWD Vehicle Speed Sensor 10.42 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
ELECTRICAL Cooling Fan 10 10.43 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
ELECTRICAL Charging System 10.44 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
ELECTRICAL Chassis Power 10 10.45 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
ELECTRICAL Key-On Battery Power 10.46 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
ELECTRICAL Electronic Power Steering (EPS) 10 10.47 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
ELECTRICAL Engine Start (Starter Interlock) 10.48 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
A Air Filter Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.13 All Wheel Drive (AWD) Coil . . . . . . . . . . . . . . . . . . . 10.15 Authorization Key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.46 Authorization, Reflash . . . . . . . . . . . . . . . . . . . . . . . . . . 4.44 AWD, Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.18 AWD, Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.
EFI System, Component Locations . . . . . . . . . . . . . . . . . .4.6 EFI System, Electrical Layout . . . . . . . . . . . . . . . . . . . .4.48 EFI System, Exploded View . . . . . . . . . . . . . . . . . . . . . . .4.5 EFI, Diagnostic Codes . . . . . . . . . . . . . . . . . . . . . . . . . . .4.36 EFI, Service Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.4 EFI, Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . .4.39 Electrical, AWD . . . . . . . . . . . . . . . . .
Fuel Pump Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.20 Fuel Sender Test . . . . . . . . . . . . . . . . . . . . . . . . . 4.19, 10.19 Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.11 Fuel System Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . 4.40 Fuel Tank Replacement (RZR / RZR S) . . . . . . . . . . . . 4.24 Fuel Tank Replacement (RZR 4) . . . . . . . . . . . . . . . . . . 4.26 Fuel Tank, Exploded View . . . . . . . . . . . . .
Rear Gearcase, Assembly (RZR S INT’L) . . . . . . . . . . .7.51 Rear Gearcase, Diff Assembly (RZR S INT’L) . . . . . . .7.50 Rear Gearcase, Diff Disassembly (RZR S INT’L) . . . . .7.49 Rear Gearcase, Disassembly . . . . . . . . . . . . . . . . . . . . . .7.38 Rear Gearcase, Disassembly (RZR S INT’L) . . . . . . . . .7.45 Rear Gearcase, Exploded View . . . . . . . . . . . . . . . . . . . .7.42 Rear Gearcase, Exploded View (RZR S INT’L) . . . . . . .7.54 Rear Gearcase, Installation . . . . . . . . . . . . . .
Suspension, Spring Preload Adjustment (FOX) . . . . . . . 2.31 Suspension, Spring Preload Adjustment (Standard) . . . . 2.31 Suspension, Spring Preload Adjustment (Walker Evans) 2.33 Sway Bar Linkage Removal . . . . . . . . . . . . . . . . . . . . . . 5.34 Switch, AWD/2WD . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.5 Switch, AWD/2WD/TURF (INT’L) . . . . . . . . . . . . . . . 10.6 Switch, Brake Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.3 Switch, Gear Position . . . . . .
IX.
RANGER RZR RANGER RZR S RANGER RZR 4 PN 9923142 Printed in USA
2011 RANGER RZR / RZR S
2011 RANGER RZR / RZR S
2011 RANGER RZR EPS
2011 RANGER RZR EPS
2011 RANGER RZR 4
2011 RANGER RZR 4
2011 RANGER RZR 4 EPS
2011 RANGER RZR 4 EPS
2011 RANGER RZR S INT’L
2011 RANGER RZR S INT’L
