Polaris RZR S User's Manual
Contents
1. Clutch Bushing Replacement Tool PN 2871226 NOTE Bunge med Pe ing heat evel e Ses on Bushing bore prior o instating new busing 6 17 CLUTCHING caution them y ne ppal a Remove tm paler nd PN 2670386 Man Paler Adaptor cma ger te to p EG mem 6 18 NOTE Use Bushing Too antenna u Drive Clutch Bushing Installation 1 Pic mai den pl mua L K hey w sake 4 nner nl paler wal hen AD wi Ae Nai mi Cac Bang Ted rA Conus tl big se CLUTCHING man ar mali eg p 07 Cover Busting instalation Det Le evenly ng hore nor Wu man ple men over omo paier d o was Clutch Assembly NOTE Important same number and Spider ang The Teton Bushings ar anto A caution ER Spacer weinen D 6 19 CLUTCHING EM caution st ch nig he in bs Nm 6 20 CLUTCHING DRIVEN CLUTCH SERVICE Exploded View Clutch Disassembly Inspection caution2. ele f 140 GENERAL INFORMATION Standard Torque Specifications B Q B m m cen men 2 man ars Tous is ini emm wos Sos 108 wes ves 1208 men man E ne the EL mino Se E E 2 Soa ESI ko TT coment be 1a nin une Font pounce by 1 382 Noto Nn y 238 SPECIFIC TORQUE VALUES OF FASTENERS GENERAL INFORMATION SAE Tap Dl ci a EIE X Ie Fi jp men 1 12 GENERAL INFORMATION Glossary of Terms a 425 o nite drive isch which lan oh weigh pie gae REM caus the rie chic to 2228 Ee 25252345222 RE lia fone to on operating position the driver ES gen rn eo er 1 13 GENERAL INFORMATION NOTE MAINTENANCE CHAPTER 2 MAINTENANCE PERIODIC MAINTENANCE CHART 23 LUBRICANTS SERVICE PRODUCTS 29 GENERAL VEHICLE INSPECTION AND MAINTENANCE 200 FUEL SYSTEM AND AIR INTAKE au enone 215 TRANSMISSION AND GEARCASES 218 COOLING SYSTEM 222 FINAL DRIVE WHEEL A
3. Battery Season St Battery Che Spark Plug Service ing Maintenance Free Spark Pug Gap wanna 2 27 MAINTENANCE Ai STEERING H al pat lg Recommended Spark Plug The sang components el be checked ja Champion RC7YC3 Spark Plug Torque Ibs check end aiment anna ering componen top ard aun be Use ony gorune Polat replacement part Steering Wheel Freeplay MAINTENANCE MAINTENANCE Wheel Toe Adjustment gamete co cs the Maen Deore determining which rod needs ajustan caution tenna he ena as serene petra ey wa aliment 230 48155 MAINTENANCE SUSPENSION STANDARD SUSPENSION FOX Spring Preload Adjustment A wanna Spring Preload Adj ent WARNING E recur Shock Spanner Wrench LT 2 31 MAINTENANCE G Shock Compression Adjustment ana 10 lk trom close elet
4. 7 44 FINAL DRIVE Gearcase Disassembly IMPORTANT The pir 745 FINAL DRIVE FINAL DRIVE FINAL DRIVE FINAL DRIVE 7 49 FINAL DRIVE FINAL DRIVE WARNING FINAL DRIVE FINAL DRIVE 7 53 FINAL DRIVE Gearcase Exploded View FINAL DRIVE WHEEL HUBS Front Hub Exploded View FINAL DRIVE NOTE 756 TRANSMISSION CHAPTER 8 TRANSMISSION TORQUE VALUES SPECIFICATIONS SHIFT LEVER TRANSMISSION SERVICE TROUBLESHOOTING TRANSMISSION EXPLODED VIEW 84 TRANSMISSION TORQUE VALUES SPECIFICATIONS SHIFT LEVER Mass ad change hese coda a COL ILL 2 apoco eal te e Installation 82
5. 5 31 BODY STEERING SUSPENSION Exploded View 828 Exploded View RZR S RZR 4 BODY STEERING SUSPENSION BALL JOINT SERVICE iO 5 33 BODY STEERING SUSPENSION Installation ro Upper Kam staneg nag O 5 34 FRONT STABILIZER BAR RZR RZR S INT L Sway Bar Linkage Removal ENG BODY STEERING SUSPENSION 5 35 BODY STEERING SUSPENSION REAR A ARMS wanuna NOTE Use the exploded view in this section 3 Terence during the procedure se page S 1 BODY STEERING SUSPENSION pin A am nil he Armand tna egy lth am ad Lower arm Removal RZ Installation mamma 2 Rees ing LLL IS at T M UIT amp EFER te ase tig ver a o 8511 etme ad mone tee Am ek rie hinge prs Bap View SN Replace d wam Dc wa RR ST RAR 4an Ah 5 37 BODY STEERING SUSPENSION Exploded View 828 Exploded View RZR S RZR 4
6. Signal Switch INTL Hazard Switch NTL ELECTRICAL Transmission Gear Position Switch VEHICLE SPEED SENSOR Lh Speed Sensor Location Speed Sensor Testing Speci Took ei ELECTRICAL REAR DIFF SOLENOID INT L Differential Solenoid Overview Differential Solenoid Circuit Operation ca net A caution 10 8 ELECTRICAL INSTRUMENT CLUSTER ELECTRICAL Rider Information Display overvatage may occured instrument cluster may protect the Sean speedometer t Ne yA ee KM ig Lol Migh Bam Indicator LED o sas whenever he Disa ni newer ng wren nae BM 10 10 a Signa Eo sk ga 14 Pover Seige MIL LED cn ane 15 Tarn Sul cr LED Information Display Area Take ELECTRICAL H 1200 ELECTRICAL 1 Toggle the MODE lsh sterile ea wi unin HT IL he MODE cn uni ee 10 12 ELE
7. CLUTCHING CLUTCHING CLUTCHING TROUBLESHOOTING i sss 6 24 CLUTCHING ing Continued 625 CLUTCHING NOTE 626 FINAL DRIVE CHAPTER 7 FINAL DRIVE SPECIAL TOOLS TORQUE SPECIFICATIONS FRONT BEARING CARRIER FRONT DRIVE SHAFT PROPSHAFT SERVICE PROPSHAFT L JOINT SERVICE FRONT GEARCASE CENTRALIZED HILLIARD REAR BEARING CARRIER REAR DRIVE SHAFT REAR GEARCASE REAR GEARCASE RZR S INTL WHEEL HUBS 7 1 FINAL DRIVE SPECIAL TOOLS FRONT BEARING CARRIER Bearing Can Inspection Removal mi TORQUE SPECIFICATIONS Wheel and Hub Torque Table 3 miet Faves IET e 72 FINAL DRIVE 1m b ES 3 ping una for rough spota discoloration 24 73 FINAL DRIVE Cone Washers Wheel FINA
8. ns ONY NOMA NOUN Lew ama 143 01 1na1nO NI 511063 NOS OL NO eemes A pm me Ga Hm r jim 25 us H H i 3 BODY STEERING SUSPENSION CHAPTER 5 BODY STEERING SUSPENSION TORQUE SPECIFICATIONS 53 SPECIAL TOOLS a CAB FRAME RZA 8285 54 FRAME RZR 4 55 BODY EXPLODED VIEWS Er BODY COMPONENT REMOVAL MT EB STEERING ASSEMBLY MM ELECTRONIC POWER STEERING ASSEMBLY MNT FRONT AARMS BALL JOINT SERVICE M FRONT STABILIZER BAR RZR RRS NTL MNT 54 BODY STEERING SUSPENSION REAR ARMS REAR STABILIZER BAR REAR STABILIZER BAR AZA S RZR DECAL REPLACEMENT SHOCKS SPRINGS FASTENERS Fox SHOCK EXPLODED VIEWS EEA 20 puc FOX SHOCK SERVICE WALKER EVANS v SHOCK EXPLODED VIEW WALKER EVANS SHOCK SERVICE 52 BODY STEERING SUSPENSION TORQUE SPECIFICATIONS SPECIAL TOOLS p Upper Lower BEL iii Tank Sam Wara ote NM enm rea Spang Cress Multi Function Pliers 53 BODY STEERING SUSPENSION FRAME RZR 828 5 Assembly Removal NOTE Finger ien al component
9. ELECTRICAL Charging System Testing Flow Chart Da stan the SET age an he 1 es Rawal urged tatay 45 ec pet ras ss sido tite Sarg ng sa eines fice vola ep 10 26 ELECTRICAL BATTERY SERVICE Battery Specifications RIR RZRS Battery PN 4011496 General Battery Information A wanna ATOR ALL EPS AND RZR 4 MODELS Battery 4011224 er pommes ino sio moco rn A wanwa iul Eater electrolyte is poisonous contains acid moore mesa OV Open Cri Valga Tat 10 27 ELECTRICAL Battery Removal Installation Battery Off Season Storage NOTE bte rs can be y ung Tam mate up rr Bary Battery Testing OCV Open Circuit Voltage Test hh ae charge cig storage Battery PN 4011496 1028 Battery PN 4011224 Load Test caution AAA ELECTRICAL Battery Conductance Analyze Meinzemen i Conductanc
10. g x Ma Bdge Ol E Compression Adjustment Table ek ne Factory WAS cic ham cowed ss 25105 N 88 2 32 MAINTENANCE SUSPENSION WALKER EVANS Spring Preload Adjustment A WARNING Shock Spanner Wrench Shock Compression Adjustment NOTE Ven tr i ed ca position eee Compression q x a 9 Compression Tabie 233 MAINTENANCE BRAKE SYSTEM Brake Fluid Inspection and p the brake pe 2 34 Brake Pad Disc Inspection Brake Hose and Fitting Inspection MAINTENANCE MAINTENANCE LOG 2 35 MAINTENANCE NOTE 236 ENGINE CHAPTER 3 ENGINE ENGINE SPECIFICATIONS ENGINE COOLING SYSTEM GENERAL ENGINE SERVICE ENGINE DISASSEMBLV AND INSPECTION ENGINE REASSEMBLY ENGINE INSTALLATION TROUBLESHOOTING ENGINE ENGINE SPECIFICATIONS Crankcase Exploded Views 32 ENGINE Oil Pump Gears Engine Cover Exploded View 33 ENGINE
11. rpc el en 748 FINAL DRIVE FINAL DRIVE NOTE Rollers are spring loaded Take care not to tem tal df or foss em upon roman ot ero cage 721 FINAL DRIVE FINAL DRIVE NOTE Intl roll cage that the ring gear Cec hf ths ec spring yg both Does tine up win the roi cage st see pam NOTE Very rna pat redigi FINAL DRIVE FINAL DRIVE Polaris Demand Drive Plas EN 2877922 Front Housing Capacity 6781 ox 200m 7 25 FINAL DRIVE REAR BEARING CARRIER caution FINAL DRIVE NOTE Due 10 extremely close tolerances and minimal wear the Bearings must be Insectos by fel Whe rotating bearings by ana spat for 24 Corrosion The bearings should lum smoothly and ti win no ec up and down movement Rp toi bin pe Bearing Replacement Bearing Removal ge Rois urbe dame caution rm ne tig in er eng ir sing m 8 Compounds Bearing Carrier Bushing Replacement lt Canc tem 9 ex CRS gt 6 7 27 FINAL DRIVE Con
12. Dive Ces Sper EI 6 2 General Operation wanna sh cae ano rea Drive Clutch Operation eh pa me me cn CLUTCHING Driven Clutch Operation Sesh pod ale wpe m tte chi dia di PVT Breakin Drive Belt Clutches Sea cramps Pl Mi ode ages idem an hgh se stan ing de hacia Maintenance Inspection Sacra pl aot dc sl ee een Ep ter p 63 CLUTCHING Overheating Diagnosis e slopes poston armatos fine ence PUTENT BETES sti musor som WARNING GENERAL RANGE OPERATION rough rough terrain swamps mountains ect ot ow ground speeds pees TP Operating in Low Gear IMPORTANT Using High gear tor heavy loads Ny errain or in wet muddy conditions the chance 64 CLUTCHING PVT SYSTEM SERVICE vers and Ducting Components CLUTCHING CLUTCHING PVT Assembly CLUTCHING Clutch Offset Procedure Inner Cover Bolt Torque ar 120s 66 Outer Cover Bolt Torque 455040 In 5 6 Nm Driven Clutch Retaining
13. BODY STEERING SUSPENSION BODY COMPONENT REMOVAL Rear Console Cover RZR 4 BODY STEERING SUSPENSION Rear Bumper Front Body Dash Removal f i k Er sey Hood and Front Body Work E BODY STEERING SUSPENSION BODY STEERING SUSPENSION Rocker Panels Console and Floor NOTE W removing FH rocker panel kam RIR 4 isa te ges Cap once Console and Lower Floor Removal RER AZA S Rear Floor Removal ZR 4 BODY STEERING SUSPENSION STEERING ASSEMBLY Exploded View Non EPS Models BODY STEERING SUSPENSION Steering Wheel Removal Non EPS Models CAUTION Steering Shaft Removal Non EPS Models epic pcc or olio 5 23 BODY STEERING SUSPENSION Steering Shaft Bearing Replacement IMPORTANT Replacement pivot tube assembly Comes ith new upper an lower beings tal eth procedure ua beings on Bin the Bez NOTE Be sure over washes and spacers l on the steering shat NOTE Use care not to stow any of the Lect to etin NOTE Bearings wil be seated in the pivot housing pon the steering
14. Digit Wench Diagnostic Sofware eed scent tt ed eas EEE IMPORTANT he PC you are using is nat equipped srl port USE t stl port adapior die now SPX AIDS ELECTRONIC FUEL INJECTION aed os negli Digital Wrench and update downlode pleas is he website wane plas dog com 44 Service Notes ELECTRONIC FUEL INJECTION System Exploded View ELECTRONIC FUEL INJECTION EFI System Componer ELECTRONIC FUEL INJECTION ELECTRONIC FUEL INJECTION FUEL TANK Exploded View Fue Sender Fuel Flow Fuel Finers e Fool Pump Assembly Lm Quick Connect Fuet Line ELECTRONIC FUEL INJECTION Fuel Lines Quick Connect i tomes ed cig te tk ELECTRONIC FUEL INJECTION Principal Components Operation Overview te mown l w van 49 ELECTRONIC FUEL INJECTION Initial Priming Starting Procedure NOTE The injection system must be purged ofa Diagnostic Software denier oniy 4 10 ELECTRONIC CONTROL UNIT ECU Operation Overview nese tt i Ce ag ie Code Ter by ill Wach Te CU ELECT
15. EP Nm ENGINE INSTALLATION Engine Assembly and Installation tng cn pl g gan al ane eet ay Sag TaN T2 Lower SF 40 be eh yet haz drop 3 59 ENGINE NOTE mounts were removed or replaced he flowing taro rio ensure proper nation during 3 60 Engine Break In Period i i CAUTION PoE ERU Do not operat at ul ee or Nos speeds tor L G TAS Gare Fite Krone PU SONOS oh Pressure speciation Soo M Pal Poa PLUS pinte Erie tempera ENGINE TROUBLESHOOTING Engine Spark Plug Fouling Spt pa poso corm spak ping ea Engine Turns Over But Fails To Start Tek sn Bagged jn Xo pate Spt lg oa aon conponat Engine Does Not Turn Over Engine Runs But Wil Not Idle Engine dies But Wil Not Accelerate Sp la to uk Engine Has Low Power Sp ti Piston Failure Scoring Excessive Smoke and Carbon Buildup Piston Failure Scoring 3 61 ENGINE Excessive Smoke and Carbon Buildup Cooling System Doce pomo pin Overheating Warn vibe de Mong pen of ta Val nat sening poopy Clann Spt pla cr eat nage ay hc Temen cl co sp ie mig rep not ane main Temperature Too Low eT Leak
16. TRANSMISSION Shift Cable Inspection 83 TRANSMISSION TRANSMISSION SERVICE Transmission Removal Service Notes Chapter to remove he engine and drivetrain Transter Case Disassembly IMPORTANT Shit housing repairs are not possible ils rat ad NOTE Exploded views are located at the end of this Chapter or sons information 84 TRANSMISSION TRANSMISSION TRANSMISSION 87 TRANSMISSION 88 TRANSMISSION NOTE Shah components may esteh during ae Tal Work siwi component seo 89 TRANSMISSION TRANSMISSION TRANSMISSION TRANSMISSION Transmission Shift Housing Reassembly 8 13 TRANSMISSION TRANSMISSION Xe Seve SST TRANSMISSION 8 16 TRAN
17. MAINTENANCE Throttle Pedal MAINTENANCE ces MAINTENANCE MAINTENANCE ayia ier ibe to kep Ihe ange and depth ot the pat NOT Over me Engine NOTE Due to the any angle into th Being on topo on bota tne nent Ea ae e ta mar ghas Sl MAINTENANCE Engine Oi nd Filter Service WARNING Recommended Engine PSA Plus Synthetic Engine OU EN 2876244 Quart Ambient Temperature Range caution 2 16 Crankease Drain Plug Torque 161 bs 22 Nm Oil Fiter Torque Turn by hand until ter gasket contacts sealing surface then turn an additional 1 2 turn Ou Fiter Wrench PU 80105 25 64 mm MAINTENANCE Engine Breather Hose Inspection Engine and Transmission Mounts Compression and Leakdown Test conserere Compression riga wi a pr Service tima 15 Exhaust Spark Arrestor A wanna ew protection goi 2 17 MAINTENANCE TRANSMISSION AND GEARCASES Transmission Gearcase Specification Chart J Rags Dave F
18. mm
19. ENGINE SEHE Ei NOTE Install the Cam Gear Alignment Tool PU 5407 2 into one assembly hole corte clockwise ftom te tng mat NOTE For of the Cam Gear Alignment Too motion then pushing down on the tool ENGINE ENGINE EN NOTE Be place tapered end o the valve comin ih aetna i Presse and ll priming problem wil 344 ENGINE NOTE ony remove att damaged When te boli uses gun to eat and Lo This wt prevent any posible damage ote ol tothe 345 ENGINE nak Si MOST ATI mm Exhaust St 2382 ENGINE sedans ENGINE REASSEMBLY Crankcase Reassembly CAUTION TTE wd SEL ol Roles win Primer PN 287425 to remove any A MAG 1 054 0038 A2 10 mm CTR ta 0009 1502 010 mm Ia In mm 225 omme HETE n mm St 0 027 070 mm Lima 0039 C10 mn NOTE ep aa damaged tany patie NOTE Replace the engine crankcase assembly Cnet aw
20. POLARIS Way Out 2011 RANGER RZR RZR S RZR 4 SERVICE MANUAL PN 9923142 POLARIS The Way Out 2011 RANGER RZR RZR 5 RZR 4 SERVICE MANUAL FOREWORD UNDERSTANDING MANUAL SAFETY LABELS AND DIRECTIONS pot hie tri Mog yor tb li ya A warning caution CAUTION TRADEMARKS GENERAL INFORMATION m MAINTENANCE 2 ENGINE ELECTRONIC FUEL INJECTION m BODY STEERING SUSPENSION E CLUTCHING FINAL DRIVE TRANSMISSION BRAKES ELECTRICAL GENERAL INFORMATION CHAPTER 1 GENERAL INFORMATION MODEL INFORMATION 12 VEHICLE INFORMATION E 13 SPECIAL TOOLS GENERAL SPECIFICATIONS MISC SPECIFICATIONS AND CHARTS E 14 GENERAL INFORMATION MODEL INFORMATION Model ection Engine Designation Number VIN Identification Vehicle and Engine Serial Number Location The VIN can be ond amp ame rl th eon wh site 1 12 GENERAL INFORMATION VEHICLE INFORMATION Publication Numbers Replacement Keys Key Seres Number SPECIAL TOOLS NOTE Polaris to Publications can be found at 13 GENERAL INFORMATION GENERAL SPECIFICATIONS MODEL 2011 RANGER RZR
21. Piston Pin Bore See 800 EFI Engine Service Specifications on page 38 3 36 ENGINE Starter Drive Bendix Removal Inspection See 300 EFT Engine Service NOTE Do not thread the puler bolis into the on page M more than 14 of sitor cole may e IAE Noe e Papa o plus m EN a 7 SS Piston Ring Installed Gap See 800 EFI Engine Service Specifications on page 38 ENGINE wheel Stator Removal Inspection Dans TER caution 3 38 ENGINE caution 2871043 Nic the ponen of he gean inthe pat ENGINE gar caution NOTE replacing one ol ine gear tte gear be replaced feu aged va scam PU4S49741 NOTE Install the Cam Gear Tooth Alignment Tost ino the assembly hai counter Socie rom he timing mark eee page 342 13 Accent Timing Marks 3 40 ENGINE Tabs Inspect Te Replace 3 Springs Install Springs NOTE Do not remove ne taparsa pins at iis ime E PU 45497 1 k 3 41
22. 10 41 ELECTRICAL ELECTRICAL SYSTEM BREAKOUTS m mere E GROUND AT ECM PIN 228 REQUESTS GROUND OUTPUT AT PIN 217 UNDER CONDITIONS WHEN AWD IS PERMITTED Vehicle Speed Sensor EUER vs sow EZ VEHICLE SPEED SENSOR SIGNAL ENTERS ECM ON PIN 245 TRANSMITS ENGINE SPEED MESSAGE ON CAN BUS TO THE SPEEDOMETER FOR DISPLAY VSS VEHICLE SPEED SENSOR 10 42 ELECTRICAL Cooling Fan jim pest pem a i tT ae AE gt EX EE FAN RELAY TO RUN THE FAN MOTOR WHEN NEEDED 10 43 ELECTRICAL Charging System NO 133HMAT4 9319901 4011 youvinesy 4 10 44 ELECTRICAL Chassis Power 1045 rs Fame nouae nr T mem ELECTRICAL Battery Power xua 10 46 ELECTRICAL Electronic Power Steering EPS EN sow CONTROL CANBUS key n e oor
23. Operation Overview Temperature FTO ECT Sensor Test ECT Sensor Replacement LES 434 ELECTRONIC FUEL INJECTION IGNITION COIL Ignition Coll Tests Operation Overa Falo hatin sd esti de ei Wc sea W a sal wanes Dar me Ignition Coll Resistance Readings ignition Coil HT Lead Replacement TE WD Rag Es Tor sin ibs 4 35 ELECTRONIC FUEL INJECTION DIAGNOSTICS n Instrument Cluster Trouble Code Display NOTE there diagnostic probem withthe 4 36 ELECTRONIC FUEL INJECTION DIAGNOSTIC TROUBLE CODE TABLE ELECTRONIC FUEL INJECTION DIAGNOSTIC TROUBLE CODE TABLE 4 38 ELECTRONIC FUEL INJECTION Troubleshooting o ho ki poping Symptons yen sae erem Fouled spart ag Sympto
24. A caution CV Boot Clamp Pliers artes Type 8700226 79 FINAL DRIVE PROPSHAFT SERVICE Removal Installation RZR RZR S nil ninsn ne mn Gas ken per uh om A caution FINAL DRIVE FINAL DRIVE 8 M remaning the rear ponian e a Support Bearing Replacement RZR 4 FINAL DRIVE SEA Nm wa PROPSHAFT U JOINT SERVICE Disassembly A caution FINAL DRIVE FINAL DRIVE FRONT GEARCASE CENTRALIZED HILLIARD Centralized Hi Exploded view on rer FINAL DRIVE All Wheel Drive Operation A caution FINAL DRIVE AWD Diagnosi Symptom AND Wil Not Engage Slee tad ia ded piat eby ns pi na men Sum ae pc he cove Front Gearcase Coll Resistance 216 264 Ohms
25. ELECTRICAL k NOTE Il is important to tighten the bottom starter 2 ELECTRICAL Starter Solenoid Bench Test Tot a sles by panering the snl e Starter Solenoid Oper om 3 10 34 ELECTRICAL ELECTRICAL STARTING SYSTEM TESTING FLOW CHART Condition Starter tails to turn over the engine 1 Ye 10 36 ELECTRICAL ELECTRONIC POWER STEERING EPS EPS Operation ne nn wanna NOTE See Chapter 5 Body Seeing Suspension 15 gerer seg unl ramm a2 aon EPS 8 Way Wire Harness Connector Wire Color Functions sew e EEI Proper EPS System Osos en 10 37 ELECTRICAL E er ELECTRICAL ing Power Steering Non Functional with MIL ON H 10 39 ELECTRICAL EPS Troubleshooting Power Steering Non Funetional with MIL OFF BE MTA 1040 ELECTRICAL shooting Using Digital Wrench ee EES Toth rer Coe esting Ao ri ungen ata vonage ovar un as 1 eaten Soong mato 1 cp Mcd
26. EFL DIAGNOSTICS EFI Component Testing ses nC FUEL SENDER Testing wein Fuel Sender Empty 90 45 0 Fud Sender Full 10 19 ELECTRICAL FUSE BOX FUSES RELAYS CIRCUIT BREAKER Overview Operation 10 20 ELECTRICAL Fuse Box Detail 40 21 ELECTRICAL Relay Operation FAN RELAY CHASSIS RELAY FUEL PUMP RELAY provides pouer to ling er FUEL PUMP RELAY pm ER RELAY u zii 1022 ELECTRICAL REAR DIFF SOLENOID RELAY INTL 10 23 ELECTRICAL CHARGING SYSTEM Current Draw Key Off A caution Current Draw Key Off Maximum of 01 DCA 10 mA Charging System Break Even Test caution 10 24 A wanna Charging System Alternator Tests A TEST 1 Resistance Valse of Bach Ster ag
27. RANGER RZR S RANGER RZR 4 PN 9923142 Printed in USA FELAY BLOCK marie ml 3i DEE an a Eur FUSE FELSY BLOCK
28. 5 38 BODY STEERING SUSPENSION REAR STABILIZER BAR RZR 5 39 BODY STEERING SUSPENSION REAR STABILIZER BAR RZR S RZR 4 Removal Installation 4 Remove he ute a fe BODY STEERING SUSPENSION DECAL REPLACEMENT A wanna WARNING ua im ad pl caution SHOCKS SPRINGS FASTENERS Exploded View RZR RZR S Exploded View RZR S RZR S INTL tae ral partied paste compares Pura pani se Sond 541 BODY STEERING SUSPENSION Exploded View RZR 4 Shock Removal Installation 542 Shock Replacement IMPORTANT The spring retainer gap should be 10 rem the end of the spring upon instalation BODY STEERING SUSPENSION FOX SHOCK EXPLODED VIEWS FOX PODIUM X Piggyback Shock RZR S 543 BODY STEERING SUSPENSION FOX 20 Piggyback Shock RZR 4 uy Dern 544 BODY STEERING SUSPENSION FOX SHOCK SERVICE General Service Information Front Sh
29. EA ress Vea Seen ESS MODEL 2011 RANGER RZR EPS E Fe 75001 14 GENERAL INFORMATION MODEL 2011 RANGER RZR EPS sure B esed St Weigh 15 GENERAL INFORMATION MODEL 2011 RANGER RZR S MODEL NUMBER RIIVETEAC AD AW Try eon TAS Seer vende wege 75001 MODEL 2011 RANGER RZR S EPS INTL ie CIEE EEE TET Te aS 16 GENERAL INFORMATION MODEL 2011 RANGER RZR S EPS INTL ys Rae Ba gi 17 GENERAL INFO
30. ENGINE Valve inspection 972 001mm cana Thoy be replaced 0 0075 mm NOTE The valve guides cannot be replaced ENGINE Combustion Chamber ar abrasive to Dean boton fhe Sander ned Erencv mag tte cylinder head Fest Wear safely lasse dung Seanin Valve Seat Reconditioning By a teca machine shop that ini NOTE The cylinder head valve guides cannot be replaced WARNING Valve Seat Inspection Proper al the way around me seat i compression leakage wi rau the sat i reduced causing jon and posse compression ety relig in but ve OOO 329 ENGINE ee i ak po NOTE When using an the seat Sorge on ae sl ve narom ara e oni point al the may around tne valve ace A 3 30 imt 071 18 mm nda ma compe ENGINE tein pila id ln NOTE Lapping is not required with an interference waive jo Cylinder Head Reassembly maintain proper order L Ang ot pus wd ea ken thn oh NOTE A aman magnet can Installation ofthe keepers NOTE To prevent damage to the valve seats do not sth valve sping
31. ENGINE COOLING SYSTEM Cooling System Specifications Awasnine Temperature Fre warm or not The cooing stom a unter Antifreeze Pressure Cap Test n Galon Cooling System Pressure Test 341 ENGINE Cooling System Exploded View po Engine et Hose ones rig on File Neck 312 ENGINE Cooling System Bleeding Procedure A wanna Tree ver SSE TT TAS caution d o nthe cso ae caution 3 13 ENGINE wanuna bon al ma qe mn GENERAL ENGINE SERVICE tion Specifications PO PLUS Sale 2735 pel 6000 RPM Polaris PLUS Engine Lubri 188 3 Acces le Engine Components Oil Pressure Test OU Pressure at ou Pressure 6000 RPM Engine Hot Minimum 27 pl Standard 31 pl Maximum 35 pd ENGINE Ou Flow Chart o pm pza Be
32. Hg Imes EPS TL POWER KEY SWITCH SUPPLIES POWER THE EPS CONTROL CIRCUITS AND ACTIVATES EPS RELAY TO ENERGIZE THE POWER LINES TO THE EPS UNIT EPS CONTROL SIGNALS ARE RECEIVED FROM THE CAN BUS 10 47 ELECTRICAL Engine Start Starter Interlock BATTERY A nde Heal nc Amy Exploded Vw Sine Danny Sind Heng To bese 5 ant Dipl Wen Ups Ni Ves anid iD Bice etate Dive di Weg rd in Clg Sp al Dan eral Sy Breau Amen ial 1 Bat eod m porem Tomer kau ECT m na cSt is Deena Nunc Ena Ede Vier poire Ol nd iter Cage 118 D How Chae m Di Pa Ka Engi Ou Paine m opes Ou Pomp bal n 1 Engi Remora m sena Namie ocn npa Sere Spinne Temp Sener du Tempe nce Tat iu npa Sec us 8 3 Bale Sa Remora m w Cuna sp ni Cami lt mi Cong Synem Fac 2 m Crab ion m 2 3 Eng Cnr Hel sp 1 Cnr Hel Remo Cine Wa ix Eng Cline Honig mi Cine pen m npa Sunde ace 1 Cynder Renal 2
33. at Water Pump Weep Hole 3 62 ELECTRONIC FUEL INJECTION CHAPTER 4 ELECTRONIC FUEL INJECTION GENERAL INFORMATION FUEL TANK ELECTRONIC FUEL INJECTION ELECTRONIC CONTROL UNIT ECU TEMP MANIFOLD ABSOLUTE PRESSURE SENSOR MAP CRANKSHAFT POSITION SENSOR CPS FUEL INJECTORS FUEL PUMP OLE CONTROL AC THROTTLE POSITION SENSOR TPS CAMSHAFT PHASE SENSOR ENGINE COOLANT TEMPERATURE SENSOR ECT 1982 EFI DIAGNOSTICS DIGITAL WRENCH Y OPERATION EFI SYSTEM ELECTRICAL OPERATION 41 ELECTRONIC FUEL INJECTION GENERAL INFORMATION WARNING s Postion Sensor TPS Tester 2201519 A 2201519 2 Special Tools NOTE Voltage Regulator 57827 ie required Using TPS Tener Wie You may 42 ELECTRONIC FUEL INJECTION TES Tester Regulator 547927 kr tn pn NOTE You may have regulator marked part of another TPS Taster Kit you do ot have the regulator you must order one frm IMPORTANT The FI ul system remains under high Pressre venen engines natrunnino Boot Semet 10 service any part of the fue system must tl The Ful Pressure euge Ingrid presse roll valve at canbe used eed once you ive completed he tel pressure Fuel Pressure Gauge Adaptor
34. more necessary 10 3 31 ENGINE Valve Sealing Test Cylinder Removal 3 32 Valve Lifter Removal Inspection 1 Remon the valve tr by reaching imo ke pig ier gh H ba b und zing solve an wipe is not smooth should be replaced with new lifters Ana cam an soso the Mars he SAN head be plated ENGINE ENGINE Cylinder Inspection Ra o tm Max leder Out ot Round 050 Tage Ws DOF TT Standard Bore Sie Both Cylinders 3 1496 80 mm ENGINE Cylinder Hone Selection and Honing Procedure Cine may be war bal pening pa de ne a jie i ed wis ss CAUTION ation bere par kz E arina Ode my te waway Honing To Deglaze Crs Mah Panem Cleaning the Cylinder After Honing 3 35 ENGINE Piston Pin 00 See 800 EFI Engine Service Piston to Cylinder Clearance See 400 EFI Engine Service x Mesure comen ae Piston OD See 800 EFI Engine Service Specifications on page 38 Piston Rod Inspection Connecting Small End LD See 800 EFT Engine Service Specifications on page 38
35. updates subject to change 4 42 ELECTRONIC FUEL INJECTION Digital Wrench Feature Map Digital Wrench rs 2 3 one the ASSERT 7 po 9 unr mera para Fm b an a np Tes jes a Emi 4 43 ELECTRONIC FUEL INJECTION Engine Controller Reprogramming Reflash oC may py DM shan Sna ann IMPORTANT Failure to follow the reprogramming instructions completely and can reut man gine that doe nol run Replacement ECU are Bra S eos wd qur sri lr programming Rash Tos ie sn w ng ag d k tps sepes da Dea ponn opcs are pan dal and amet de sma men lin ae 444 FIL Pe rama mi de et Sts cnn sui Thx 4 aa w femi kagome pc Beprogrammig Rest Procedure ez ee nade en and Upc Don pope 41 ELECTRONIC FUEL INJECTION 2 Open gil Wren pga 445 ELECTRONIC FUEL INJECTION 4 47 ELECTRONIC FUEL INJECTION EFI SYSTEM ELECTRICAL OPERATION cee 74954 SONS NOGISVESTOO NOLLINDI OL S3QIAONd 1423 TANA OL 39V1TOA 03118 NI SNL TAS 109 0730 MN
36. wheal tin top 14 524 12 nr eit pti ee Fg BODY STEERING SUSPENSION ELECTRONIC POWER STEERING ASSEMBLY BODY STEERING SUSPENSION Upper Steering Shaft Rer BODY STEERING SUSPENSION Steering Wheel Removal EPS Models 3 Usas a upc base da and ui the ii CAUTION Power Steering Unit Removal B CAUTION 527 BODY STEERING SUSPENSION wanna BODY STEERING SUSPENSION Lower Steering Shaft Removal EPS Models Power Steering Unit Installation oun racket BODY STEERING SUSPENSION Upper Steering Shatt Installation EPS Models CAUTION Positioned corecti see Exploded View 5 30 ere A Sag We EE ENS TSR E GO Nm BODY STEERING SUSPENSION FRONT A ARMS Removal Replacement rone Arm bigs it ube apa wanna x arm dere des Kam ad 17 amine A am ngs site pi 18 ne arm plate opm n WARNING TE FT Fon Upper Ram au EE e 80 Nm RR ST RZ 8 Nm EEE Car Nm 8 4
37. 0 FRONT 9 16 Disc Inspection BRAKES Brake Disc Thickness caution Nov iB am Seni tna Stem Serie Link oe Sa See E S 9 17 BRAKES REAR BRAKE PADS caution BRAKES Pad inspection Pad Assembly Installation Rear Brake Pad Thickness New 298 4 007 7 57 mm 178m Service Limit 180 4 6 mm WARNING ie Master Cylinder Fluid Up to MAX line inside reservoir Burnishing Procedure Son machine Gay way male us ct RS Dona mae mare tha u per te Lon 9 19 BRAKES REAR CALIPER SERVICE Caliper Exploded View BRAKES BRAKES Caliper Installation REAR BRAKE DISC me mama md pl amat Repl beyond service S 1 Brake bix Tias Bee Serie iit 190 32 mm Brake Dic Thickness Variance Seve Limit 002 881 mm ARE TIT 2 9 23 BRAKES Disc Replacement TROUBLESHOOTING 1 Henne
38. 16 nj cc ia e Boot Clamp ee d 7 34 FINAL DRIVE Drive Shaft Exploded View Drive Shatt installation Isme FINAL DRIVE caution Fan SIRE B Nm Cone Washers Wheel Hub wt EXE D ei 7 36 FINAL DRIVE REAR GEARCASE Gearcase Removal FINAL DRIVE Gearcase Disassembly iena ge so NOT Pinion and ring ger shining information ie esed Te Component are machte ato located under wach bearing Keep sh together tor reso FINAL DRIVE 3 Ingest ing ee vaa cries sh wa ng l pl te replacement the etre be piace Bearings or housing requires replacement e enr mus be repaced 7 39 FINAL DRIVE Gearcase Assembly 2 mo sl ach ale quad bnin a WARNING FINAL DRIVE FINAL DRIVE Gearcase Exploded View FINAL DRIVE REAR GEARCASE RZR INT L General Operation 7 43 FINAL DRIVE
39. 5 4 1 44 m npe Saw ix 1x2 Engi yate moral m nga Gearts ona i on E nga Od Pong Remon E Pto m posten B nga Pawa Rig old Gp E Pawa o Code Cece 1 Pto iae 1 2 ix Am nectar ix Roma m npe Cono Sino 122730 Sur m Tics Vac ir Removal pci m nien yaw Sali Sr ix Vat Slat ta Mes VS nig F Festi a besten G eS in Sant aoa u maa Ca ie ale p L Quek Reins Chat Pps Suppor Benn Reisen opi ha Se O Dion EY par bl EVT ine Cimen Sp war R ee Rez Dv Saat Boo Resco Re Drive Sh gn on Bot T Rew Gen Ain INTL Rea demas Disc Row lao ZR S INFL Walter Evans gt Walker Evan Din E ox Du view ARS aa Ed s ei vae Sng eae Er Seng weet Rano FOX a Spence Spring rod Asja 28 VIN Laan sping ed naar Vtg Drop el Hale Lagh Wal 41 ie re Ane Pate SS per prn E merce Sha sg RANGERRZR
40. Bolt Torque 170 ths 23 5 Nm Drive Clutch Retaining Bolt Torque 54 Nim 68 CLUTCHING A caution 69 CLUTCHING DRIVE BELT CLUTCHING DRIVE CLUTCH SERVICE Spring Specifications caution may real in capo Primary Clutch Springs CLUTCHING ns Pn 1322914 Pu Pusan Bushed Wolght Drive Clutch Exploded View CLUTCHING Clutch Disassembly Bi Nc B arsi Clutch Holding Fixture Spider Removal Tool PN 2870341 CLUTCHING CLUTCHING re Shit Weight Inspection 3 B A wanna CLUTCHING Clutch Inspection NOTE Remove cover spring and spider flowing site fr die en rose Standard 030 mm 244 6 16 stndar t 491 2430 mn Service Uni 13730 mm Standard 030 76 CLUTCHING Moveable Sheave Bushing Inspection Bushing Service Shes IMPORTANT Special Tools Required Sing De glare nates me 3M Sachse EBS Clutch Bushing Kit 2201379 Additional Special Tools Pa
41. CTRICAL Fic ra gt lt En Liv jm ELECTRICAL NOTE there ie ton with he luminata and blink in place of the check engine MIL Instrument Cluster Pinouts FONCTION Instrument Cluster Installation riernstons Gay strument Cluster Removal MOTE sto 3 acing yon ndi att cl op 3 Apply pese an he bezel vhi rong 10 14 ELECTRICAL ALL WHEEL DRIVE COIL Operation Overview Diagnosing System Failures HEAD LIGHTS Headlight Adjustment 40 15 ELECTRICAL ELECTRICAL TAIL BRAKE LIGHTS Bulb Replacement leering lia malt Paling bu at Replace ati bal Eu 10 17 ELECTRICAL COOLING SYSTEM Cooling System Break Out Diagram 10 18 ELECTRICAL Fan Control Circuit Ope yn Testing A caution ana pad lt Copier arc Fan Control Circuit Bypass Test Coolant Temper sens 2 Wik us mer ia he mode pac mete ede he radiator auto ON
42. Installation 4 28 ELECTRONIC FUEL INJECTION IDLE AIR CONTROL IAC Operation Overview IAC Test lcd stab chi mig e ct Smigh AC IAC Replacement c Connector IAC Resistance Readings 4 29 ELECTRONIC FUEL INJECTION THROTTLE POSITION SENSOR TPS Operation Overview Tre correctposinan otin roe body stop established st a ine factory BONOT gasen me rate body stop screw postion in any manner The stop screw contrats te air How calibration othe bos stop serow te repositioned or adjusted tne ae body must be replaced 4 30 TPS Resistance Tests ea tn vias a along TPS Connector TPS Resistance Readings TPS Tester Regulator ELECTRONIC FUEL INJECTION TPS Replace ELECTRONIC FUEL INJECTION CAMSHAFT PHASE SENSOR Phase Sensor Replacement Gn e a NOTE Use Digital Wrench Diagnostic Software nt you suspect he sensor s ou 4 33 ELECTRONIC FUEL INJECTION ENGINE COOLANT TEMPERATURE SENSOR ECT
43. L DRIVE MECO caution FINAL DRIVE FRONT DRIVE SHAFT amp Remove pr bl Drive Shaft Removal caution EER 76 FINAL DRIVE Drive Shaft Joint Handling Saget oc hot engine and erha compact Outer CV Joint Boot Replacement NOTE Electronic Parts Catalog tor the Pre pri sevice he drive hat Some dive lis have Boot Replacement Ki that incude few tect Ind We rare amm d qa IMPORTANT grease in the joint obviously Contaminated wit water andlor dirt the joint should Be replaces taz ia al pie uns ling ee NOTE Ii very important to use the caret rer ie ini 05552 A Use asoli faced hammer brass dito separate the outer imi foren romancing irom ur a Gy FINAL DRIVE 78 Boot Clamp Pers Ears Type 8700226 cpl CV Boot Clamp Pers areas Type 8700226 Inner Plunging Joint Boot Replacement CV Boot Clamp Pliers ales Type 8700226 km ra o Wa jin n caution contaminated with water and or dir the joint shouid paced FINAL DRIVE
44. ND TIRE ELECTRICAL AND IGNITION SYSTEM 226 STEERING 22 21 MAINTENANCE SUSPENSION STANDARD E om s SUSPENSION WALKER EVANS Fa BRAKE COMPRESION AD UST 222 22 MAINTENANCE PERIODIC MAINTENANCE CHART Periodic Maintenance Overview NOTE Service and adjustments are 00601 youve not famila with sate service and adjustment Proset Reve quel prior hese operations Breakin Period Maintenance Chart Key gt CAUTION Due to the nature these adjustments i recommended thi service be performed by an E Emission Control System Service Cloris A wanna 23 MAINTENANCE Pre Ride 25 Hour Maintenance Interval pes w jel ta nam 24 MAINTENANCE 50 500 Hour Maintenance Inter HZ 00061009 esparce et Tenere a E Eman Cool Sara Calor 25 MAINTENANCE Maintenance Quick Reference Fen veo PRR tte merus parm or saate rue yant are N mes or Pe 1 Engine Benna Pa
45. PADS Pak te nn Pad Removal caution cyinder BRAKES Pad inspection Pad Assembly 1 x marino Front rae Pad Thickness T 3348 99 BRAKES Master Cylinder lid Up to MAX line inside reservoir Missam Vina 30 8174 Brake Burnishing Procedure machine and uy pedo Gly 9 10 BRAKES FRONT CALIPER SERVICE BRAKES Caliper Removal A BRAKES oxy per pin NOTE Be sur to clan seal grooves in caper boy 9 13 BRAKES Caliper inspection 2 Ki 1 1mm 1 002 25 45 mm Sa 22568 mm bu lt n Ez ki Xn BRAKES Caliper Assembly IMPORTANT Wa scraper was removed reinstall it Upon caliper instalation RR 4 Or T BRAKES FRONT BRAKE DISC Disc Runout NOTE new pads are instalo reler 1
46. RMATION MODEL 2011 RANGER RZR 4 Ty eon O ESSE Capuc E0 be MODEL 2011 RANGER RZR 4 EPS ier Ty weg IEA USA 18 GENERAL INFORMATION MODEL 2011 RANGER RZR 4 EPS em wom seine 19 GENERAL INFORMATION MISC SPECIFICATIONS AND CHARTS Conversion Table 23 003 EE ORT Fades co Br ca Cut nn won egara pris E eU 00600 frar pear GEJ seam ua np o u IDE ame OST 54950554 een ION rss ER ALI paras cour E ogame one a sa e E Wipes
47. RONIC FUEL INJECTION ECU Service ECU Replacement Toin ber E TEMP MANIFOLD ABSOLUTE PRESSURE SENSOR T MAP Operat n Overview T MAP Sensor Test me repr the Dig Wrench Dagnoste Software dei E T MAP Sensor Replacement ELECTRONIC FUEL INJECTION gt CPS Test 252251 CRANKSHAFT POSITION SENSOR CPS Operation Overview 1 Connect an hawa the pa emia ning sand CPS Resistance Specification ba Dt en m AC Fellow to White 600 2 105 reagan enon Black to Ground 0 050 10 4 12 ELECTRONIC FUEL INJECTION ELECTRONIC FUEL INJECTION NOTE Special tool PA 4B73 wit be required to ERES ES 444 ELECTRONIC FUEL INJECTION FUEL INJECTORS Operation Overview ELECTRONIC FUEL INJECTION Fuel Injector Service NOTE Do not apply voltage directly to the et Injectors Exceso voltage wil fur out the lector Do nat ground the injector win the oy i tempt to daconned te connector rom the Vul E Fuel Injector Resistance Spe
48. SMISSION Z NOTE Shit cable bracket instalation is required ERA T a Novara Serve TRANSMISSION TROUBLESHOOTING Troubleshooting Checklist Te in tg iy ce EE SS EX ai and spec gear dogs or wear rounding damage Inspect bearings clipe 8 18 TRANSMISSION TRANSMISSION EXPLODED VIEW Shift Housing Transfer Case Exploded View Bueno uns m TRANSMISSION NOTE 820 BRAKES CHAPTER 9 BRAKES GENERAL SPECIFICATIONS TORQUE SPECIFICATIONS a SPECIAL TOOLS a BRAKE SYSTEM SERVICE NOTES BRAKE NOISE TROUBLESHOOTING HYDRAULIC BRAKE SYSTEM OPERATION BRAKE SYSTEM EXPLODED VIEW 35 MASTER CYLINDER HM BRAKE PEDAL LEVER BRAKE BLEEDING FLUID CHANGE FRONT BRAKE PADS FRONT CALIPER SERVICE an FRONT BRAKE DISC T REAR BRAKE PADS E REAR CALIPER SERVICE REAR BRAKE DISC TROUBLESHOOTING BRAKES GENERAL SPECIFICATIONS TORQUE SPECIFICATIONS SPECIAL TOOLS ae EL 92 BRAKES BRAKE SYSTEM SERVICE NOTES en
49. Stator Cover Starter Water Pump Lubrication System Exploded View 34 ENGINE Cylinder Cylinder Head Piston Exploded View ENGINE Engine EFI Sensors Valve Cover General Components Exploded View NOTE See chapter for mare information on the EF System 36 ENGINE Engine Torque Specifications Fastener pru quo 37 ENGINE 800 EFI Engine Service Specifica Cylinder Head Engine Specifications Tin Component nr 1202707 38 ENGINE Cylinder Piston Engine Specifications Man Components Older Paton Connecting Rod Piston Connecting Rod i Crankshaft Engine Specifications Components Paton Connecting Rod PERIOD 39 ENGINE Special Tools Part Number Tool Description 3 10 ENGINE
50. aged or wor ENGINE ENGINE ENGINE ENGINE caution NOTE Occasionally spin the ol pump when al to check tr ENGINE NOTE Cam Spanner Wrench only Euro L Nm ENGINE Bete lizz laos NOTES Inetal the erankehft seal P wih the sest ip tls agar Being fwar the ern em de a al pne Se harp io pe Ip NOTE remove the water pump seal the gear tty e Coni ENGINE NOTE Betore assembly clean the bolis and bol N Roles win Primer N PN 2874278 to remove any Tie proper vien 106 ain GA 3 55 ENGINE Tae 98 7 be 88 53016 ENGINE EA 3 57 ENGINE 20 5 e 15 055 Nm Pump Priming CAUTION ENGINE er engine ma lr B PLUS Sons age Oi FN Am La ing Na ADR ot et la ue
51. an Walker Evans Shock Assembly provided carer hia seen IMPORTANT torque ihe nutor damage lo NOTE Mat washers ore or 5 59 BODY STEERING SUSPENSION BODY STEERING SUSPENSION 1 Puta pais up ey 1 2S4 c NOTE During Installation some shock over fs e md eee Ht op in and soc bo o IMPORTANT when the Too i removed the Iman mman submerged in sl ie proven a2 Sethe IFP eo psd agi omer on geting under he Homing piston 8 roe Wie eka Z Elm NOTE Apply grease to the end of Allen wrench ZC 5 61 BODY STEERING SUSPENSION A wanna mar SRR eT tay o era soo nd the suspension is performing ore 5 62 CLUTCHING CHAPTER 6 CLUTCHING SPECIAL TOOLS AND SUPPLIES TORQUE SPECIFICATIONS 52 PVT SYSTEM OVERVIEW 8 PVT SYSTEM SERVICE es DRIVE BELT 610 DRIVE CLUTCH SERVICE DRIVEN CLUTCH SERVICE TROUBLESHOOTING CLUTCHING SPECIAL TOOLS AND SUPPLIES SYSTEM OVERVIEW TORQUE SPECIFICATIONS System Fastener Torques
52. ari Main Bearing ES MAGNETO SIDE p ems Pen Man Galery 1 E Fiter En 315 ENGINE ENGINE ENGINE ENGINE ENGINE ENGINE 3 23 ENGINE ENGINE DISASSEMBLY AND INSPECTION Cylinder Head Assembly Exploded View _ Retainers a tl Head re tes 24 ENGINE A wanna ENGINE Cylinder Head Inspection CAUTION Cylinder Head Warp rider Warp Uni T018 mr 3 26 Valve Seal Spring Service On Engine NOTE The folowing procedure is only tor servicing top endothe vlr ak when epacing valve Springs o replacing vale sete wanna inser hed and raster sa tal Host the baz w n ai Sos y Sov dete Tic wi sere sis Se van qi mma a mt NOTE A smal parts magnet A can aid in the removal ofthe reiner EY NOTE To prevent damage to the valve seste do compress he valve spring more than 1s needed fo Tenore he viv ENGINE Cylinder Head Disassembly
53. cification 1260 connector tor proper engine uncon PTO GRAY MAG BLACK 4 17 ELECTRONIC FUEL INJECTION tol 10 separate at a lesion ELECTRONIC FUEL INJECTION FUEL PUMP Operation Overview E A Fuel Sender Test 4 19 ELECTRONIC FUEL INJECTION Fuel Pump Test Normal Fuel Pressure 45 2 pl WARNING Battery ignition sich relays wiring harness and Ae ELECTRONIC FUEL INJECTION Fuel Pump Replacement mm wanuna Pun mese trai Fo CAUTION caution el ine or tank Property drain ue into suitable 421 ELECTRONIC FUEL INJECTION ELECTRONIC FUEL INJECTION CAUTION ELECTRONIC FUEL INJECTION Fuel Tank Reme A WARNING ELECTRONIC FUEL INJECTION ELECTRONIC FUEL INJECTION Fuel Tank Removal RZR 4 S Remove kw bot ring hun WARNING TE Remove the us tank cap and 4 26 ELECTRONIC FUEL INJECTION ELECTRONIC FUEL INJECTION city Fuel Tank
54. e b more WARNING boron Battery PN 4011496 Aston Battery PN 4011224 Tas vonage mc Charing Procedure oe ae 10 29 ELECTRICAL STARTING SYSTEM Troubleshooting ester led sse Voltage Dro exo ge Do es 10 30 Voltage Drop Test de A cometa wil ONN Ni Soon imm ate kaw depron rer pom Starter Motor Removal Disassembly motor parte Some solvent may lave a residue or Sage tral parts an relation Ramone tet tl waa eg Ops Ringe esi dana ELECTRICAL NOTE Note the alignment marke on both ende ot 3 Mono between aa bi sse eate motor easing These marks most oi Menz alte Loge during reassembly rah wear arr S punit NOTE The input post must stay withthe fita housing Brush Inspection Replacement 4 did andi pl T 4031 ELECTRICAL Bruch Replacement ic a ee psig amp I 09g he grand rma pe A caution uc coc c Armature Testing 2 open aa of ny 10 32 caution ter mu be paces Starter Reassembly Installation 1 tal bush pla to eld magnet housing gig FO
55. e Washers caution Apply es ale 7 28 FINAL DRIVE At REAR DRIVE SHAFT Drive Shaft Remova A caution 7 29 FINAL DRIVE FINAL DRIVE E caution Spheres are normal Do nai replace CV lonis io oi V are credi betas worn caution Bout Replacement Grease Requirement Grease Only Service Kits stent sep PN a 731 FINAL DRIVE Axle Boot Clamp Tool CV Boot Clamp Pers 8700226 7 32 Boot Clamp Tool CV Boot Clamp Pliers 700226 FINAL DRIVE Inner Plunging Joint Boot Replacement E u A caution s r IMPORTAN e Joint is obviously Contaminated wit water andor drt he joint should FINAL DRIVE A caution Boot Replacement Grease Requirement Greate Onl Service Kits PN soe tet ss Boot Clamp Tool CV Boot Clamp Pliers 700226
56. e un cab rei completely sentit on vehice Ai rear ob rune sod the o taune ci 2nd wath four CUI and k m am 54 BODY STEERING SUSPENSION FRAME RZR 4 Assembly Remove NOTE Figen component unt cu g me pa Ab ae pr ad cav ld ram completely assembled on vehicle then tighten a 7 GER Nm Panen a act the l Nackt cn cach side ap ccm o 20 Nm nases i B ah ne Bob el sI a H 3 gnc ai eo pa ta Boni 25208 gt l ma lt 5 us A ver gd D SS EH um E 55 BODY STEERING SUSPENSION BODY EXPLODED VIEWS Side Safety Nets 56 BODY STEERING SUSPENSION BODY STEERING SUSPENSION Hood Front Body Work BODY STEERING SUSPENSION Front Bumper BODY STEERING SUSPENSION BODY STEERING SUSPENSION Floor Rocker Panels RZR RZR S BODY STEERING SUSPENSION Floor Rocker Panels RZR 4 BODY STEERING SUSPENSION BODY STEERING SUSPENSION Rear Cargo Box Fenders RZR 4 BODY STEERING SUSPENSION Chassis Main Frame RZR S BODY STEERING SUSPENSION Chassis Main Frame RZR 4
57. ee eke sr REAR CALIPER Brakes Squsal Poor Brake Performance Caer or Pedal Vibration E Caliper Overheats Brakes Drag Campers pon phage Brakes Lock A caution y een og 9 24 ELECTRICAL CHAPTER 10 ELECTRICAL GENERAL INFORMATION 103 SWITCHES CONTROLS 103 VEHICLE SPEED SENSOR 107 REAR DIFF SOLENOID NTL EM INSTRUMENT CLUSTER 109 ALL WHEEL DRIVE COL 1015 HEAD LIGHTS BRAKE LIGHTS 1017 COOLING SYSTEM 1018 EFI DIAGNOSTICS 1019 FUEL SENDER 1019 FUSE BOX FUSES RELAYS CIRCUIT BREAKER 1020 CHARGING SYSTEM BATTERY SERVICE 1027 10 1 ELECTRICAL STARTING SYSTEM STARTING SYSTEM TESTING FLOW CHART ELECTRONIC POWER STEERING EPS ELECTRICAL SYSTEM BREAKOUTS 10 2 ELECTRICAL GENERAL INFORMATION Special Tools Pa Number Electrical Service Notes Under Dash Components SWITCHES CONTROLS ake Light Switch 103 ELECTRICAL NOTE Pins 7 and B provide power and ground to Roh he sth tn ELECTRICAL Ignition Key Switch NTL AWD 2WD Switch ELECTRICAL 2WD TURF Switch 1 INTL
58. ind Bo E EA Transmission Lubrication 4 Adit comme dg lg ale un Transmission Specifications rapus Specified Lubricant AGL Pls Gearease Lubricant 30 45 in bs 55 Nm Fil Plug Torque 4050 ths SSS Noy MAINTENANCE Remove let plag and hack ec Level Chock Pug Transmission Lucani Change sce pan std e li Transfer Case Lubricant Change e dde ied i e Sheps mel lg Mpima e eve pg 048 Be Renal pod o B Main Gesresse Lubricant Change P Rene de l l pa er Mn One al pan under he main gue da 10 Remon di plug dei coll 14 Check ors Demi he ri propel pom Sex 2 amave te plug ii alow to drain completely 2 19 MAINTENANCE Rear Gearcase Lubrication ran like mr prre e Mileve Mec des de plug gue 2050 B Lubricant Change Te da pis ioe on the botom ght side oh d i an pk the Bh wih new d ta 7 Rai de pag 221 MAINTENANCE COOLING SYSTEM Cooling System Overview NOTE Some coolant level drop on new machine iz rot ly purged rom system Coolant Level Inspection 2 22 NOTE overheat
59. ing is evident allow system to Str and epe for sions of topped qr A wanna Slow ine recovery system to funtion propt Coolant Strength Type Polaris 6040 Ant Freene Coolant PN 2871323 MAINTENANCE Cooling System Pressure Test 1 Coty sien any ben ce tn Cooling System Hoses ki A cd da waw s pum B Coolant Drain Radiator Removal Z waana Y Tar Sa pe St e a caution ce ined sorte trip in Radiator 2 23 MAINTENANCE 2 24 FINAL DRIVE WHEEL AND TIRE Wheel and Hub Torque Table 0 e Wheel Removal A esas gio af the seco y ping Wheel 0022 MAINTENANCE B caution Tire Pressure A caution In opes ic aer on we Warning Aways replace tres when he ne depth TE em ore Tee Trend Depth MAINTENANCE ELECTRICAL AND IGNITION SYSTEM Battery Removal Battery Maintenance A WARNING wanna 2 26 caution MAINTENANCE Battery Installation Falon me 55 i im Chapter 10
60. m To High rt tan 1300 RPM wen Symptom ie Too Low ls an RPM wen epi Hugged sir te Symptom ra s 439 ELECTRONIC FUEL INJECTION DIGITAL WRENCH OPERATION Digital Wrench Diagnostic Software Overview IMPORTANT Re Satan 2 3 and tin De schon Man provides in ita Wrench Diagnostic Special Tools also refer to page 42 id above INCLUDES awa or HELP sock fr miriona vogue Diagnostic Software Version Stet outst nes pase econ ied ac spas a ey Mula fr on rio Dt Na en an Up Ib ECU Replacement dc i cd Guided Diagnostic Available 4 40 Digital Wrench Communication Errors somma domi iri Ma ELECTRONIC FUEL INJECTION Digital Wrench Diagnostic Connector Lacie und di mh as pla Digital Wrench Serial Number Location Digital Wrench Version and Update ID NOTE Versions and updates are subject o change 1 Open de Dipu Wasara na Lise ena IMPORTANT Aways operate with he latest update 441 ELECTRONIC FUEL INJECTION Digital Wrench Updates Unika Digtal Wen da I at pip i ne ms IMPORTANT You must already have version 31 Inne betore ing an updaten tl eae da ne NOTE Do not no open fam ware S NOTE Versions and
61. ock Service Information RZR S Front Shock Service Information RZR 4 a e B 545 BODY STEERING SUSPENSION Rear Shock Service Information RZR 5 Rear Shock Service Information RZR 4 D 4 546 BODY STEERING SUSPENSION FOX Shock Rebuild Information wanna og FOX sacks ard rontsa presare Pe ea 2 reap o Te Pie ar pee och E FOX eno IFS Hd il ana ne T Pi Spanner ene YE en Koy an ane TEE Werte ten en 20 82 Pimp E Tors Wrench but Feed er uqta 28 ragen Tank w Realtor 5 47 BODY STEERING SUSPENSION FOX Shock Disassembly 5 48 nay TG TEE ard body BODY STEERING SUSPENSION 549 BODY STEERING SUSPENSION FOX Shock Rebuild BODY STEERING SUSPENSION 9 Rep he Pd Di FOX Shock Reassembly 1 Clamp sy n ie an la be k Polaris Gas Shock Ol 5 wt PN 2870995 at PN 2872279 25 gal Uing e Del Seg Te P e 5 51 BODY STEERING SUSPENSION Al bene lee ek body ds
62. pak re salto scons in aren Sk pig ye mit BRAKE NOISE TROUBLESHOOTING utente pla kul CRC Walaa me BRAKES HYDRAULIC BRAKE SYSTEM OPERATION eat ep a pra a eee As e mane ae pte ai en A pl e it ae us a A age sat ba ne por car d una tm Du hg Str di deren kn nr teen BRAKES BRAKE SYSTEM EXPLODED VIEW E f BRAKES MASTER CYLINDER NOTE Mate ote of ton and rer Lome eH ine banjo bok C and alow adio Installation BRAKE PEDAL LEVER cl A clei pin Pedal Removal lt 424 Ss Pedal Installation rch ake ri e 228 mm caution 9 6 BRAKES BRAKE BLEEDING FLUID CHANGE B Ser ash ta ager tn caution caution Vac PN 2470075 Polaris DOT 4 Brake Fluid EN 2872189 Screw eight or air may be drawn ito master caution Master Cylinder Fluid Level Between the MIN and MAX line shown on the reservoir 97 BRAKES FRONT BRAKE
63. ssenger Set Manian Lave ne range 2 Engine Coolant Under Pront Pood 3 Brake Fluid Front LH wet Mester Cinder 26 MAINTENANCE Maintenance Quick Reference Continued a m Transmission 27 MAINTENANCE Grease Lubrication Points re gra tings arm pov pit ash toe sal aig py Tem L Tako Fen Boda Prepara B 28 MAINTENANCE LUBRICANTS SERVICE PRODUCTS NOTE aen tem ca be purchased st Saas Agents Misc LL ae Grease Specie 871420 ES 29 MAINTENANCE GENERAL VEHICLE INSPECTION AND MAINTENANCE Pre Ride Daily Inspection Shift Cable Inspection Adjustment bti tne proper juin 2 10 MAINTENANCE FUEL SYSTEM AND AIR INTAKE Fuel System A wanna Fuel Line Fuel Pump Fuel Filter he pun ont NOTE Reter to Chapter for tuei pump replacement And other iteration related ta the EF Vent Lines 241
64. tao Ings mad ie cct sn a 5 52 Shock IFP Depth Front 240 610 em Rear 8 64 em emer te IPP TIP Apply eso he o he BODY STEERING SUSPENSION BODY STEERING SUSPENSION WALKER EVANS SHOCK EXPLODED VIEW Walker Evans Compression Adjuster Reservoir Shock RZRL E BODY STEERING SUSPENSION WALKER EVANS SHOCK SERVICE Recommended Service Intervals Rear Shock Service Information 5 55 BODY STEERING SUSPENSION Walker Evans Shock Rebuild Information A wanna ss pana aa Valve Shim Arrangement greet o haw the shock assent nales Specie Toots special Toots amen ame Lp Piston Orientation BODY STEERING SUSPENSION Walker Evans Shock Disassembly Sng ssp ig emi nag une Shock the use oe arcanos A wanna mand tom esos bl ae soy permez ve sy a P 7 BODY STEERING SUSPENSION BODY STEERING SUSPENSION IMPORTANT Keep he te he was dar tn Ir
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