Polaris RZR, RZR 4, RZR S User Manual

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2011 RANGER RZR / RZR S / RZR 4

SERVICE MANUAL

PN 9923142

2011 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 equipped shop and should be kept available for reference. All references to left and right side of the vehicle are from the operator's perspective when seated in a normal riding position.

Some procedures outlined in this manual require a sound knowledge of mechanical theory, tool use, and shop procedures in order to perform the work safely and correctly. Technicians should read the text and be familiar with the service procedures before starting any repair. Certain procedures require the use of special tools. Use only the proper tools as specified. If you have any doubt as to your ability to perform any of the procedures outlined in this Service Manual, contact an authorized dealer for service.

We value your input and appreciate any assistance you can provide in helping make these publications more useful. Please provide any feedback you may have regarding this manual. Authorized dealers can submit feed back using 'Ask Polaris'. Click on 'Ask Polaris', and then click on 'Publications Question'.

Consumers, please provide your feedback in writing to: Polaris Industries Inc. ATTN: Service Publications Department, 2100 Hwy 55, Medina, MN 55340.

technicians in a properly

Publication Printed September 2010 (PN 9923142) Rev 1

© Copyright 2010 Polaris Sales Inc. All information contained within this publication is based on the latest product information at the time of publication. Due to constant improvements in the design and quality of production component s, some minor discrep ancies may result between t he actual vehicle and the inf ormation presented in t his publication. Depictions and/or procedures in this publication are intended for reference use only. No liability can be accepted for omissions or inaccuracies. Any reprinting or reuse of the depictions and/or procedures contained within, whether whole or in part, is expressly prohibited. Printed in U.S.A.

UNDERSTANDING MANUAL SAFETY LABELS AND DIRECTIONS

WARNING

CAUTION

Throughout this manual, important information is brought to your attention by the following symbols:

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.

SAFETY ALERT CAUTION indicates a potential hazard that may result in minor personal injury or damage to the vehicle.

CAUTION indicates special precautions that must be taken to avoid vehicle damage or property damage.

NOTE:

NOTE provides key information by clarifying instructions.

IMPORTANT:

IMPORTANT provides key reminders during disassembly, assembly and inspection of components.

TRADEMARKS

POLARIS ACKNOWLEDGES THE FOLLOWING PRODUCTS MENTIONED IN THIS MANUAL: Loctite, Registered Trademark of the Loctite Corporation Nyogel, Trademark of Wm. F. Nye Co. Fluke, Registered Trademark of John Fluke Mfg. Co. Mity-Vac, Registered Trademark of Neward Enterprises, Inc. Torx, Registered Trademark of Textron Hilliard, Trademark of the Hilliard Corporation Warn, Trademark of Warn Industries FOX, Registered Trademark of FOX RACING SHOX RydeFX, Registered Trademark of ArvinMeritor Some Polaris factory publications can be downloaded from www.polarisindustries.com, purchased from www.purepolaris.com or

by contacting the nearest Polaris dealer.

GENERAL INFORMATION

MAINTENANCE

ENGINE

ELECTRONIC FUEL INJECTION

BODY / STEERING / SUSPENSION

CLUTCHING

FINAL DRIVE

TRANSMISSION

BRAKES

ELECTRICAL

GENERAL INFORMATION

CHAPTER 1

GENERAL INFORMATION

MODEL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2

MODEL IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.2

ENGINE DESIGNATION NUMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.2

VIN IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.2

VEHICLE AND ENGINE SERIAL NUMBER LOCATION . . . . . . . . . . . . . . . . . . . . . . . . .1.2

VEHICLE INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3

PUBLICATION NUMBERS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.3

REPLACEMENT KEYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.3

SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3

GENERAL SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4

GENERAL: 2011 RANGER RZR / EPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.4

DETAILED: 2011 RANGER RZR / EPS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.5

GENERAL: 2011 RANGER RZR S / EPS INT’L. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.6

DETAILED: 2011 RANGER RZR S / EPS INT’L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.7

GENERAL: 2011 RANGER RZR 4 / EPS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.8

DETAILED: 2011 RANGER RZR 4 / EPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.9

MISC. SPECIFICATIONS AND CHARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.10

CONVERSION TABLE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.10

STANDARD TORQUE SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.11

SAE TAP / DRILL SIZES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.12

METRIC TAP / DRILL SIZES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.12

DECIMAL EQUIVALENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.12

GLOSSARY OF TERMS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.13

9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual

1.1

GENERAL INFORMATION

}

Machine Model Number Identification

}

Model Year Designation

Basic Chassis

Designation

Engine Designation

Emissions & Model Option

R 1 1 V H 7 6 A D

}

4 X A V H 7 6 A * B P 0 0 0 0 0 0

}

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17

World

Mfg. ID

Engine

Vehicle Description

Vehicle Identifier

Check Digit

Model

Year

Body Style

Plant No.

Individual Serial No.

* This could be either

a number or a letter

Powertrain

Emissions

VIN

Figure 1-1

Engine Serial

Figure 1-2

Number

MODEL INFORMATION

Model Identification

The machine model number must be used with any correspondence regarding warranty or service.

Engine Designation Number

1204276 RZR800HO-11...................................................................Twin Cylinder, Liquid Cooled, OHV 4 Stroke, Electric Start

VIN Identification

V e hicle and Engine Serial Number Location

Whenever corresponding about a Polaris ORV, refer to the vehicle identification number (VIN) and the engine serial number. The VIN can be found stamped on a portion of the front left frame rail, close to the left front wheel (see Figure 1-1). The engine model and serial number can be found on a decal applied to the cylinder on the side of the engine (see Figure 1-2).

1.2

9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual

GENERAL INFORMATION

Key Series Number

KEY COVER P/N 5533534

VEHICLE INFORMATION

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. NOTE: Polaris factory publications can be found at www.polarisindustries.com or purchased from

www.purepolaris.com.

Replacement Keys

Replacement keys can be made from the original key. T o identify which series the key is, take the first two digits on the original key and refer to the chart to the right for the proper part number.

Series# Part Number

20 4010278 21 4010278 22 4010321 23 4010321 27 4010321 28 4010321 31 4110141 32 4110148 67 4010278 68 4010278

SPECIAL TOOLS

Special tools may be required while servicing this vehicle. Some of the tools listed or depicted are mandatory, while other tools maybe substituted with a similar tool, if available. Polaris recommends the use of Polaris Special Tools when servicing any Polaris product. Dealers may order special tools through Polaris’ official tool supplier, SPX Corporation, by phone at 1-800-328-6657 or on-line at http://polaris.spx.com/

1.3

9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service 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 42 in. x 22 in. / 107 cm x 56 cm Cargo Box Capacity 300 lbs. / 136 kg

Maximum Weight Capacity (Payload)

Hitch Towing Capacity 1500 lbs. / 680 kg Hitch Tongue Capacity 150 lbs. / 68 kg

(Includes rider(s), cargo, accessories

25 lbs. / 11.3 kg

740 lbs. / 335.6 kg

and trailer tongue weight)

MODEL: 2011 RANGER RZR EPS

MODEL NUMBER: R11VY76AO 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 961 lbs. / 436 kg Gross Vehicle Weight 1727 lbs. / 783 kg Front Storage

Capacity Cargo Box Dimension 42 in. x 22 in. / 107 cm x 56 cm Cargo Box Capacity 300 lbs. / 136 kg

Maximum Weight Capacity (Payload)

Hitch Towing Capacity 1500 lbs. / 680 kg Hitch Tongue Capacity 150 lbs. / 68 kg

(Includes rider(s), cargo, accessories

25 lbs. / 11.3 kg

740 lbs. / 335.6 kg

and trailer tongue weight)

1.4

9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual

GENERAL INFORMATION

MODEL: 2011 RANGER RZR / EPS

MODEL NUMBER: R11VH76AA, AD, AF, AH MODEL NUMBER: R11VY76AO ENGINE NUMBER: 1204276

Engine

Platform

Engine Number 1204276

Engine Displacement 760cc H.O.

Number of Cylinders 2

Bore & Stroke (mm) 80 x 76.5 mm

Compression Ratio 11:1

Compression Pressure 165 - 185 psi

Engine Idle Speed 1250 ± 100 RPM

Engine Max Operating RPM 6600 RPM

Lubrication Pressurized Wet Sump

Oil Requirements PS-4 Plus Synthetic

Oil Capacity 2 qts. / 1.9 liters

Coolant Capacity 4.8 qts. / 4.5 liters

Overheat Warning Instrument Cluster Indicator

Exhaust System Dual Headpipe / Single Silencer

Fuel System Type Bosch M17 EFI

Fuel Delivery Electronic Fuel Pump (in tank)

Fuel Pressure 45 +/- 2 psi (310 +/- 14kPa)

Fuel Filters See Chapter 4

Fuel Capacity / Requirement

Alternator Max Output 500 Watts @ 3000 RPM

Headlights 2 - Halogen: Low 55 W / High 60 W

Tail / Brake 2 - 6 Watts / 2 - 27 Watts Starting System Electric Start Ignition System Bosch M17 (ECU Controlled)

Ignition Timing (Variable) 3° - 10° BTDC @ 1200 RPM

Spark plug / Gap RC7YC3 / .035 in. (0.9 mm)

Battery (RZR)

Battery (RZR EPS)

Instrument Type Multifunction Instrument Cluster

DC Outlet Standard 12 Volt

Relays

Circuit Breaker Fan Motor: 20 Amp

Fuses (Fuse/Relay Box)

Fuses (Power Fuse Holder)

H.O. Domestic Twin Cylinder,

Liquid Cooled, 4-Stroke

Fuel System

7.25 gal. (27.4 liters)

87 Octane (minimum)

Electrical

Yuasa YTX20HL /

18 Amp Hr. / 310 CCA / 12 Volt

Deka ETX30L / 30 AH

365 CCA / 12 Volt

Chassis / EFI / Fan

Fuel Pump / EPS

Drive / Fuel Pump: 10 Amp

Lights / EFI / Accessory: 20 Amp

EFI: 20 Amp

Chassis / EPS: 30 Amp

Drivetrain

Transmission Type Polaris Automatic PVT

Drive Ratio - Front 3.82:1

Drive Ratio - Final 3.70:1

Shift Type In Line Shift - H / L / N / R / P

Front Gearcase

Fluid Type / Capacity

Transmission: Main Gearcase

Fluid Type / Capacity

Transmission: Transfer Case

Fluid Type / Capacity

Rear Gearcase

Fluid Type / Capacity

Belt 3211113

Steering / Suspension

Front Suspension

Front Travel 9 in. / 23 cm

Rear Suspension Rolled IRS w/Anti-Sway Bar

Rear Travel 9.5 in. / 24 cm

Shock Preload Adjustment

Front / Rear

Toe Out 1/8 - 1/4 in. (3 - 6.4 mm)

Wheels / Brakes

Front Wheel Size

Front Tire Type / Size

Rear Wheel Size

Rear Tire Type / Size

Tire Air Pressure - Front / Rear 8 psi (55 kPa)

Brake - Front / Rear

Brake Fluid DOT 4

Polaris Demand Drive Plus

6.75 oz. (200 ml) Polaris AGL Plus

24 oz. (710 ml)

Polaris AGL Plus

14 oz. (414 ml)

Polaris Premium ADF

26 oz. (769 ml)

Independent Dual A-arm

w/Anti-Sway Bar

Standard: Cam Adjustment

Walker Evans: Threaded

Spanner Wrench Adjustment

12 x 6 / Steel

12 x 6 / Cast Aluminum

Maxxis / 25 x 8 R12

12 x 8 / Steel

12 x 8 / Cast Aluminum

Maxxis / 25 x 10 R12

Foot Actuated - 4 Wheel

Hydraulic Disc

CLUTCH CHART

Meters

(Feet)

Altitude

0-1500

(0-5000)

1500-3700

(5000 - 12000)

Shift

Weight

23-62

(5632337)

23-58 (B)

(1322911)

Drive

Spring

Black

(7043594)

Black

(7043594)

(B) = Bushed Shift Weight

Driven Spring

Blk / Almond

(7043167)

Blk / Almond

(7043167)

9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual

1.5

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 42 in. x 22 in. / 107 cm x 56 cm Cargo Box Capacity 300 lbs. / 136 kg

Maximum Weight Capacity (Payload)

Hitch Towing Capacity 1500 lbs. / 680 kg Hitch Tongue Capacity 150 lbs. / 68 kg

(Includes rider(s), cargo, accessories

25 lbs. / 11.3 kg

740 lbs. / 335.6 kg

and trailer tongue weight)

MODEL: 2011 RANGER RZR S EPS INT’L

MODEL NUMBER: R11VM76FX 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 1016 lbs. / 461 kg Gross Vehicle Weight 1782 lbs. / 808 kg Front Storage

Capacity Cargo Box Dimension 42 in. x 22 in. / 107 cm x 56 cm Cargo Box Capacity 300 lbs. / 136 kg

Maximum Weight Capacity (Payload)

Hitch Towing Capacity 1500 lbs. / 680 kg Hitch Tongue Capacity 150 lbs. / 68 kg

(Includes rider(s), cargo, accessories

25 lbs. / 11.3 kg

740 lbs. / 335.6 kg

and trailer tongue weight)

1.6

9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual

GENERAL INFORMATION

MODEL: 2011 RANGER RZR S / EPS INT’L

MODEL NUMBER: R11VE76AC, AD, AW MODEL NUMBER: R11VM76FX ENGINE NUMBER: 1204276

Engine

Platform

Engine Number 1204276

Engine Displacement 760cc H.O.

Number of Cylinders 2

Bore & Stroke (mm) 80 x 76.5 mm

Compression Ratio 11:1

Compression Pressure 165 - 185 psi

Engine Idle Speed 1250 ± 100 RPM

Engine Max Operating RPM 6750 RPM

Lubrication Pressurized Wet Sump

Oil Requirements PS-4 Pl us Synthetic

Oil Capacity 2 qts. / 1.9 liters

Coolant Capacity 4.8 qts. / 4.5 liters

Overheat Warning Instrument Cluster Indicator

Exhaust System Dual Headpipe / Single Silencer

Fuel System Type Bosch M17 EFI

Fuel Delivery Electronic Fuel Pump (in tank)

Fuel Pressure 45 +/- 2 psi (310 +/- 14kPa)

Fuel Filters See Chapter 4

Fuel Capacity / Requirement

Alternator Max Output 500 Watts @ 3000 RPM

Headlights 2 - Halogen: Low 55 W / High 60 W

Tail / Brake 2 - 6 Watt s / 2 - 27 Watt s Starting System Electric Start Ignition System Bosch M17 (ECU Controlled)

Ignition Timing (Variable) 3° - 10° BTDC @ 1200 RPM

Spark plug / Gap RC7YC3 / .035 in. (0.9 mm)

Battery (RZR S)

Battery (RZR S EPS)

Instrument Type Multifunction Instrument Cluster

DC Outlet Standard 12 Volt

Relays

Circuit Breaker Fan Motor: 20 Amp

Fuses (Fuse/Relay Box)

Fuses (Power Fuse Holder)

H.O. Domestic Twin Cylinder,

Liquid Cooled, 4-Stroke

Fuel System

7.25 gal. (27.4 liters)

87 Octane (minimum)

Electrical

Yuasa YTX20HL /

18 Amp Hr. / 310 CCA / 12 Volt

Deka ETX30L / 30 AH

365 CCA / 12 Volt

Chassis / EFI / Fan

Fuel Pump / EPS

Drive / Fuel Pump: 10 Amp

Lights / EFI / Accessory: 20 Amp

EFI: 20 Amp

Chassis / EPS: 30 Amp

Drivetrain

Transmission Type Polaris Automatic PVT

Drive Ratio - Front 3.82:1

Drive Ratio - Final 3.70:1

Shift Type In Line Shift - H / L / N / R / P

Front Gearcase

Fluid Type / Capacity

Transmission: Main Gearcase

Fluid Type / Capacity

Transmission: Transfer Case

Fluid Type / Capacity

Rear Gearcase

Fluid Type / Capacity

Rear Gearcase (INT’L)

Fluid Type / Capacity

Belt 3211133

Steering / Suspension

Front Suspension / Shock

Front Travel 12 in. / 30.5 cm

Rear Suspension / Shock

Rear Travel 12 in. / 30.5 cm

Shock Preload Adjustment

Front / Rear

Toe Out 1/8 - 1/4 in. (3 - 6.4 mm)

Wheels / Brakes

Front Wheel Size

Front Tire Type / Size

Rear Wheel Size

Rear Tire Type / Size

Tire Air Pressure - Front / Rear 8 psi (55 kPa)

Brake - Front / Rear

Brake Fluid DOT 4

Polaris Demand Drive Plus

6.75 oz. (200 ml) Polaris AGL Plus

24 oz. (710 ml)

Polaris AGL Plus

14 oz. (414 ml)

Polaris Premium ADF

26 oz. (769 ml)

Polaris Premium ADF

22 oz. (650 ml)

Independent Dual A-arm

Standard: Monotube

FOX™: PODIUM X

Rolled IRS w/Anti-Sway Bar

Standard: Monotube

FOX™: PODIUM X

Standard: Cam Adjustment

FOX™: Threaded Spanner

Wrench Adjustment

12 x 6 / Cast Aluminum

Maxxis Bighorn / 26 x 9 R12

ITP “900XCT” / 27 x 9 R12

12 x 8 / Cast Aluminum

Maxxis Bighorn / 26 x 12 R12

ITP “900XCT” / 27 x 11 R12

Foot Actuated - 4 Wheel

Hydraulic Disc

CLUTCH CHART

Meters

(Feet)

Altitude

0-1500

(0-5000)

1500-3700

(5000 - 12000)

Shift

Weight

23-62

(5632337)

23-58 (B)

(1322911)

Drive

Spring

Black

(7043594)

Black

(7043594)

(B) = Bushed Shift Weight

Driven Spring

Blk / Almond

(7043167)

Blk / Almond

(7043167)

9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual

1.7

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 42 in. x 22 in. / 107 cm x 56 cm Cargo Box Capacity 300 lbs. / 136 kg

Maximum Weight Capacity (Payload)

Hitch Towing Capacity 1500 lbs. / 680 kg Hitch Tongue Capacity 150 lbs. / 68 kg

(Includes rider(s), cargo, accessories

25 lbs. / 11.3 kg

900 lbs. / 408 kg

and trailer tongue weight)

MODEL: 2011 RANGER RZR 4 EPS

MODEL NUMBER: R11XY76AA 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 1271 lbs. / 577 kg Gross Vehicle Weight 2171 lbs. / 985 kg Front Storage

Capacity Cargo Box Dimension 42 in. x 22 in. / 107 cm x 56 cm Cargo Box Capacity 300 lbs. / 136 kg

Maximum Weight Capacity (Payload)

Hitch Towing Capacity 1500 lbs. / 680 kg Hitch Tongue Capacity 150 lbs. / 68 kg

(Includes rider(s), cargo, accessories

25 lbs. / 11.3 kg

900 lbs. / 408 kg

and trailer tongue weight)

1.8

9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual

GENERAL INFORMATION

MODEL: 2011 RANGER RZR 4 / EPS

MODEL NUMBER: R11XH76AW MODEL NUMBER: R11XY76AA ENGINE NUMBER: 1204276

Engine

Platform

Engine Number 1204276

Engine Displacement 760cc H.O.

Number of Cylinders 2

Bore & Stroke (mm) 80 x 76.5 mm

Compression Ratio 11:1

Compression Pressure 165 - 185 psi

Engine Idle Speed 1250 ± 100 RPM

Engine Max Operating RPM 6750 RPM

Lubrication Pressurized Wet Sump

Oil Requirements PS-4 Pl us Synthetic

Oil Capacity 2 qts. / 1.9 liters

Coolant Capacity 5.5 qts. / 5.2 liters

Overheat Warning Instrument Cluster Indicator

Exhaust System Dual Headpipe / Single Silencer

Fuel System Type Bosch M17 EFI

Fuel Delivery Electronic Fuel Pump (in tank)

Fuel Pressure 45 +/- 2 psi (310 +/- 14kPa)

Fuel Filters See Chapter 4

Fuel Capacity / Requirement

Alternator Max Output 500 Watts @ 3000 RPM

Headlights 2 - Halogen: Low 55 W / High 60 W

Tail / Brake 2 - 6 Watt s / 2 - 27 Watt s Starting System Electric Start Ignition System Bosch M17 (ECU Controlled)

Ignition Timing (Variable) 3° - 10° BTDC @ 1200 RPM

Spark plug / Gap RC7YC3 / .035 in. (0.9 mm)

Battery

Instrument Type Multifunction Instrument Cluster

DC Outlets (2) Standard 12 Volt

Relays

Circuit Breaker Fan Motor: 20 Amp

Fuses (Fuse/Relay Box)

Fuses (Power Fuse Holder)

H.O. Domestic Twin Cylinder,

Liquid Cooled, 4-Stroke

Fuel System

7.25 gal. (27.4 liters)

87 Octane (minimum)

Electrical

Deka ETX30L / 30 AH

365 CCA / 12 Volt

Chassis / EFI / Fan

Fuel Pump / EPS

Drive / Fuel Pump: 10 Amp

Lights / EFI / Accessory: 20 Amp

EFI: 20 Amp

Chassis / EPS: 30 Amp

Drivetrain

Transmission Type Polaris Automatic PVT

Drive Ratio - Front 3.82:1

Drive Ratio - Final 3.70:1

Shift Type In Line Shift - H / L / N / R / P

Front Gearcase

Fluid Type / Capacity

Transmission: Main Gearcase

Fluid Type / Capacity

Transmission: Transfer Case

Fluid Type / Capacity

Rear Gearcase

Fluid Type / Capacity

Belt 3211133

Steering / Suspension

Front Suspension / Shock

Front Travel 12 in. / 30.5 cm

Rear Suspension / Shock

Rear Travel 12 in. / 30.5 cm

Shock Preload Adjustment

Front / Rear

Toe Out 1/8 - 1/4 in. (3 - 6.4 mm)

Wheels / Brakes

Front Wheel Size

Front Tire Type / Size

Rear Wheel Size

Rear Tire Type / Size

Tire Air Pressure

Brake - Front / Rear

Brake Fluid DOT 4

Polaris Demand Drive Plus

6.75 oz. (200 ml) Polaris AGL Plus

24 oz. (710 ml)

Polaris AGL Plus

14 oz. (414 ml)

Polaris Premium ADF

26 oz. (769 ml)

Independent Dual A-arm

FOX™ 2.0 Piggyback

Rolled IRS w/Anti-Sway Bar

FOX™ 2.0 Piggyback

Threaded Spanner Wrench

Adjustment

12 x 6 / Cast Aluminum

Maxxis Bighorn / 26 x 9 R12

12 x 8 / Cast Aluminum

Maxxis Bighorn / 26 x 12 R12

Front: 10 psi (69 kPa) Rear: 12 psi (83 kPa)

Foot Actuated - 4 Wheel

Hydraulic Disc

CLUTCH CHART

Meters

(Feet)

Altitude

0-1500

(0-5000)

1500-3700

(5000 - 12000)

Shift

Weight

23-62

(5632337)

23-58 (B)

(1322911)

Drive

Spring

Black

(7043594)

Black

(7043594)

(B) = Bushed Shift Weight

Driven Spring

Blk / Almond

(7043167)

Blk / Almond

(7043167)

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1.9

GENERAL INFORMATION

MISC. SPECIFICATIONS AND CHARTS

Conversion Table

1.10

°C to °F:

9/5

(°C + 32) = °F °F to °C:

9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual

5/9

(°F - 32) = °C

Standard Torque Specifications

GENERAL INFORMATION

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.

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1.11

GENERAL INFORMATION

SAE Tap / Drill Sizes

Decimal Equivalents

Metric Tap / Drill Sizes

1.12

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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). Polaris measures chain length in number of pitches. CI: Cubic inches. Clutch Buttons: Plastic bushings which aid rotation of the movable sheave in the drive and driven clutch. Clutch Offset: Drive and driven clutches are offset so that drive belt will stay nearly straight as it moves along the clutch face. Clutch Weights: Three levers in the drive clutch which relative to their weight, profile and engine RPM cause the drive clutch to

close and grip the drive belt. Crankshaft Run-Out: Run-out or "bend" of crankshaft measured with a dial indicator while crankshaft is supported between centers on V blocks or resting in crankcase. Measure at various points especially at PTO.

DCV: Direct current voltage CVT: Centrifugal Variable Transmission (Drive Clutch System) DCV: Direct current voltage. Dial Bore Gauge: A cylinder measuring instrument which uses a dial indicator. Good for showing taper and out-of-round in the

cylinder bore.

Electrical Open: Open circuit. An electrical circuit which isn't complete. Electrical Short: Short circuit. An electrical circuit which is completed before the current reaches the intended load. (i.e. a bare wire

touching the chassis).

End Seals: Rubber seals at each end of the crankshaft. Engagement RPM: Engine RPM at which the drive clutch engages to make contact with the drive belt. ft.: Foot/feet. Foot Pound: Ft. lb. A force of one pound at the end of a lever one foot in length, applied in a rotational direction. g: Gram. Unit of weight in the metric system. gal.: Gallon. ID: Inside diameter. in.: Inch/inches. Inch Pound: In. lb. 12 in. lbs. = 1 ft. lb. kg/cm²: Kilograms per square centimeter. kg-m: Kilogram meters. Kilogram/meter: A force of one kilogram at the end of a lever one meter in length, applied in a rotational direction. l or ltr: Liter. lbs/in²: Pounds per square inch. Left or Right Side: Always referred to based on normal operating position of the driver. m: Meter/meters. Mag: Magneto. Magnetic Induction: As a conductor (coil) is moved through a magnetic field, a voltage will be generated in the windings.

Mechanical energy is converted to electrical energy in the stator.

mi.: Mile/miles.

: Millimeter. Unit of length in the metric system. 1 mm = approximately .040".

mm Nm: Newton meters. OD: Outside diameter. Ohm: The unit of electrical resistance opposing current flow. oz.: Ounce/ounces. Piston Clearance: Total distance between piston and cylin der wall. psi.: Pounds per square inch. PTO: Power take off. PVT: Polaris Variable Transmission (Drive Clutch system) qt.: Quart/quarts. Regulator: Voltage regulator. Regulates battery charging system output at approx. 14.5 DCV as engine RPM increases. Reservoir Tank: The fill tank in the liquid cooling system. Resistance: In the mechanical sense, friction or load. In the electrical sense, ohms, resulting in energy conversion to heat. RPM: Revolutions per minute. Seized Piston: Galling of the sides of a piston. Usually there is a transfer of aluminum from the piston onto the cylinder wall. Possible causes: 1) improper lubrication; 2) excessive temperatures; 3) insufficient piston clearance; 4) stuck piston rings. Stator Plate: The plate mounted under the flywheel supporting the battery charging coils. TDC: Top dead center. Piston's most outward travel from crankshaft. Volt: The unit of measure for electrical pressure of electromotive force. Measured by a voltmeter in parallel with the circuit. Watt: Unit of electrical power. Watts = amperes x volts. WOT: Wide open throttle.

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1.13

GENERAL INFORMATION

NOTES

1.14

9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual

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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.6

MAINTENANCE QUICK REFERENCE, CONTINUED..... . . . . . . . . . . . . . . . . . . . . . . . . 2.7

GREASE LUBRICATION POINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.8

LUBRICANTS / SERVICE PRODUCTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.9

GENERAL VEHICLE INSPECTION AND MAINTENANCE. . . . . . . . . . . . . . . . . . . . . . . 2.10

PRE-RIDE / DAILY INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.10

FRAME, NUTS, BOLTS, AND FASTENERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.10

SHIFT CABLE INSPECTION / ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.10

FUEL SYSTEM AND AIR INTAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.11

FUEL LINE / FUEL PUMP / FUEL FILTERS / VENT LINES . . . . . . . . . . . . . . . . . . . . . 2.11

THROTTLE PEDAL INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.12

THROTTLE FREEPLAY ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.12

AIR FILTER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.13

ENGINE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.15

ENGINE OIL LEVEL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.15

ENGINE OIL AND FILTER SERVICE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.16

ENGINE BREATHER HOSE INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.17

ENGINE AND TRANSMISSION MOUNTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.17

COMPRESSION AND LEAKDOWN TEST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.17

EXHAUST - SPARK ARRESTOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.17

TRANSMISSION AND GEARCASES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.18

TRANSMISSION LUBRICATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.18

FRONT GEARCASE LUBRICATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.20

REAR GEARCASE LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.21

COOLING SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.22

COOLANT LEVEL INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.22

COOLANT STRENGTH / TYPE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.22

COOLING SYSTEM PRESSURE TEST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.23

COOLING SYSTEM HOSES / RADIATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.23

COOLANT DRAIN / RADIATOR REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.23

FINAL DRIVE / WHEEL AND TIRE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.24

WHEEL AND HUB TORQUE TABLE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.24

WHEEL REMOVAL / INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.24

TIRE INSPECTION / PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.25

DRIVE SHAFT BOOT INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.25

ELECTRICAL AND IGNITION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.26

BATTERY MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.26

BATTERY REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.26

BATTERY INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.27

BATTERY OFF SEASON STORAGE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.27

BATTERY CHARGING (MAINTENANCE FREE). . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.27

SPARK PLUG SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.27

ENGINE TO FRAME GROUND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.28

STEERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.28

STEERING INSPECTION / STEERING WHEEL FREEPLAY . . . . . . . . . . . . . . . . . . . .2.28

TIE ROD END / WHEEL HUB INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.29

WHEEL TOE ALIGNMENT INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.29

WHEEL TOE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.30

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MAINTENANCE

SUSPENSION (STANDARD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.31

SPRING PRELOAD ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.31

SUSPENSION (FOX™). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.31

SPRING PRELOAD ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.31

SHOCK COMPRESSION ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.32

SUSPENSION (WALKER EVANS™) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.33

SPRING PRELOAD ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.33

SHOCK COMPRESSION ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.33

BRAKE SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.34

BRAKE FLUID / PAD / DISC INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.34

BRAKE HOSE AND FITTING INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.34

MAINTENANCE LOG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.35

2.2

9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual

MAINTENANCE

WARNING

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. If you’re not familiar with safe service and adjustment procedures, have a qualified dealer perform these operations.

Maintenance intervals in the following chart are based upon average riding conditions and an average vehicle speed of approximately 10 miles per hour. Vehicles subjected to severe use must be inspected and serviced more frequently.

Severe Use Definition

• Frequent immersion in mud, water or sand

• Racing or race-style high RPM use

• Prolonged low speed, heavy load operation

• Extended idle

• Short trip cold weather operation

Pay special attention to the oil level. A rise in oil level during cold weather can indicate contaminants collecting in the oil sump or crankcase. Change oil immediately if the oil level begins to rise. Monitor the oil level, and if it continues to rise, discontinue use and determine the cause or see your dealer.

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.

• Drive vehicle slowly at first while varying the throttle position. Do not operate at sustained idle.

• Pull only light loads.

• Perform regular checks on fluid levels and other areas outlined on the daily pre-ride inspection checklist.

• Change both the engine oil and filter after 25 hours or one month.

• See “Owner’s Manual” for additional break-in information.

Maintenance Chart Key

The following symbols denote potential items to be aware of during maintenance:

 = CAUTION: Due to the nature of these adjustments, it is recommended this service be performed by an authorized Polaris dealer.

= SEVERE USE ITEM: See information provided above.

E = Emission Control System Service (California). NOTE: Inspection may reveal the need for replacement parts. Always use genuine Polaris parts.

Improperly performing the procedures marked could result in component failure and lead to ser ious injury or death. Have an authorized Polaris dealer perform these services.

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2.3

MAINTENANCE

Pre-Ride - 25 Hour Maintenance Interval

Maintenance Interval

Item

Hours Calendar

 Steering - Pre-Ride -

Front Suspension - Pre-Ride -



Rear Suspension - Pre-Ride -



Tires - Pre-Ride Brake Fluid Level - Pre-Ride -



Brake Pedal Travel - Pre-Ride -



Brake Systems - Pre-Ride Wheels / Fasteners - Pre-Ride Frame Fasteners - Pre-Ride -



Engine Oil Level - Pre-Ride -

(whichever comes first)

Miles

Remarks

(KM)

Make adjustments as needed. See Pre-Ride Checklist on Page 2.10.



Air Filter - Pre-Ride - Inspect; replace as needed

Coolant Level - Daily -

Head Lamp / Tail Lamp - Daily -



Air Filter - Weekly - Inspect; replace as needed



Brake Pad Wear 10 H Monthly 100 (160) Inspect periodically



Battery 25 H Monthly 250 (400) Check terminals; clean; test Front Gearcase Oil



(Demand Drive Plus)

 Rear Gearcase Oil

(ATV Angle Drive Fluid) Transmission - Main



(AGL Gearcase Lubricant) Transmission - Transfer



(AGL Gearcase Lubricant)



Engine Breather Filter

(if equipped)



Engine Oil Change

(Break-In Period)

25 H Monthly 250 (400) Inspect level; change yearly

25 H Monthly 250 (400) Inspect; replace if necessary

25 H 1 M 250 (400) Perform a break-in oil change at one month

Check level daily , change coolan t every 2 years

Check operation; apply dielectric grease if replacing

Perform these procedures more often for vehicles subjected to severe use.

E Emission Control System Service (California)  Have an authorized Polaris dealer perform these services.

2.4

9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual

MAINTENANCE

50 - 500 Hour Maintenance Interval

Maintenance Interval

Item



Throttle Cable / Throttle

Pedal Throttle Body Air Intake

Ducts / Flange General Lubrication 50 H 3 M 500 (800) Lubricate all fittings, pivots, cables, etc.



Shift Linkage 50 H 6 M 500 (800) Inspect, lubricate, adjust

 Steering 50 H 6 M 500 (800) Lubricate

Front Suspension 50 H 6 M 500 (800) Lubricate



Rear Suspension 50 H 6 M 500 (800) Lubricate



Cooling System 50 H 6 M 500 (800)



Fuel System 100 H 12 M 600 (1000)



Spark Plug 100 H 12 M 600 (1000) Inspect; replace as needed



Engine Oil & Filter Change 100 H 6 M 1000 (1600)

Drive Belt 100 H 12 M 1000 (1600) Inspect; replace as needed Radiator 100 H 12 M 1000 (1600) Inspect; clean external surfaces



(whichever comes first)

Hours Calendar

50 H 6 M 300 (500)

50 H 6 M 300 (500) Inspect ducts for proper sealing / air leaks

Miles

(KM)

Inspect; adjust; lubricate; replace if necessary

Inspect coolant strength seasonally; pressure test system yearly

Check for leaks at fill cap, fuel line / rail, and fuel pump. Replace lines every two years.

Perform a break-in oil change at 25 hours or one month / always replace oil filter when changing engine oil

Remarks

Cooling Hoses 100 H 12 M 1000 (1600) Inspect for leaks



Engine Assembly Mounts 100 H 12 M 1000 (1600) Inspect, torque to specification



Exhaust Muffler / Pipe 100 H 12 M 1000 (1600) Inspect

Inspect for wear, routing, security; apply

Wiring 100 H 12 M 1000 (1600)



 Clutches (Drive and Driven) 100 H 12 M 1000 (1600) Inspect; clean; replace worn parts  Front Wheel Bearings 100 H 12 M 1000 (1600) Inspect; replace as needed

Shocks 100 H - - Visually inspect shock seals



 Brake Fluid 200 H 24 M 2000 (3200) Change every two years (DOT 4)

Spark Arrestor 300 H 36 M 3000 (4800) Clean out



Shocks 500 H 12 M - Change shock oil and seals



 Toe Adjustment -

Headlight Aim - Adjust as needed

dielectric grease to connectors subjected to water, mud, etc.

Inspect periodically; adjust when parts are replaced

 Perform these procedures more often for vehicles subjected to severe use.

E Emission Control System Service (California)

 Have an authorized Polaris dealer perform these services.

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MAINTENANCE

Maintenance Quick Reference

III. # Item Lube Rec. Method Frequency*

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

1Engine Oil

Polaris PS-4 Plus Performance Synthetic 4-Cycle Engine Oil

Add oil to proper level on dipstick

2 Engine Coolant Polaris 60/40 Coolant

3 Brake Fluid Polaris DOT 4 Brake Fluid

* More often under severe use, such as operated in water or under severe loads.

Maintain coolant level in coolant reservoir bottle.

Maintain fluid level between “MAX and “MIN” lines on the master cylinder reservoir

Check level daily, change coolant every 2 years

Check level during pre-ride inspection; change fluid every two years

2.6

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MAINTENANCE

Maintenance Quick Reference, Continued.....

III. # Item Lube Rec. Method Frequency*

4 Front Gearcase Polaris Demand Drive Plus

5 Rear Gearcase

6 Transmission

* More often under severe use, such as operated in water or under severe loads.

Polaris ATV Angle Drive Fluid (ADF)

Polaris AGL Plus Gearcase Lubricant

Add lubricant until it is visible at the fill hole threads

Check level every 25 hours; change fluid yearly

Check level every 25 hours; change lubricant yearly

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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

Front Propshaft Yoke(s) A-arm Pivot Bushings Stabilizer Bar Bushings

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.

2.8

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MAINTENANCE

LUBRICANTS / SERVICE PRODUCTS

Polaris Lubricants, Maintenance and Service Products

Part No. Description

Engine Lubricant

2870791 Fogging Oil (12 oz. Aerosol) 2876244

2876245

2878068

2878069

2878070

2876160

PS-4 Plus Synthetic 4-Cycle Engine Oil (Quart)

PS-4 Plus Synthetic 4-Cycle Engine Oil (Gallon)

Gearcase / Transmission Lubricants

AGL Plus Gearcase Lubricant (1 Qt.) (12 Count)

AGL Plus Gearcase Lubricant (1 Gal.) (4 Count)

AGL Plus Gearcase Lubricant (2.5 Gal.) (2 Count)

ATV Angle Drive Fluid (8 oz.) (12 Count)

NOTE: Each item can be purchased separately at your local Polaris dealer.

Part No. Description

Additives / Sealants / Thread Locking Agent s / Misc.

2871950

2871326 2870652 Fuel Stabilizer (16 oz.) (12 count)

2872189 DOT 4 Brake Fluid (12 count) 2871557 Crankcase Sealant, 3-Bond 1215 (5 oz.)

NOTE: The number count indicated by each part number in the table above indicates the number of units that are shipped with each order.

Loctite™ Threadlock 242 (6 ml.) (12 count)

Premium Carbon Clean (12 oz.) (12 count)

2872276

2877922

2877923 2870465 Oil Pump for 1 Gallon Jug

2871312 Grease Gun Kit 2871322

2871423 2871460 Starter Drive Grease (12 Count)

2871515 Premium U-Joint Lube (3 oz.) (24 Count) 2871551 Premium U-Joint Lube (14 oz.) (10 Coun t) 2871329 Dielectric Grease (Nyoge l™)

ATV Angle Drive Fluid (2.5 Gal) (2 Count)

Demand Drive Plus (Quart)

Demand Drive Plus (2.5 Gallon)

Grease / Specialized Lubricants

Premium All Season Grease (3 oz. cartridge) (24 Count)

Premium All Season Grease (14 oz. cartridge) (10 Count)

Coolant

2871323 60/40 Coolant (Gallon) (6 Count) 2871534 60/40 Coolant (Quart) (12 Count)

9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual

2.9

MAINTENANCE

Shift Cable

Mount

Dust Boot

Clevis Pin

Shift Cable

Lower

Jam Nut

Upper

Jam Nut

GENERAL VEHICLE INSPECTION AND MAINTENANCE

Pre-Ride / Daily Inspection

Perform the following pre-ride inspection daily, and when servicing the vehicle at each scheduled maintenance.

• Tires - check condition and pressures

• Fuel tank - fill to proper level

• All brakes - check operation and adjustment

• Throttle - check for free operation and closing

• Headlights/Taillights/Brakelights - also check operation of all indicator lights and switches

• Ignition switch - check for proper function

• Wheels - check for tightness of wheel nuts and axle nuts; check to be sure axle nuts are secured by cotter pins

• Air cleaner element - check for dirt; clean or replace

1. Locate the shift cable in the rear LH wheel well area.

2. Inspect shift cable, clevis pin, pivot bushings, and dust boot. Replace if worn or damaged.

3. If adjustment is required, loosen the lower jam nut and pull the cable out of the mount to move the upper jam nut.

• Steering - check for free operation noting any unusual looseness in any area

• Loose parts - visually inspect vehicle for any damaged or loose nuts, bolts or fasteners

• Engine coolant - check for proper level at the recovery bottle

• Check all front and rear suspension components for wear or damage.

Frame, Nuts, Bolts, and Fasteners

Periodically inspect the torque of all fasteners in accordance with the maintenance schedule. Check that all cotter pins are in place. Refer to specific fastener torques listed in each chapter.

Shift Cable Inspection / 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 into a gear

• Excessive gear clash (noise)

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. Th read the upper or lower jam nut as required to obtain proper cable adjustment.

NOTE: This procedure may require a few attempts to obtain the proper adjustment.

6. Once the proper adjustment is obtained, place the shift cable and upper jam nut into the mount. Tighten the lower jam nut against the mount.

7. Start en gine and shift through all gears to ensure the shift cable is properly adjusted. If transmission still ratchets after cable adjustment, the transmission will require service.

• Gear selector moving out of desired range

2.10

9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual

MAINTENANCE

WARNING

Injector Rail

Connector

Fuel Pump

Connector

Fuel Line

Fuel Pump Asm

FUEL SYSTEM AND AIR INTAKE

Fuel System

Gasoline is extremely flammable and explosive

under certain conditions.

Always stop the engine and refuel outdoors or in

a well ventilated area. Do not smoke or allow open flames or sparks in or near the area where refueling is performed or

where gasoline is stored. Do not overfill the tank. Do not fill the tank neck. If you get gasoline in your eyes or if you swallow

gasoline, seek medical attention immediately.

If you spill gasoline on your skin or clothing, immediately wash it off with soap and water

and change clothing. Never start the engine or let it run in an enclosed area. Engine exhaust fumes are poisonous and

can result in loss of consciousness or

death in a short time.

Never drain the fuel when the engine is hot.

Severe burns may result.

Fuel Pump / Fuel Filters

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.

NOTE: Neither filter is servicable individually. Must replace the fuel pump as an assembly.

Fuel Line

1. Check the quick-connect fuel line for signs of wear, deterioration, damage or leakage. Replace if necessary.

2. Be sure fuel line is routed and retained properly.

IMPORTANT: Make sure line is not kinked or pinched.

3. Replace fuel line every two years.

NOTE: Refer to Chapter 4 for fuel pump replacement and all other information related to the EFI System.

Vent Lines

1. Check fuel tank, front gearcase, rear gearcase and transmission vent lines for signs of wear, deterioration, damage or leakage. Replace every two years.

2. Be sure vent lines are routed properly and secured with cable ties.

IMPORTANT: Ensure lines are not kinked or pinched.

2.11

9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual

MAINTENANCE

Throttle Pedal

Intake Duct

Boot

Jam Nut

Adjuster

Throttle Pedal Inspection

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. If the throttle pedal has no play , the throttle may be hard to control, and the idle speed may be erratic.

Check the throttle pedal play periodically in accordance with the Periodic Maintenance Chart and adjust the play if necessary.

3. Remove the (2) push rivets retaining the air intake box and remove the box from the frame.

4. Loosen the hose clamp retaining t he PVT intake duct and remove the duct from the vehicle to access the throttle cable freeplay adjustment.

Throttle Freeplay Adjustment

Inspection

1. Place the transmission in the P (Park) position.

2. Start the engine, and warm it up thoroughly.

3. Measure th e distance the throttle pedal moves before the engine begins to pick up speed. Freeplay should be 1/16” 1/8” (1.5 - 3 mm).

Adjustment

1. Remove both seats and rear service panel.

2. Remove the cargo box as an assembly (see Chapter 5).

5. Slide back the cable adjuster boot.

6. U sing a 14 mm open-end wrench, loosen the adjustment jam nut. Using a 12 mm open-end wrench, move the cable adjuster until 1/16” to 1/8” (1.5 - 3 mm) of freeplay is achieved at the throttle pedal.

2.12

9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual

MAINTENANCE

Air Box Cap

Cap

Seal

Air Filter

Apply Grease

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.

10. Reinstall the air intake box and (2) push rivets.

11. Reinstall the cargo box, all fasteners and reconnect the taillight harness.

12. Reinstall the rear service panel and seats.

Air Filter Service

It is recommended that the air filter be inspected as part of pre-ride inspection. Always apply grease to the seal under the air box cap and on the sealing edges of the air filter when servicing. In extremely dusty conditions, air filter replacement will be required more often.

The filter should be inspected using the following procedure:

NOTE: If the filter has been soaked with fuel or oil it must be replaced.

NOTE: Service more frequently if vehicle is operated in wet conditions or at high throttle operation for extended periods.

Installation

1. Clean the air box th oroughly.

Removal

1. The air box is located just above the left rear wheel in the

2. Unlatch the (3) clips and remove the air box cap. Inspect

3. Remove the air filter assembly.

4. Inspect the air filter element and replace if necessary. Do

wheel well area.

the seal. It should adhere tightly to the cover and seal all the way around.

not attempt to clean the air filter with anything other that low pressure compressed air.

2. Place the filter ring over the end of the filter.

NOTE: Apply a small amount of general purpose grease to the sealing edges of the filter and the air box cap seal before installing.

3. Install the filter into the air box and be sure it fits tightly.

4. Install air box cap and secure with clips.

9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual

2.13

MAINTENANCE

Cap

Seal

Clip (3)

Boot

Air Box Can

Air Intake Duct

Breather

Seal

Fitting

Breather

Intake Box

Air Filter

Clamps

Front

Foam Seal

Filter

Hose

Foil

Filter Ring

Primary

Foam Seal

Intake Seal

Air Box / Air Filter Exploded View

2.14

9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual

MAINTENANCE

Dipstick

Lever Lock

Dipstick

Lever Lock

Maintain Oil Level In SAFE Range

DO NOT Overfill the Engine

Dipstick

Always read top side of dipstick to

properly check oil level in crankcase

ENGINE

Engine Oil Level

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.

IMPORTANT: Do not run the machine and then check the dipstick.

4. Locate the engine oil dipstick:

• RZR / RZR S: Remove both seats and the rear service

panel to access the dipstick.

6. Reinstall the dipstick completely, but do not lock it.

NOTE: Make certain the dipstick is inserted all the way into the filler tube to keep the angle and depth of dipstick consistent.

7. Remove dipstick and check to see that the oil level is in the SAFE range. Add oil as indicated by the level on the dipstick. Do not overfill (see NOTE below!).

NOTE: Due to the dipstick entry angle into the crankcase, the oil level will read higher on the bottom side of the dipstick. Proper level indication is determined on the upper surface of the dipstick as it is being removed, regardless of the level marks being on top or on bottom (see the next illustration).

• RZR 4: Remove the right rear passenger seat to access

the dipstick.

5. St op engine and lift the lever lock. Remove dipstick and wipe dry with a clean cloth.

9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual

NOTE: A rising oil level between checks in cool weather driving can indicate contaminants such as gas or moisture collecting in the crankcase. If the oil level is over the full mark, change the oil immediately.

8. Reinstal l the dipstick and lock the lever.

2.15

MAINTENANCE

WARNING

CAUTION

Drain Plug

NOTE: Drain plug is accessed through the skid plate.

Oil Filter

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.

Personal injury can occur when handling used

oil. Hot oil can cause burns or skin damage.

Recommended Engine Oil:

PS-4 Plus Synthetic 4-Cycle Engine Oil

(PN 2876244) (Quart)

Ambient Temperature Range

-40° F to 120° F

1. Position vehicle on a level surface.

2. Place the transmission in PARK (P).

3. St art the engine. Allow it to idle for two to three minutes until warm. Stop the engine.

4. Clean area around oil drain plug at bottom of engine.

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. Using Oil Filter Wrench (PU-50105) and a 3/8” extension, turn the oil filter counter-clockwise to remove it.

10. Using a clean dry cloth, clean filter sealing surface on the crankcase.

11. Lubricate O-ring on new filter with a film of fresh engine oil. Check to make sure the O-ring is in good condition.

12. Install new filter and turn by hand until filter gasket contacts the sealing surface, then turn an additional 1/2 turn.

Oil may be hot. Do not allow hot oil to come into

contact with skin, as serious burns may result.

5. Place a drain pan beneath engine crankcase and remove the

6. Allow oil to drain completely.

7. Replace the sealing washer on drain plug.

drain plug.

13. Remove the engine oil dipstick (see “Engine Oil Level”).

14. Fill the sump with 2 qts. (1.9 l) of PS-4 Plus Synthetic Engine Oil (2876244).

Crankcase Drain Plug Torque:

16 ft. lbs. (22 Nm)

Oil Filter Torque:

Turn by hand until filter gasket contacts

sealing surface, then turn an

additional 1/2 turn

Oil Filter Wrench:

PU-50105: 2.5” (64 mm)

15. Verify the transmission is still positioned in PARK (P).

16. Start the engine and let it idle for one to two minutes.

17. Stop the engine and inspect for leaks.

18. Re-check the oil level on the dipstick and add oil as necessary to bring the level to the upper mark on the dipstick.

19. Dispose of used oil and oil filter properly.

2.16

9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual

MAINTENANCE

Breather

Hose

WARNING

Silencer

Retaining

Arrestor

Screen

Washer

Screw

Engine Breather Hose Inspection

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.

NOTE: Make sure line is not kinked or pinched.

Engine and Transmission Mounts

Periodically inspect engine and transmission mounts for cracks or damage.

Exhaust - Spark Arrestor

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. Allow

components to cool sufficiently before proceeding.

Wear eye protection and gloves. Never run the engine in an enclosed area. Exhaust contains poisonous carbon monoxide gas that can

cause loss of consciousness or death in a very

short time.

Periodically clean spark arrestor to remove accumulated carbon.

1. Remove the retaining screw, washer and spark arrestor from the end of the silencer.

2. Use a non -synthetic brush to clean the arrestor screen. A synthetic brush may melt if components are warm.

3. Inspect the screen for wear and damage. Replace if needed.

4. Reinstal l the arrestor and torque the screw to 40 in. lbs. (4.5 Nm).

Refer to Chapter 3 “Engine Assembly and Installation” for mounting fastener torque values.

Compression and Leakdown Test

NOTE: This engine does NOT have decompression components. Compression readings will vary in proportion to cranking speed during the test.

A smooth idle generally indicates good compression. Low engine compression is rarely a factor in running condition problems above idle speed.

A cylinder leakdown test is the best indication of engine condition. Follow manufacturer's instructions to perform a cylinder leakage test (never use high pressure leakage testers, as crankshaft seals may dislodge and leak).

Cylinder Compression:

165-185 PSI

Cylinder Leakdown

Service Limit: 15%

(Inspect for cause if test exceeds 15%)

2.17

9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual

MAINTENANCE

TRANSMISSION AND GEARCASES

T ransmission / Gearcase Specification Chart

EARCASE LUBRICANT CAPACITY FILL PLUG TORQUE

Transmission

(Main Gearcase)

Transmission

(Transfer Case)

Front Gearcase Demand Drive Plus 6.75 oz. (200 ml) 8-10 ft. lbs. (11-14 Nm) 8-10 ft. lbs. (11-14 Nm)

Rear Gearcase ATV Angle Drive Fluid 26 oz. (769 ml) 40-50 ft. lbs. (54-68 Nm) 30-45 in. lbs. (3-5 Nm) Rear Gearcase

Differential (INT’L)

Transmission Lubrication

AGL Plus

Gearcase Lubricant

AGL Plus

Gearcase Lubricant

ATV Angle Drive Fluid 22 oz. (650 ml) 40-50 ft. lbs. (54-68 Nm) 30-45 in. lbs. (3-5 Nm)

24 oz. (710 ml) 40-50 ft. lbs. (54-68 Nm) 30-45 in. lbs. (3-5 Nm)

14 oz. (414 ml) 40-50 ft. lbs. (54-68 Nm) 30-45 in. lbs. (3-5 Nm)

4. Add the recommended fluid through the fill plug hole until it begins to flow out the level check plug hole.

DRAIN / LEVEL CHECK

LUG TORQUE

Transmission Specifications

Specified Lubricant:

AGL Plus Gearcase Lubricant

(PN 2878068)

Approximate Capacity at Change:

Main Gearcase - 24 oz. (710 ml)

Transfer Case - 14 oz. (414 ml)

Drain / Level Plug Torque:

30-45 in. lbs. (3-5 Nm)

Fill Plug Torque:

40-50 ft. lbs. (54-68 Nm)

The transmission lubricant levels should be checked and changed in accordance with the maintenance schedule.

• 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.

Transfer Case - Lubricant Level Check:

1. Position vehicle on a level surface.

2. Remove the fill plug.

5. Reinstall the level check plug and torque to 30-45 in. lbs. (3-5 Nm).

6. Reinstall the fill plug and torque to 40-50 ft. lbs. (54-68 Nm).

3. Remove the level check plug.

2.18

9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual

MAINTENANCE

Main Gearcase - Lubricant Level Check:

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.

1. Position vehicle on a level surface.

2. Remove the fill / level plug and check the fluid level.

5. 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).

7. Reinstall the fill plug and torque to 40-50 ft. lbs. (54-68 Nm).

Main Gearcase Lubricant Change:

8. Remove the fill / level plug (refer to “Main Gearcase Lubricant Level Check”).

9. Place a drain pan under the main gearcase drain plug.

10. Remove the drain plug and allow to drain completely.

11. Clean and reinstall the drain plug with a new O-ring. Torque to 30-45 in. lbs. (3-5 Nm).

12. Add the recommended fluid through the fill plug hole. Maintain the fluid level at the bottom of the fill plu g hole when filling the Main Gearcase. Do not overfill.

13. Reinstall the fill / level plug and torque to 40-50 ft. lbs. (54-68 Nm).

3. If fluid level is not at fill plug hole, add the recommended fluid as needed.

4. Rein stall the fill / level plug and torque to 40-50 ft. lbs. (54-68 Nm).

Trans m ission Lubricant Change:

The lubricant change procedure is relatively the same for the main gearcase and the transfer case. To minimize confusion, perform the lubricant change on only one gearcase at a time. Access the drain plugs through the drain holes in the skid plate.

Transfer Case Lubricant Change:

1. Remove the fill plug and the level check plug (refer to “Transfer Case - Lubricant Level Check”).

2. Place a drain pan under th e transfer case drain plug.

14. Check for leaks. Discard the used lubricant properly.

3. Remove the drain plug and allow to drain completely.

4. Clean and Reinstall the drain plug with a new O-ring. Torque to 30-45 in. lbs. (3-5 Nm).

9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual

2.19

MAINTENANCE

Front Gearcase Lubrication

The front gearcase lubricant level should be checked and changed in accordance with the maintenance schedule.

• 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.

Front Gearcase Specifications

Specified Lubricant:

Polaris Demand Drive Plus

(PN 2877922)

Capacity: 6.75 oz. (200 ml)

Fill Plug: 8-10 ft. lbs. (11-14 Nm)

Drain Plug: 8-10 ft. lbs. (11-14 Nm)

1. Position vehicle on a level surface.

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).

Lubricant Change:

The drain plug is located on the bottom of the gearcase.

Lubricant Level Check:

The fill plug is located on the bottom right side of the front gearcase. Maintain the lubricant level even with the bottom threads of the fill plug hole.

1. Remove the fill plug.

2. Place a drain pan under the drain plug.

3. Remove the drain plug and allow fluid to drain completely.

4. Clean the drain plug. Inspect the O-ring and replace if damaged.

5. Reinstall the drain plug; torque to 8-10 ft. lbs. (11-14 Nm).

6. A dd the recommended fluid. Maintain the lubri cant level even with the bottom threads of the fill plug hole.

7. Reinstall the fill plug; torque to 8-10 ft. lbs. (11-14 Nm).

2.20

8. Check for leaks. Discard the used lubricant properly.

9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual

MAINTENANCE

Rear Gearcase Lubrication

The rear gearcase lubricant level should be checked and changed in accordance with the maintenance schedule.

• 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.

Rear Gearcase Specifications

Specified Lubricant:

ATV Angle Drive Fluid (PN 2876160)

Capacity: 26 oz. (769 ml)

RZR S INT’L Capacity: 22 oz. (650 ml)

Fill Plug Torque: 40-50 ft. lbs. (54-68 Nm)

Drain Plug Torque: 30-45 in. lbs. (3-5 Nm)

Lubricant Level Check:

Lubricant Change:

The drain plug is located on the bottom right side of t he rear gearcase.

1. Remove the fill plug.

2. Place a drain pan under the drain plug.

3. Remove the drain plug and allow the lubricant to drain completely.

4. Clean the drain pl ug.

5. Reinstall the drain plug with new O-ring and torque to 30-45 in. lbs. (3-5 Nm).

The fill plug is located on the right side of the rear gearcase. Maintain the fluid level even with the bottom of the threads of the fill plug hole.

1. Position the vehicle on a level surface.

2. Remove the fill plug and check the fluid level. The lubricant level should be even with the bottom of the threads of the fill plug hole.

6. Add the recommended lubricant. Maintain the fluid level even with the bottom threads of the fill plug hole.

7. Reinstall the fill plug and torque to 40-50 ft. lbs. (54-68 Nm).

8. Check for leaks. Discard used lubricant properly.

3. Add the recommended lubricant as needed.

4. Reinstall the fill plug and torque to 40-50 ft. lbs.

(54-68 Nm).

9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual

2.21

MAINTENANCE

Recovery Bottle

Pressure Cap

WARNING

Antifreeze Hydrometer

COOLING SYSTEM

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.

As coolant operating temperature increases, the expanding (heated) excess coolant is forced out of the radiator past the pressure cap and into the recovery bottle. As engine coolant temperature decreases the contracting (cooled) coolant is drawn back up from the tank past the pressure cap and into the radiator.

NOTE: Some coolant level drop on new machines is normal as the system is purging itself of trapped air. Observe coolant levels often during the break-in period.

NOTE: Overheating of engine could occur if air is not fully purged from system.

Polaris Premium 60/40 is already premixed and ready to use. Do not dilute with water.

Coolant Level Inspection

The pressure cap and recovery bottle are located under the front hood of the vehicle. The coolant level must be maintained between the minimum and maximum levels indicated on the recovery bottle.

4. If the coolant level is below the MIN line, inspect the coolant level in the radiator.

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.

Never remove the pressure cap when the

engine is warm or hot. Escaping steam can

cause severe burns. The engine must be cool

before removing the pressure cap.

5. Remove the pressure cap. Using a funnel, add coolant to the top of the filler neck.

6. Reinstall the pressure cap.

NOTE: Use of a non-standard pressure cap will not allow the recovery system to function properly.

7. Remove recovery bottle cap and add coolant using a funnel.

8. Fill recovery bottle to MAX level with Polaris 60/40 premix Anti Freeze/Coolant or 50/50 or 60/40 mixture of antifreeze and distilled water as required for freeze protection in your area.

9. Reinstall the recovery bottle cap.

10. If coolant was required, start engine and check for leaks. Make sure radiator fins are clean to prevent overheating.

With the engine at operating temperature, the coolant level should be between the upper and lower marks on the coolant recovery bottle. If not, perform the following procedure:

1. Position the vehicle on a level surface.

2. Remove the hood from the front cab.

3. View the coolant level in the recovery bottle.

Coolant Strength / Type

Test the strength of the coolant using an antifreeze hydrometer .

• A 50/50 or 60/40 mixture of antifreeze and distilled

water will provide the optimum cooling, corrosion protection, and antifreeze protection.

• Do not use tap water, straight antifreeze, or straight

water in the system. Tap water contains minerals and impurities which build up in the system.

• Straight water or antifreeze may cause the system to

freeze, corrode, or overheat.

Polaris 60/40 Anti-Freeze / Coolant

(PN 2871323)

2.22

9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual

MAINTENANCE

CAUTION

Flush radiator fins

in this direction

CAUTION

WARNING

Drain Here

Cooling System Pressure Test

Refer to Chapter 3 for cooling system pressure test procedure.

Cooling System Hoses

1. Inspect all hoses for cracks, deterioration, abrasion or leaks. Replace if necessary.

2. Carefully straighten any bent radiator fins.

3. Remove any obstructions with compressed air or low pressure water.

Washing the vehicle with a high-pressure

washer could damage the radiator fins and

impair the radiators effectiveness. Use of a high-

pressure washer is not recommended.

Coolant Drain / Radiator Removal

Coolant Drain

1. Remove the hood from the front cab.

Never drain the coolant when the engine and radiator are warm or hot. Hot coolant can cause severe burns. Allow engine and radiator to cool.

2. Check ti ghtness of all hose clamps.

Do not over-tighten hose clamps at radiator,

or radiator fitting may distort, causing a

restriction to coolant flow.

Radiator hose clamp torque is 36 in. lbs. (4 Nm).

Radiator

1. Check radiator (A) air passages for restrictions or damage.

2. Slowly remove the pressure cap to relieve any cooling system pressure.

3. Place a suitable drain pan underneath the radiator fitting on the front RH side of the vehicle.

4. Drain the coolant from the radiator by removing the lower coolant hose from the radiator as shown. Properly dispose of the coolant.

5. Allo w coolant to completely drain.

2.23

9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual

MAINTENANCE

Recovery

Engine

T-Fitting

Radiator

Fan Motor Asm.

Screws

Grommets

Inserts

Hose

Outlet Hose

Engine

Inlet Hose

Steel Wheel

27 ft. lbs. (37 Nm)

Aluminum Wheel

30 ft. lbs. + 90° (1/4 turn)

Radiator Removal

1. Remove the front bumper (see Chapter 5).

2. Remo ve the upper engine outlet hose and recovery hose from the top of the radiator.

3. Remo ve the (2) upper radiator retaining bolts and the (4) bolts retaining the lower radiator mount brack et. Remove the bracket from the frame.

4. Disconnect the fan motor and remove the radiator from the vehicle. Take care not to damage the cooling fins.

FINAL DRIVE / WHEEL AND TIRE

Wheel and Hub Torque Table

Item Nut Type Specification

Aluminum Wheels

(Cast)

Steel Wheels

(Black / Camo)

Hub Retaining Nuts - 80 ft. lbs. (108 Nm)

NOTE: Do not lubricate the stud or the lug nut.

Lug Nut

Flange Nut

30 ft. lbs. + 90° (1/4 turn)

27 ft. lbs. (37 Nm)

5. Reverse procedure for installation.

Wheel Removal

1. Position the vehicle on a level surface.

2. Place the transmission in PARK (P) and stop the engine.

3. Lo osen the wheel nuts slightly. If wheel hub removal is required, remove the cotter pin and loosen the hub nut slightly.

4. Elevate the appropriate side of the vehicle by placing a suitable stand under the frame.

5. Remove the wheel nuts and remove the wheel.

6. If hub removal is required, remove the hub nut and washers.

Wheel Installation

1. Verify the transmission is still in PARK (P).

2. Instal l the wheel hub, washers, and hub nut, if previously removed.

3. Place the wheel in the correct position on the wheel hub. Be sure the valve stem is toward the outside and rotatio n arrows on the tire point toward forward rotation.

4. Attach the wheel nuts and finger tighten them.

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5. Carefully lower the vehicle to the ground.

6. Torq ue the wh eel nuts and/or hub nut to th e proper torqu e

CAUTION

WARNING

Wheel Nuts (4)

Hub Nut

Use a new

cotter pin

Note

Tire Rotation

Valve stem

facing outward

(RZR Only)

CAUTION

Tread Depth 1/8" (3 mm)

Front Boots

Rear Boots

specification listed in the torque table at the beginning of this section.

7. If hu b nut was removed, install a new cotter p in after the hub nut has been tightened.

If wheels are improperly installed it could affect vehicle handling and tire wear. On vehicles with tapered rear wheel nuts, make sure tapered end

of nut goes into taper on wheel.

MAINTENANCE

Tire Pressure

Maintain proper tire pressure.

Refer to the warning tire pressure decal

applied to the vehicle.

Tire Pressure Inspection (Cold)

Front Rear

8 psi (55 kPa) 8 psi (55 kPa)

RZR-4: 10 psi (69 kPa) RZR-4: 12 p si (8 3 kPa)

Drive Shaft Boot Inspection

Tire Inspection

• Improper tire inflation may affect vehicle maneuverability.

• When replacing a tire always use original equipment size and type.

• The use of non-standard size or type tires may affect vehicle handling.

Operating with worn tires will increase the

possibility of the vehicle skidding easily with

possible loss of control.

Worn tires can cause an accident.

Always replace tires when the tread depth

measures 1/8", (.3 cm) or less.

Tire Tread Depth

Inspect the drive shaft boots for damage, tears, wear or leaking grease. If the boots exhibit any of these symptoms, they should be replaced. Refer to Chapter 7 for drive shaft boot replacement.

Replace tires when tread depth is worn to 1/8" (3 mm) or less.

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2.25

MAINTENANCE

WARNING

CAUTION

Battery

RZR / RZR S

RZR 4

Battery

ELECTRICAL AND IGNITION SYSTEM

Battery Maintenance

Keep battery terminals and connections free of corrosion. If cleaning is necessary, remove the corrosion with a stiff wire brush. W ash 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.

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.

Battery Removal

1. Remove the driver’s seat to access the battery.

Battery electrolyte is poisonous. It contains sulfuric acid. Serious burns can result from

contact with skin, eyes or clothing. Antidote:

External: Flush with water.

Internal: Drink large quantities of water or milk.

Follow with milk of magnesia, beaten egg, or

vegetable oil. Call physician immediately.

Eyes: Flush with water for 15 minutes and get

prompt medical attention.

Batteries produce explosive gases.

Keep sparks, flame, cigarettes, etc. away.

Ventilate when charging or using in an enclosed

space. Always shield eyes when

working near batteries.

KEEP OUT OF REACH OF CHILDREN.

NOTE: Batteries must be fully charged before use or battery life will be reduced by 10-30% of full potential. Charge battery according to “Charging Procedure” provided in Chapter 10. Do not use the vehicle’s stator/alternator to charge a new battery.

2. Disconnect the black (negative) battery cable.

3. Disconnect the red (positive) battery cable.

4. Remove the hold-down strap and lift the battery out of the vehicle.

To reduce the chance of sparks: Whenever

removing the battery, disconnect the black

(negative) cable first. When reinstalling the

battery, install the black (negative) cable last.

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MAINTENANCE

WARNING

RZR 4 Shown

Note for

reassembly

Inspect electrode for wear and buildup

Gap - .035" (0.90 mm)

Spark Plug Gap

Battery Installa ti on

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. Connect and tighten the red (positive) cable first.

5. Connect and tighten the black (negative) cable last.

2. Remove the cargo box assembly to access the spark plugs (see Chapter 5).

3. Remove both spark plug caps and clean plug area so no dirt or debris can fall into engine when plugs are removed.

4. Clean plug area so no dirt and debris can fall into engine when plugs are removed.

5. Remove spark plugs.

6. Verify that cables are properly routed and reinstall the driver’s seat.

Battery Off Season Storage

Refer to Chapter 10 “Electrical” for off season storage procedures.

Battery Charging (Maintenance Free)

Refer to Chapter 10 “Electrical” for charging procedure.

Spark Plug Service

1. Rem ove the rear service panel:

• RZR / RZR S: Remove the driver and passenger seats.

• RZR 4: Remove both rear passenger seats.

6. Inspect electrodes for wear and carbon buildup. Look for a sharp outer edge with no rounding or erosion of the electrodes.

7. Clean with electrical contact cleaner or a glass bead spark plug cleaner only. CAUTION: A wire brush or coated abrasive should not be used.

8. Measure gap with a wire gauge. Adjust gap if necessary by carefully bending the side electrode.

A hot exhaust system and engine can cause

serious burns. Allow engine to cool or wear

protective gloves when removing the spark plugs.

9. If necessary, replace spark plug with proper type. CAUTION: Severe engine damage may occur if the incorrect spark plug is used.

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MAINTENANCE

Engine

Ground Strap

RZR / RZR S

Ground Terminal

RZR 4

Ground Terminal

WARNING

Tie Rod

U-Joints

Gearbox

Tie Rod

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.

Engine To Frame Ground

Inspect ground cable connections. Be sure they are clean and tight. The engine ground cable runs from the starter motor to the chassis ground terminal.

STEERING

Steering Inspection

The steering components should be checked periodically for loose fasteners, worn tie rod ends, ball joints, and damage. Also check to make sure all cotter pins are in place. If cotter pins are removed, they must not be re–used. Always use new cotter pins.

Replace any worn or damaged steering components. Steering should move freely through the entire range of travel without binding. Check routing of all cables, hoses, and wiring to be sure the steering mechanism is not restricted or limited.

NOTE: Whenever steering components are replaced, check front end alignment.

Due to the critical nature of the procedures

outlined in this chapter, Polaris recommends

steering component repair and adjustmen t be

performed by an authorized Polaris

MSD certified technician.

Use only genuine Polaris replacement parts.

Steering Wheel Freeplay

Check the steering wheel for specified freeplay and operation.

1. Position the vehicle on level ground.

2. Lightly turn the steering wheel left and right.

3. There should be 0.8”-1.0” (20-25 mm) of freeplay.

4. If there is excessive freeplay or the steering feels rough, inspect the following components.

• Tie Rod Ends

• Steering Shaft U-Joints

• Steering Gearbox

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MAINTENANCE

Check for Loose Wheel or Hub

= In. / mm.

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.

Wheel Toe Alignment Inspection

1. Place machine on a smooth level surface and set steering wheel in a straight ahead position. Secure the steering wheel in this position.

2. Place a chalk mark on the center line of the front tires approximately 10” (25.4 cm) from the floor or as close to the hub/axle center line as possible.

• 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. Try to move the wheel and hub by pushing inward and pulling outward.

• If abnormal movement is detected, inspect the hub and wheel assembly to determine the cause (loose wheel nuts or loose front hub nut).

NOTE: It is important the height of both marks be equally positioned to get an accurate measurement.

3. Measure the distance between the marks and record the measurement. Call this measurement “A”.

4. Rotate the tires 180 Position chalk marks facing rearward, even with the hub/ axle center line.

5. Again measure the distance between the marks and record. Call this measurement “B”. Subtract measurement “B” from measurement “A”. The difference between measurements “A” and “B” is the vehicle toe alignment. The recommended vehicle toe tolerance is 1/8”, to 1/4”, (.3 to .6 cm) toe out. This means the measurement at the front of the tire (A) is 1/8”, to 1/4”, (.3 to .6 cm) wider than the measurement at the rear (B).

(A) - (B) = 1/8 - 1/4" (.3 to .6 cm)

 by moving the vehicle forward.

Wheel Toe-Out:

• Refer to Chapter 7 “Final Drive” for front hub service procedures.

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2.29

MAINTENANCE

CAUTION

= T

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.

Tie Rod Jam Nut Torque:

12-14 ft. lbs. (16-19 Nm)

NOTE: Be sure steering wheel is straight ahead before determining which tie rod needs adjustment.

During tie rod adjustment, it is very important that

the following precautions be taken when

tightening tie rod end jam nuts.

If the rod end is positioned incorrectly it will not

pivot, and may break.

To adjust toe alignment:

• Hold tie rod end to keep it from rotating.

• Loosen jam nuts at both end of the tie rod.

• Shorten or lengthen the tie rod until alignment is as required to achieve the proper toe setting as specified in “Wheel Toe Alignment”.

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MAINTENANCE

WARNING

Increase

Preload

Decrease

Preload

Cam

WARNING

Spring

Spacer

Ride-In

Spring

Increase

Preload

Decrease

Preload

RZR S

Factory Preload Setting

3.5 in. (8.9 cm)

Podium X

Front Shock

Increase

Preload

Decrease

Preload

Factory Preload Setting

5.4 in. (13.7 cm)

RZR S

Podium X

Rear Shock

SUSPENSION (STANDARD)

Spring Preload Adjustment

The front and rear shock absorber springs are adjustable by rotating the adjustment cam to change spring tension preload.

Uneven adjustment may cause poor handling of the

vehicle, which could result in an accident and

serious injury or death. Always adjust both the left

and right spring preloads equally.

Suspension Spring Adjustment

1. Position the vehicle on a level surface and stop the engine.

2. Raise and safely support the front or rear of the vehicle off the ground to allow the suspension to fully extend.

NOTE: The tires should not be touching the ground.

3. To adjust the suspension, rotate the adjustment cam clockwise to increase spring tension or counter-clockwise to decrease spring tension.

SUSPENSION (FOX™)

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.

Uneven adjustment may cause poor handling of the

vehicle, which could result in an accident and

serious injury or death. Always adjust both the left

and right spring preloads equally.

1. Raise and safely support the front or rear of the vehicle off the ground to allow the suspension to fully extend.

2. Lo osen the up per jam nu t adjustmen t ring. Tu rn the lower adjustment ring (1) clockwise to increase preload or counter-clockwise to decrease preload.

Shock Spanner Wrench

(PN 2871095)

4. Each notch of the adjustment will add 6% - 8% more preload to the spring over the primary position.

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2.31

MAINTENANCE

Increase

Preload

Decrease

Preload

Factory Preload Setting

4.2 in. (10.7 cm)

RZR 4

2.0 Piggyback Front Shock

Increase

Preload

Decrease

Preload

Factory Preload Setting

4.8 in. (12.2 cm)

RZR 4

2.0 Piggyback

Rear Shock

Clicker

Adjuster

Increase

Damping

Decrease

Damping

Shock Compression Adjustment

The compression damping adjustment is located on top of the shock ‘Piggyback’ reservoir of each shock.

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. Turn the clicker counter-clockwise to decrease compression damping.

NOTE: The factory setting is 8 clicks from closed (RZR-S) and 10 clicks from closed (RZR-4). Refer to

the “Compression Adjustment Ta bl e” below.

3. Once you have obtained the correct preload, hold the lower adjustment ring while tightening the upper adjustment ring to lock them in place.

Shock Spanner Wrench

(PN 2870803)

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9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual

Compression Adjustment Table

Setting Compression Damping

Softest 18 clicks from closed

Factory (RZR S) 8 clicks from closed Factory (RZR 4) 10 clicks from closed

Firmest 2 clicks from closed

SUSPENSION (WALKER EVANS™)

WARNING

Front Shock

Factory

Preload Setting

Increase

Preload

Decrease

Preload

10.4 in. (26.4 cm)

Rear Shock

Factory

Preload Setting

Increase

Preload

Decrease

Preload

12 in. (30.5 cm)

Increase

Damping

Decrease

Damping

Clicker

Knob

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.

MAINTENANCE

Shock Spanner Wrench

(PN 2870803)

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. Always adjust both the left

and right spring preloads equally.

1. Raise and safely support the front or rear of the vehicle off the ground to allow the suspension to fully extend.

2. Turn the preload adjustment collar (1) clockwise to increase preload or counter-clockwise to decrease preload.

Damping adjustments can be made without using any tools.

NOTE: When the adjuster knob is turned counterclockwise until it stops, the damping is in the fully open position (Soft).

Turn the clicker clockwise to increase compression damping. Turn the clicker counter-clockwise to decrease compression damping.

NOTE: The factory setting is 6 clicks clockwise from the softest position (see “Compression Adjustment Table”).

Compression Adjustment Table

Setting Compression Damping

Softest Full counter-clockwise position

Factory 6 clicks from softest position

Firmest Full clockwise position

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2.33

MAINTENANCE

Master Cylinder

Maximum

Minimum

Measure Pad Material

Service Limit:

.040" (1 mm)

Thickness

Measure Brake Disc Thickness

Service Limit:

.170" (4.32 mm)

Front

Disc

Rear

Disc

BRAKE SYSTEM

Brake Fluid Inspection

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.

Brake fluid should be changed every two years. The fluid should also be changed anytime the fluid becomes contaminated, the fluid level is below the minimum level, or if the type and brand of the fluid in the reservoir is unknown.

The brake fluid master cylinder reservoir can be accessed through the left front wheel well.

1. Position the vehicle on a level surface.

2. Place the transmission in PARK (P).

3. View the brake fluid level in the reservoir. The level should be between the MAX and MIN level lines.

4. If the fluid level is lower than the MIN level line, add brake fluid until it reaches the MAX level line.

5. Install the reservoir cap and apply the brake pedal forcefully for a few seconds and check for fluid leakage around the master cylinder fittings and the brake caliper fittings.

Brake Pad / Disc Inspection

1. Check the brake pads for wear, damage, or looseness.

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).

4. Check surface condition of the brake discs.

5. Measure the thickness of the front and rear brake discs.

6. The disc(s) should be replaced if thickness is less than .170” (4.32 mm).

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Brake Hose and Fitting Inspection

Check brake system hoses and fittings for cracks, deterioration, abrasion, and leaks. Tighten any loose fittings and replace any worn or damaged parts.

MAINTENANCE

MAINTENANCE LOG

Service Date Hours / Miles (km) Service Performed / Comments Dealer / Technician

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2.35

MAINTENANCE

NOTES

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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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.5

ENGINE EFI SENSORS / VALVE COVER / GENERAL COMPONENTS . . . . . . . . . . . .3.6

ENGINE TORQUE SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.7

800 EFI ENGINE SERVICE SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.8

SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.10

ENGINE COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.11

COOLING SYSTEM SPECIFICATIONS / PRESSURE TEST / CAP TEST. . . . . . . . . .3.11

COOLING SYSTEM EXPLODED VIEW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.12

COOLING SYSTEM BLEEDING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.13

GENERAL ENGINE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.14

ENGINE LUBRICATION SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.14

ACCESSIBLE ENGINE COMPONENTS / OIL PRESSURE TEST . . . . . . . . . . . . . . . .3.14

OIL FLOW CHART. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.15

ENGINE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.16

ENGINE / TRANSMISSION SEPARATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.23

ENGINE DISASSEMBLY AND INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.24

CYLINDER HEAD ASSEMBLY EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.24

ROCKER ARMS / PUSH RODS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.25

CYLINDER HEAD REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.25

CYLINDER HEAD INSPECTION / WARP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.26

VALVE SEAL / SPRING SERVICE (ON ENGINE). . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.26

CYLINDER HEAD DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.27

VALVE INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.28

COMBUSTION CHAMBER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.29

VALVE SEAT RECONDITIONING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.29

CYLINDER HEAD REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.31

VALVE SEALING TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.32

CYLINDER REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.32

VALVE LIFTER REMOVAL / INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.32

PISTON REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.33

CYLINDER INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.34

CYLINDER HONE SELECTION AND HONING PROCEDURE. . . . . . . . . . . . . . . . . . .3.35

HONING TO DEGLAZE / CLEANING THE CYLINDER AFTER HONING. . . . . . . . . . . 3.35

PISTON-TO-CYLINDER CLEARANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.36

PISTON / ROD INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.36

PISTON RING INSTALLED GAP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.37

STARTER DRIVE BENDIX REMOVAL / INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . .3.37

FLYWHEEL / STATOR REMOVAL / INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . .3.38

ENGINE CRANKCASE DISASSEMBLY / INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 3.38

CAMSHAFT INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.46

ENGINE REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.47

CRANKCASE REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.47

FLYWHEEL / STATOR INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.56

CYLINDER HEAD REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.56

OIL PUMP PRIMING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.58

ENGINE INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.59

ENGINE ASSEMBLY AND INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.59

ENGINE BREAK-IN PERIOD. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.60

TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.61

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3.1

ENGINE

ENGINE SPECIFICATIONS

Crankcase Exploded Views

3.2

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Oil Pump / Gears / Engine Cover Exploded View

ENGINE

9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual

3.3

ENGINE

Stator Cover / Starter / Water Pump / Lubrication System Exploded View

3.4

9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual

Cylinder / Cylinder Head / Piston Exploded View

ENGINE

9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual

3.5

ENGINE

NOTE: See chapter 4 for more information on the EFI System

Engine EFI Sensors / Valve Cover / General Components Exploded View

3.6

9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual

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) Coolant Bypass Hose Fitting 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 ± 0.9) Cylinder Head Bolts 11 mm - * 35 ± 4 (47.5 ± 5.5) Exhaust Manifold 8 mm 216 ± 24 (24.5 ± 2.70) 18 ± 2 (24.5 ± 2.7) Flywheel 14 mm - 65 ± 7 (88 ± 9.50) Injector Rail 8 mm 216 ± 24 (24.5 ± 2.70) 18 ± 2 (24.5 ± 2.7)

Magneto Cover 6 mm * 96 ± 3 (10.85 ± 0.35) Oil Baffle Weldment 5 mm 60 ± 6 (6.8 ± 0.68) Oil Drain Bolt (Crankcase) 12 mm 192 ± 24 (21.7 ± 2.7) 16 ± (21.7) Oil Fill Tube Bolt 5 mm 50 ± 5 (5.64 ± 0.56) Oil Filter Pipe Fitting 20 m m - 35 ± 4 (47.5 ± 5.4) Oil Pick Up 5 mm 60 ± 6 (6.8 ± 0.68) Oil Pressure Relief Plug 10 mm - 17 ± 2 (23 ± 2.7) Oil Pump Housing Screw 6 mm * 84 ± 8 (9.5 ± 0.9) Rocker Arm 8 mm - * 22 ± 2 (30 ± 3) Rocker Cover 6 mm * 84 ± 8 (9.5 ± 0.9) Spark Plug 14 mm 216 ± 24 (24.5 ± 2.7) 18 ± 2 (24.5 ± 2.7) Starter Motor 6 mm * 84 ± 8 (9.5 ± 0.9) Stator Assembly 6 mm 96 ± 3 (10.85 ± 0.35) Stator Housing 6 mm * 96 ± 3 (10.85 ± 0.35) Stator Wire Retainer Plate 5 mm * 96 ± 3 (10.85 ± 0.35) Thermistor Sensor 3/8 NPT - 17 ± 2 (23 ± 3) Thermostat Housing 6 mm 84 ± 8 (9.5 ± 0.9) Throttle Body Adaptor Bolts 8 mm 216 ± 24 (24.5-± 2.7) 18 ± 2 (24.5 ± 2.7) T-MAP Sensor Bolt 5 mm 25 ± 3 (2.8 ± 0.3) Water Pump Housing Cover 6 mm * 96 ± 3 (10.85 ± 0.35) Water Pump Impeller Nut 8 mm 108 ± 3 (12 ± 0.35) -

NOTE: * See exploded views for notes or torque sequences.

9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual

3.7

ENGINE

800 EFI Engine Service Specifications

Cylinder Head - Engine Specifications

Main Component: Cylinder Head RZR800HO-11 (PN 1204276)

Cam Lobe Height - Intake 1.3 57” (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

Counter Balance Counter Balance End Play 0.005" (0.127 mm)

Cylinder Head

Valve Seat

Valve Guide

Camshaft Journal Outer Diameter - PTO 1.614"  0.000 39" (41  0.010 mm) Camshaft Journal Bore Inner Diameter - Mag 1.656"  0.00039" (42.07  0.010 mm) Camshaft Journal Bore Inner Diameter - Center 1.637"  0.00039" (41.58  0.010 mm) Camshaft Journal Bore Inner Diameter - PTO 1.617"  0.000 39" (4 1.07  0.010 mm) Camshaft Oil Clearance 0.00276"  0.00079" (0.07  0.02 mm) Camshaft End Play 0.0167"  0.0098" (0.425  0.25 mm)

Cylinder Head - Surface warp limit 0.00394" (0.1 mm) Cylinder Head - Standard height 3.478" (88.35 mm)

Valve Seat - Contacting Width - Intake 0.0472"  0.00787" - 0.0039" (1.20  0.20 - 0.10 mm)

Valve Seat - Contacting Width - Exhaust 0.0591"  0.00787" - 0.0039" (1.50  0.20 - 0.10 mm) Valve Seat Angle 45.5  0.255

Valve Guide Inner diameter 0.2367"  0.00029" (6.012  0.007 mm) Valve Guide Protrusion Above Head 0.807"  0.0039" (20.50  0.01 mm) Valve Stem Diameter - Intake 0.2356"  0.00039" (5.985  0.01 mm)

Valve Spring

3.8

Valve

Valve Stem Diameter - Exhaust 0.2351"  0.00039" (5.972  0.01 mm) Valve Stem Oil Clearance - Intake 0.00228"  0.00098" (0.058  0.025 mm) Valve Stem Oil Clearance - Exhaust 0.00275"  0.00098" (0.0870  0.025

alve Stem Overall Length - Intake 4.51"  0.01476" (114.5550  0.375 mm)

V Valve Stem Overall Length - Exhaust 4.5453"  .01496" (115.45  0.38 mm) Valve Spring Overall Length - Free Length 1.735" (46.069 m m)

Valve Spring Overall Leng th - Installed Height

9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual

Intake - 1.4638" (37.18 mm) Exhaust - 1.4736" (37.43 mm)

mm)

ENGINE

Cylinder / Piston - Engine Specifications

Main Components: Cylinder / Piston / Connecting Rod RZR800HO-11 (PN 12042 76)

Cylinder

Lifter

Piston

Piston Pin

Cylinder - Surface warp limit (mating with cylinder head)

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  0.00635 mm) Lifter Block Bore 0.8438"  0.00062" (21.4322  0.0157 mm) Piston - Standard 3.14803"  .00028" (79.960  .007 mm) Piston Standard Inner Diameter of

Piston Pin Bore Piston Pin Outer Diameter 0.70866" - 0.70846" (18 - 17.995 mm) Piston Pin - Standard Clearance - Piston Pin to

Pin Bore Piston Pin - Degree of Fit Piston pin must be push fit (by hand) at 68° F (20° C)

0.004" (0.10 mm)

0.70902"  .00012" (18.009  0.003 mm)

0.00047"  0.00024" (0.012  0.006 mm)

Piston / Connecting Rod / Crankshaft - Engine Specifications

Main Components: Piston / Connecting Rod RZR800HO-11 (PN 1204276)

Top Ring - Standard 0.0059 - 0.0138" (0.15 - 0.35 mm) Top Ring - Limit > 15% Leakdown

Installed

Gap

Piston Ring

Ring to Groove

Clearance

Connecting Rod

Crankshaft Crankshaft Runout Limit 0.0 0236" (0.060 mm)

Second Ring - Standard 0.0098 - 0.0197" (0.25 - 0.50 mm) Second Ring - Limit > 15% Leakdown Oil Ring - Standard 0.0197 0.0098" (0.50 0.25 mm) Oil Ring - Limit > 15% Leakdown Top Ring - Standard 0.0024"  0.0008" (0.060  0.020 mm) Top Ring - Limit > 15% Leakdown Second Ring - Standard 0.0028"  0.0008" (0.070  0.020 mm) Second Ring - Limit > 15% Leakdown

Connecting Rod Small End I.D. 0.7096" 0.70846" (18  17.995 mm)

Connecting Rod Small End

Radial Clearance

Connecting Rod Big End

Side Clearance

Connecting Rod Big End

Radial Clearance

0.00098" 0.00039" (0.025  0.010 mm)

0.01181" 0.00591" (0.30  0.15 mm)

0.0015" 0.0006" (0.038  0.015 mm)

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3.9

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 WAT ER PUMP SEAL SAVER

2870975 MITY VAC™

PU-45778 OIL SYSTEM PRIMING TOOL

PRESSURE TEST TOOL

3.10

9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual

ENGINE COOLING SYSTEM

WARNING

Remove

Cap

Test Here

Pressure Cap

Cooling System Specifications

Condition Coolant Temperature F (C)

Room Temperature 68F (20C) Thermostat Closed 175° F (79° C) Thermostat Open 180° F (82° C)

ENGINE

Never remove pressure cap when engine is

warm or hot. The cooling system is under

pressure and serious burns may result.

Allow the engine to cool before servicing.

2. Remove pressure cap and pressure test the cooling system using a commercially available pressure tester.

Fan Off 194F (90C) Thermostat Full Open Lift 202° F (94° C) Fan On 205 F (96C)

Engine Temperature Overheat Indicator

Engine Protection Ignition Misfire

Engine Protection Shutdown

Item Specification

Cooling System Capacity

Pressure Cap Relief 13 PSI

Moving Vehicle: 235

Idle Vehicle: 241F (116C)

Moving Vehicle: 239

Idle Vehicle: 244F (118C)

Moving Vehicle: 257

Idle Vehicle: 262F (128C)

RZR / RZR S 4.8 qts. (4.5 l)

RZR 4 5.5 qts. (5.2 l)



F (113 C)



F (115C)



F (125C)

Polaris Premium Antifreeze

2871534 - Quart

2871323 - Gallon

Recommended Coolant

Use only high quality antifreeze/coolant mixed with distilled water in a 50/50 or 60/40 ratio, depending on freeze protection required in your area.

3. The system must maintain 10 psi for five minutes or longer. If pressure loss is evident within five minutes, check the radiator, hoses, clamps and water pump seals for leakage.

Pressure Cap Test

1. Remove the front hood (see Warning under “Cooling System Pressure Test”).

2. Remove pressure cap and test using a pressure cap tester (commercially available).

3. The pressure cap relief pressure is 13 psi. Replace cap if it does not meet this specification.

CAUTION: Using tap water in the cooling system will lead to a buildup of deposits which may restrict coolant flow and reduce heat dissipation, resulting in possible engine damage. Polaris Premium 60/40 Antifreeze/Coolant is recommended for use in all cooling systems and comes pre-mixed, ready to use.

Cooling System Pressure Test

1. Remove the hood from the front cab.

9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual

3.11

ENGINE

Recovery Bottle

Engine Inlet Hose

Engine Outlet Hose

Radiator

Shroud

Radiator

Pressure Cap

Fan Motor

(Water Pump Cove r)

(Thermostat Housing)

Outlet Hose

Inlet Hose

Filler Neck

To Top Fitting on Filler Neck

To Lower Fitting on Filler Neck

Bypass Hose (To Cylinder Head)

Coolant Flow Diagram

Radiator

Recovery Bottle

Engine

Water Pump

Engine

Thermostat Housing

Filler Neck

Engine

Cylinder Head Bypass

Cooling System Exploded View

3.12

9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual

ENGINE

WARNING

CAUTION

Pressure Cap

Recovery Bottle

Pressure Cap

Top LH Side

of Cylinder Head

Spark Plug

Cooling System Bleeding Procedure

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.

Use caution when performing these procedures.

Coolant may be hot and may cause

severe injury or burns.

NOTE: If the coolant level is LOW in the radiator, or if there are leaks in the system, the coolant system will not draw coolant from the reservoir tank.

NOTE: Use this procedure when a unit overheats and no apparent leaks in the cooling system are found.

1. Drive the vehicle onto a slight incline and use properly weight rated ramps. If an incline is not available, slightly elevate the front of the vehicle.

3. Remove pressure cap and top off coolant.

4. Remove recovery bottle cap and fill bottle to the full line.

5. Leave the cap off of the radiator to allow any possible air to escape.

6. Start the engine and let it idle for 5-10 minutes or until the thermostat opens and allows coolant to flow through the system.

7. Squeeze the coolant lines by hand to help purge the system of air.

2. Place the vehicle in Park and block the rear wheels.

Be sure the engine has cooled and no pressure is built up in the cooling system before removing

the pressure cap. The coolant may be hot and

could cause severe injury or burns.

8. Slightly loosen the bleed screw (C) on the cylinder head to let air escape. If no air is present, a steady stream of coolant will stream out. If air is present, the screw will bubble and sputter as the air escapes.

9. Ti ghten the bleed screw to 70 ± 10 in. lbs. (8 ± 1.13 Nm) and properly install the pressure cap.

NOTE: If there is air in the system you will see air bubbles forming through the radiator filler neck.

3.13

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ENGINE

WARNING

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.

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. If you hear or see a “glug” at the filler neck , or there is a dropping of the coolant level, indicating that coolant has been pulled into the system; Fill the recovery bottle only after you have completely filled the cooling system at the radiator filler neck.

12. Repeat this procedure, if overheating still occurs.

GENERAL ENGINE SERVICE

Engine Lubrication Specifications

Capacity: Approximately 2 U.S. Quarts (1.9 L)

Oil Type: Polaris PS-4 PLUS Synthetic

Filter Wrench: PU-50105 - 2.5” (64 mm)

- Oil Pressure Specification -

27-35 psi @ 6000 RPM, Polaris PS-4 PLUS Synthetic, Engine at operating temperature.

Accessible Engine Components

The following components can be serviced or removed with the engine installed:

• Starter Motor / Drive

• Cylinder Head

• Cylinder

• Piston / Rings

• Rocker Arms

• Water Pump

The following components require engine removal for service:

• Flywheel

• Alternator (Stator)

• Counterbalance Shaft or Bearings

• Gear Train Components

• Camshaft

• Oil Pump / Oil Pump Drive Gear

• Connecting Rod

• Crankshaft

• Crankshaft Main Bearings

•Crankcase

Oil Pressure Test

1. Remove blind plug/sender from left side of crankcase.

2. Insert a 1/8 NPT oil pressure gauge adaptor into the crankcase and attach the gauge.

3. Start engine and allow it to reach operating temperature, monitoring gauge indicator.

Oil Pressure at Idle: 6 psi

Oil Pressure at 6000 RPM (Engine Hot):

Minimum: 27 psi

Standard: 31 psi

Maximum: 35 psi

3.14

9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual

ENGINE

Oil Flow Chart

This chart describes the flow of oil through the 800 EFI engine. Beginning in the crank case 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. Oil is then diverted three ways from the main oil galley , with the fi rst path entering the camshaft bores, onto the rear balance shaft journal and then draining back into the crankcase sump. The second oil path from the main oil galley feeds the lifter bores and then drains back to the crankcase sump. The third oil path flows through a crankcase galley to the MAG side crankshaft journal and also to the front balance shaft journal and onto the crankcase sump.

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3.15

ENGINE

Engine Removal

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. Refer to “Accessible Engine Components” on Page 3.1

: The use of an overhead or portable engine

NOTE hoist is the only recommended method for removing and installing the engine / transmission / rear gearcase assembly.

NOTE: Have an assistant help guide the engine in and out of the vehicle while using an engine hoist to prevent personal injury or damage to vehicle components.

 for further information.

WARNING

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.

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:

• RZR / RZR S: Remove the (2) fasteners from the rear

seat base (as shown above).

• RZR 4: Remove the (2) fasteners and seat latch plunger

(A). Slide the rear seat base to the left and remove it.

1. If vehicle was recently operated, allow it to cool down before attempting to perform any work.

2. Clean work area.

3. Thoroughly clean the engine and chassis.

4. Drain appropriate lubricant(s):

• If servicing the engine, drain engine oil.

• If servicing the transmission, drain the lubricant from

the main gearcase and transfer case.

• If servicing the rear gearcase, drain the gearcase

lubricant.

5. Remove the driver’s seat (see Chapter 5).

6. Disconnect (-) negative battery cable.

7. Remo ve the passenger seat (s) and remove th e rear service panel (see Chapter 5).

10. Remove the rear bumper, rear cargo box and box supports from the vehicle (see Chapter 5).

3.16

9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual

ENGINE

Remove

Push Rivets

Outlet Duct

PVT Cover

Harness

Connection

Ignition

Coil

Frame Support

PVT Duct

Standard RZR

Shown

11. Remove the (2) push rivets and remove the intake box from the vehicle.

12. Elevate the rear of the vehicle off the ground using a suitable ATV lift and remove both rear wheels.

13. Remove all exhaust components from vehicle and engine.

14. Loosen the hose clamp attaching the outlet duct to the PVT cover. Leave the duct attached to the upper frame support.

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. Remove the vent lines from the upper bolt-i n frame brace and plug vent lines to prevent fluid leakage during removal.

18. Remove the (6) fasteners retaining the upper bolt-in frame brace and remove it from the vehicle with the ignition coil and PVT duct attached.

15. Remove the (8) screws that retain the PVT cover and

16. Remove the high tension leads from the spark plugs and

19. Remove the rear stabilizer bar from the linkage on both sides of the vehicle.

remove cover.

disconnect the ignition coil harness.

9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual

3.17

ENGINE

Standard RZR

Shown

Loosen

Clamp

Disconnect Here

DO NOT

Disconnect Here

Fuel

Injector

Harness

20. Remove the (4) fasteners retaining the stabilizer bar and bracket and remove the assembly from the vehicle.

21. Remove the engine breather hose from the valve cover.

22. Loosen the hose clamp between the throttle body and intake adaptor.

24. Remove the remaining bolt attaching the airbox to the frame (see photo).

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. Carefully place the assembly on the floor next to the vehicle. Insert a shop towel into the engine intake adaptor to prevent dirt from entering the engine.

NOTE: Ensure throttle cable is not being excessively bent or kinked while removed from the vehicle.

23. Disconnect the T-MAP, IAC and TPS sensor connectors from throttle body.

26. Mark the fuel injector harnesses to identify MAG and PTO harness connections to aid during reassembly. Disconnect the fuel injector harnesses.

NOTE: The fuel injector harness connector and locking spring is bonded to the fuel injectors with an epoxy mix. DO NOT attempt to disconnect the connector from the fuel injectors. Damage will occur to the injector and/or harness if attempting to separate at that location. Separate the fuel injector from the vehicle by disconnecting at the end of the harness as shown.

IMPORTANT: Take note of PTO and MAG fuel injector harness connectors before disconnecting them. The harnesses are different and can not incorrectly (PTO - Gray; MAG - Black).

be connected

3.18

9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual

ENGINE

Squeeze locking tabs together

Push lock outward

Remove

Clip

Lower

Jam Nut

Mark Upper

Jam Nut

Gear Switch

Connector

CPS

Connector

Stator

Connector

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.

28. Disconnect the shift cable from the transmission bell crank.

NOTE: If the upper jam nut is moved, shift cable adjustment will be required during engine installation (see Chapter 2 “Shift Cable Inspection / Adjustment”).

30. Disconnect the transmission gear indicator switch harness.

31. Disconnect the CPS harness.

29. Mark the upper jam nut and loosen the lower jam nut. Pull the shift cable out of the mount.

32. Disconnect the stator / alternator harness.

3.19

9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual

ENGINE

Speed Sensor

Connector

Cam Phase

Connector

Castle Nut

Hub Carrier

33. Disconnect the transmission speed sensor harness.

34. Disconnect the cam phase sensor connector.

36. Remove the through-bolt that attaches the upper A-arm to the rear hub on both sides of the vehicle.

37. Pivot the A-arms upward and rear hub carriers downward and remove the drive shafts from the hub carriers.

35. Remove the castle nuts from both rear wheel hubs.

3.20

9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual

38. Grasp the rear drive shafts and pull sharply outward on the shafts to disengage them from the rear gearcase.

NOTE: Clean area around drive shaft orifices on both sides of rear gearcase and cover orifices using duct tape. This will prevent the lubricant from leaking out during removal.

ENGINE

ECT

Connector

Coolant

Bypass

Remove

(2) Lower Bolts

39. Disconnect the engine coolant temperature (ECT) sensor harness and the bypass coolant hose.

40. Loosen the hose clamp and remove the lower coolant hose from the water pump cover inlet and drain coolant into a suitable container.

45. Remove RH engine mount fastener.

46. Remove the (2) lower bolts that retain the LH transmission mount to the frame.

41. Remove the filler neck pressure cap to relieve the cooling system vacuum.

NOTE: Use a portable wet-vac or syphon to prevent any coolant from spilling.

42. Remove the upper coolant hose from the thermostat housing outlet to relieve any coolant vacuum created in the engine. Allow engine coolant to completely drain. Properly dispose of the engine coolant / antifreeze.

43. Remove the (+) positive battery cable from the starter motor terminal and (-) negative battery cable from the starter motor engine mount.

44. Remove the outer PVT cover.

9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual

47. Remove the (2) rear gearcase mount bracket fasteners and mount bolt and remove bracket from vehicle.

NOTE: The use of an overhead or portable engine hoist is the only recommended method for removing and installing the engine / transmission / rear gearcase assembly.

3.21

ENGINE

Standard RZR

Shown

Transmission/Gearcase

Mount Plate

Engine/Transmission

Mount Plate

Allow valve cover

to clear frame

Standard RZR

Shown

48. Using an engine hoist, hook a chain between the engine / transmission mounting plate and the transmission / rear gearcase mounting plate.

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.

NOTE: Have an assistant help guide the engine in and out of the vehicle while using an engine hoist to prevent personal injury or damage to vehicle components.

49. Lift the front portion of the assembly out first to allow the engine valve cover to clear the vehicle frame.

3.22

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ENGINE

Engine / Transmission Separation

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. Rem ove th e drive belt, drive clutch and driven clutch (see Chapter 6).

2. Remove the (6) fasteners reta ining the inner clutch cover to the engine and transmission.

4. Tilt the assembly up and remove the remaining (2) nuts that retain the transmission to the engine.

5. Carefully separate the engine and perform the required service (see “Engine Disassembly and Inspection”).

3. Remove only the (4) outer fasteners retaining the engine to the transmission bracket.

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3.23

ENGINE

Push Rods

Hydraulic Lifters

Valves

Cylinder Head

Coolant Bleeder

Springs

Spring Retainers

Rocker Arms

Retainer Locks (keepers)

Valve Spring Seats (2)

Valve Seals (2)

Head Bolts

ENGINE DISASSEMBLY AND INSPECTION

Cylinder Head Assembly Exploded View

3.24

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ENGINE

WARNING

Rocker Arms

1. Rem ove the valve cover.

2. Mark or tag rocker arms in order of disassembly to keep them in order for reassembly.

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. Check the rocker arm pad and fulcrum seat for excessive wear, cracks, nicks or burrs.

5. If the push rod (A) is visibly bent, it should be replaced.

Cylinder Head Removal

NOTE: The cargo box assembly and the upper frame bolt-in brace must be removed to allow enough clearance to remove all the cylinder head bolts. Refer to Chapter 5 for removal procedures.

1. Loosen the six cylinder head bolts evenly 1/8 turn each in a criss-cross pattern until loose.

2. Remove bolts (A) and tap cylinder head (B) lightly with a soft face hammer until loose. CAUTION: Tap only in reinforced areas or on thick parts of cylinder head casting to avoid damaging the head or cylinder.

Push Rods

1. Clean push rods (A) in a suitable sol vent. Blow dry push rods with compressed air.

2. Use compressed air to confirm the oil passage is clear in the center of the push rod.

Always wear safety glasses when working with

compressed air to prevent personal injury.

3. Check the ends of the push rods (A) for nicks, grooves, roughness or excessive wear.

4. The push rods (A) can be visually checked for straightness while they are installed in the engine by rotating them with the valve closed. Push rods can also be checked with a dial indicator or rolled across a flat surface to check for straightness.

3. Remove cylinder head (B) and head gasket (C) from the cylinder (D).

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3.25

ENGINE

CAUTION

= In. / mm.

Measure at different

points on the surface.

WARNING

PU-45257

Cylinder Head Inspection

Thoroughly clean cylinder head surface to remove all traces of gasket material and carbon.

Use care not to damage sealing surface.

Cylinder Head Warp

1. Lay a straight edge (A) across the surface of the cylinder head (B) at several different points and measure warp by inserting a feeler gauge between the straight edge and the cylinder head surface. If warp exceeds the service limit, replace the cylinder head.

Valve Seal / Spring Service (On Engine)

NOTE: The following procedure is only for servicing the top end of the valve train when replacing valve springs or replacing valve seals.

In some cases the valve train can be serviced while the cylinder head is still on the engine. Keep all parts in order with respect to their location in the cylinder head.

Wear eye protection or a face shield during

cylinder head disassembly and reassembly.

1. Having already removed the valve cover, rocker arms and pushrods, align the cylinder to be worked on at top dead center (TDC). Install the Valve Pressure Hose (PU-45652) into the spark plug hole. Hook the hose to an air compressor and supply 50 to 100 psi to the hose. This will seat the valves during valve spring removal. Do not remove air from the hose at anytime until reassembly is completed.

2. Using the Valve Spring Compressor (PU-45257), compress the valve spring and remove the valve keepers.

NOTE: A small parts magnet (A) can aid in the removal of the retainers (B).

Cylinder Head Warp Limit:

.004" (.1016 mm) max

NOTE: To prevent damage to the valve seals, do not compress the valve spring more than is needed to remove the valve keepers.

3. Remove spring retainer and spring.

3.26

4. The valve seals are now serviceable.

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ENGINE

= In. / mm.

V alve Spring

Free Length

Mark the Valves

Cylinder Head Disassembly

1. Carefully remove the cylinder components.

2. Place the hydraulic lifters (C), pushrods (D), and rocker arms (E) in a safe, clean area.

4. Remove valve guide seals.

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.

5. 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. Measure free length of spring with a Vernier caliper. Compare to specifications. Replace spring if measurement is out of specification.

Valve Spring Free Length:

Std: 1.735" (44.069 mm)

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3.27

ENGINE

Measure valve stem in several places. Rotate the valve 90 degrees and measure for wear.

= In. / mm.

Valve Inspection

1. Remo ve all carbon from valves with a soft w ire wheel or brush.

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.

3. Check end of valve stem for flaring, pitting, wear or damage (A). Inspect split keeper groove for wear or flaring of the keeper seat area (B).

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. Measure in two directions.

NOTE: The valves can be re-faced or end ground, if necessary. They must be replaced if extensively worn, burnt, bent, or damaged.

4. Measure diameter of valve stem with a micrometer in three places, then rotate 90 degrees and measure again (six measurements total). Compare to specifications.

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Valve Guide I.D.:

0.23672"  0.000295" (6.0617  0.0075 mm)

6. Subtract valve stem measurement from the valve guide measurement to obtain stem to guide clearance.

NOTE: The valve guides cannot be replaced. Be sure to measure each guide and valve combination individually.

ENGINE

WARNING

Combustion Area

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.

NOTE: Valve seat width and point of contact on the valve face is very important for proper sealing. The valve must contact the valve seat over the entire circumference of the seat, an d the seat must be the proper width all the way around. If the seat is uneven, compression leakage will result. If the seat is too wide, seat pressure is reduced, causing carbon accumulation and possible compression loss. If the seat is too narrow, heat transfer from valve to seat is reduced. The valve may overhe at an d warp, resulting in burnt valves.

Valve Seat Reconditioning

NOTE: Polaris recommends that the work be done by a local machine shop that specializes in this area.

NOTE: The cylinder head valve guides cannot be replaced.

Wear eye protection or a face shield during

cylinder head disassembly and reassembly.

Valve Seat Inspection

Inspect valve seat in cylinder head for pitting, burnt spots, roughness, and uneven surface. If any of the above conditions exist, the valve seat must be reconditioned. If the valve seat is

cracked the cylinder head must be replaced.

Follow the manufacturers instructions provided with the valve seat cutters in the commercially available cylinder head reconditioning kit. Abrasive stone seat reconditioning equipment can also be used. Keep all valves in order with their respective seat.

1. Install pilot into valve guide.

2. Apply cutting oil to valve seat and cutter.

3. Place 46

 cutter on the pilot and make a light cut.

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ENGINE

= In. / mm.

Proper Seat Contact

on Valve Face

Bottom 60

Seat 45

Top 30

Seat

Width

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

* If the cutter now contacts the uncut portion of the seat, check the pilot. Look for burrs, nicks, or runout. If the pilot is bent it must be replaced.

* If the contact area of the cutter is in the same place, the valve guide is distorted from improper installation.

* If the contact area of the initial cut is greater than 75%, continue to cut the seat until all pits are removed and a new seat surface is evident. NOTE: Remove only the amount of material necessary to repair the seat surface.

5. To check the contact area of the seat on the valve face, apply a thin coating of Prussian Blue paste to the valve seat. If using an interference angle (46 marker to the entire valve face (A).

 and make another light cut.

) apply black permanent

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).

6. Insert valve into guide and tap valve lightly into place a few times.

7. Remove valve and check where the Prussian Blue indicates seat contact on the valve face. The valve seat should contact the middle of the valve face or slightly above, and must be the proper width.

* If the indicated seat contact is at the top edge of the valve face and contacts the margin area (B) it is too high on the valve face.

Use the 30

* If too low, use the 60 area is centered on the valve face, measure seat width.

* If the seat is too wide or uneven, use both top and bottom cutters to narrow the seat.

* If the seat is too narrow, widen using the 45 check contact point on the valve face and seat width after each cut.

 cutter to lower the valve seat.

 cutter to raise the seat. When contact

 cutter and re-

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

Valve Seat Width:

Intake Std: .028" (.7 mm)

Limit: .055" (1.4 mm)

Exhaust Std: .039” (1.0 mm)

Limit: .071" (1.8 mm)

8. Clean all filings from the area with hot soapy water. Rinse and dry with compressed air.

ENGINE

PU-45257

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.

11. Rotate the valve rapidly back and forth until the cut sounds smooth. Lift the valve slightly off of the seat, rotate 1/4 turn, and repeat the lapping process. Do this four to five times until the valve is fully seated, and repeat process for the other valve(s).

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. Coat valve stem with molybdenum disulfide grease or PS-4 PLUS Synthetic engine oil.

3. Install valve carefully with a rotating motion to avoid damaging valve seal.

4. Valve seals sho uld be installed after the valves are in the head to avoid valve seal damage. Install new valve seals on valve guides.

5. Dip valve spring and retainer in clean engine oil and install.

6. Place retainer on spring and install Valve Spring Compressor (PU-45257). Install split keepers with the gap even on both sides.

NOTE: A small magnet can be used to aid in the installation of the keepers.

12. Thoroughly clean cylinder head and valves.

7. Repeat procedure for remaining valves. When all valves are installed, tap lightly with soft faced hammer on the end of the valves to seat the split keepers.

NOTE: To prevent damage to the valve seals, do not compress the valve spring more than necessary to install the keepers.

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3.31

ENGINE

Mark Hydraulic Lifter

Inspect Hydraulic Lifter

Valve Sealing Test

1. Clean and dry the combustion chamber area (A).

2. Po ur a small amount of clean solvent onto the intake port and check for leakage around each intake valve. The valve seats should hold fluid with no seepage.

3. Repeat for ex haust valves by pouring fluid into exhaust port.

Valve Lifter Removal / Inspection

1. Remove the valve lifters by reaching into the crankcase and pushing the lifter up through the lifter bore by hand.

2. Th oroughly clean the lifters in cleaning solvent and wipe them with a clean, lint-free cloth.

3. M ark the lifters with a white pen if using the lifters for reassembly. This will ensure that the lifters are properly placed during engine reassembly.

Cylinder Removal

1. Fo llow engine disassembly procedures to remove rocker cover and cylinder head.

2. Tap cylinder (A) lightly with a rubber mallet in the reinforced areas only until loose.

3. Rock cyli nder forward and backward while lifting it from the crankcase, supporting pistons and connecting rods. Support pistons with Piston Support Block (PN 2870390).

4. Check the lifters for wear or scores.

5. Check the bottom end of lifter to make sure that it has a slight convex.

6. If the bottom surface has worn flat, it may be used with the original camshaft only.

NOTE: Lifters that are scored, worn, or if the bottom is not smooth should be replaced with new lifters and cam as an assembly. If replacing the lifters, the camshaft should also be replaced.

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ENGINE

Compression

Rings

Oil Ring

Piston Removal

1. Rem ove the circlip. Mark the piston with a white pen to ensure proper orientation (if reused) during assembly.

NOTE: If the pistons are to be reused, reassemble the pistons in the same cylinder and direction from which they were removed.

NOTE: New pistons are non-directional and can be placed in either cylinder.

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.

2. Remove piston circlip and push piston pin out of piston. If necessary, heat the crown of the piston slightly with a propane torch. CAUTION: Do not apply heat to the piston rings. The ring may lose radial tension.

3. Remove top compression ring:

*Using a piston ring pliers: Carefully expand ring and lift it off the piston. CAUTION: Do not expand the ring more than the amount necessary to remove it from the piston, or the ring may break.

*By hand: Placing both thumbs as shown, spread the ring open and push up on the opposite side. Do not scratch the ring lands.

4. Repeat procedure for second ring.

5. Remove the oil control ring.

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ENGINE

= In. / mm.

Measure at different

points on surface.

= In. / mm.

1/2” Down From Top of Cylinder

1/2” Up From Bottom

Cylinder Inspection

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.

4. 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. If cylinder is tapered or out of round beyond .002", the cylinder must be replaced.

Cylinder Warp: .004" (0.1 mm) Ma x.

3. Inspect cylinder for wear, scratches, or damage.

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Cylinder Taper Limit:

.002" (.050 mm) Max.

Cylinder Out of Round:

Limit: .002" (.050 mm) Max.

Standard Bore Size

(Both Cylinders): 3.1496" (80 mm)

ENGINE

CAUTION

Example of Cross Hatch Pattern

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.

A hone which will straighten as well as remove

material from the cylinder is very important.

Using a common spring loaded glaze breaker

for honing is not advised for nicasil cylinders.

Polaris recommends using a rigid hone or arbor

honing machine. Cylinders may be wet or dry

honed depending upon the hone manufacturer's

recommendations.

Wet honing removes more material faster and

leaves a more distinct pattern in the bore.

Honing To Deglaze

A finished cylinder should have a cross-hatch pattern to ensure piston ring seating and to aid in the retention of the fuel/oil mixture during initial break in. Hone cylinder according to hone manufacturer's instructions, or these guidelines:

• Honing should be done with a diamond hone. Cylinder could be damaged if the hone is not hard enough to scratch the nicasil lining.

• Use a motor speed of approximately 300-500 RPM, run the hone in and out of the cylinder rapidly until cutting tension decreases. Remember to keep the hone drive shaft centered (or cylinder centered on arbor) and to bring the stones approximately 1/2” (1.3 cm) above and below the bore at the end of each stroke.

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.

IMPORTANT: Clean the cylinder after honing

Cleaning the Cylinder After Honing

It is very important that the cylinder be thoroughly cleaned after honing to remove all grit material. Wash the cylinder in a solvent, then in hot, soapy water. Pay close attention to areas where the cylinder sleeve meets the aluminum casting (transfer port area). Use electrical contact cleaner if necessary to clean these areas. Rinse thoroughly, dry with compressed air, and oil the bore immediately with Polaris Lubricant.

• Release the hone at regular intervals and inspect the bore to determine if it has been sufficiently de-glazed, and to check for correct cross-hatch. NOTE: Do not allow cylinder to heat up during honing.

• After honing has been completed, inspect cylinder for thinning or peeling.

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ENGINE

5 mm

Piston

Piston Pin

Piston Pin Measurement Locations

Piston-to-Cylinder Clearance

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.

Piston to Cylinder Clearance:

See “800 EFI Engine Service

Specifications” on page 3.8

2. Measure piston pin O.D. Replace piston and/or piston pin if out of specification.

Piston Pin O.D.:

See “800 EFI Engine Service

Specifications” on page 3.8

3. Measure connecting rod small end ID.

Piston O.D.:

See “800 EFI Engine Service

Specifications” on page 3.8

Piston / Rod Inspection

1. Measure piston pin bore.

Piston Pin Bore:

See “800 EFI Engine Service

Specifications” on page 3.8

Connecting Rod Small End I.D.:

See “800 EFI Engine Service

Specifications” on page 3.8

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ENGINE

Piston

Ring

Feeler Gauge

25-50 mm

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.

See “800 EFI Engine Service

Specifications” on page 3.8

Piston Ring Installed Gap

1. Place each piston ring (A) inside cylinder (B) using a piston to push ring squarely into place as shown.

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. A re-bored cylinder should always be scrubbed thoroughly with hot soapy water, rinsed, and dried completely. Wipe cylinder bore with oil immediately to remove residue and prevent rust.

Starter Drive Bendix Removal / Inspection

1. Remove stator housing bolts and remove housing.

2. Remove the flywheel nut and washer. Install Flywheel Puller (PN 2871043) and remove flywheel.

NOTE: Do not thread the puller bolts into the flywheel more than 1/4, or stator coils may be damaged.

3. Remove starter bendix assembly (A). Note the thrust washers located on both sides of the bendix.

Piston Ring Installed Gap:

See “800 EFI Engine Service

Specifications” on page 3.8

NOTE: Ring should be installed with the mark facing upward.

2. Measure installed gap with a feeler gauge (C) at both the top and bottom of the cylinder.

IMPORTANT: A difference in end gap indicates cylinder taper. The cylinder should be measured for excessive taper and out of round.

9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual

4. Inspect the thrust washer for wear or damage and replace if necessary.

5. After the bendix is removed, remove the two bolts retaining the starter. Tap on the starter assembly (B) with a soft faced mallet to loosen the starter from the crankcase.

3.37

ENGINE

CAUTION

Remove Stator

Cover

2871043

6. Inspect gear teeth on starter drive (A). Replace starter drive if gear teeth are cracked, worn, or broken.

7. In sp ect the bend ix bushing (C) in the mag co ver for wear. Replace as needed.

Flywheel / Stator Removal / Inspection

1. Remove stator cover bolts and remove stator cover.

4. 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.

2. Remove flywheel nut and washer.

3. Install Flywheel Puller (PN 2871043) and remove flywheel (A).

Do not thread the puller bolts into the flywheel

more than 1/4, or stator coils may be damaged .

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5. Remove the bendix (E) if necessary.

Engine Crankcase Disassembly / Inspection

1. Remove the stator cover (A) and water pump cover (B).

ENGINE

CAUTION

2871043

Counterbalance Gear

Camshaft Gear

Crank Gear

2. Rem ove the nut (C), washer (D) and water pump i mpeller (E). Remove part of the water pump seal behind the impeller.

3. Remove flywheel nut and washer.

4. Install Flywheel Puller (PN 2871043) and remove flywheel (F).

5. Remov e 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.

6. Remove the gear/stator housing bolts and remove the gear/ stator housing cover (J) and gasket from the crankcase. Be sure to catch the excess oil from the crankcase.

Do not thread the puller bolts into the flywheel

more than 1/4, or stator coils may be damaged.

7. Note the position of the gears in the photo.

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ENGINE

Timing Marks

Water Pump Gear

3 Loaded Springs

CAUTION

PU-45497-1

Accent Timing Marks

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.

NOTE: If replacing one of the gears, it is recommended that all of the gears be replaced. A gear kit is available.

9. Use the Cam Gear Tooth Alignment Tool (PU-45497-2) to align and hold the cam split gear assembly. With the split gear aligned, remove the bolt and cam gear assembly.

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).

NOTE: Install the Cam Gear Tooth Alignment Tool (PU-45497-2) into the assembly hole counter clockwise from the timing mark (see page 3.42).

10. Inspect the cam gear teeth and check to make sure there is spring tension offsetting the teeth between the two gears. If there is no tension, check the springs inside of the cam gear assembly.

11. The cam gear assembly contains three loaded springs. To open the cam gear assembly:

• Place the cam gear on a flat surface with the timing

• While holding both gears together, lightly work a small

mark side facing up.

flathead screwdriver between the two gears.

13. With a white marking pen, accent the timing mark on the gear that contains the springs.

• Remove the top gear. The springs should stay in place.

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ENGINE

Inspect Teeth & Tabs

Replace 3 Springs

Install Springs

PU-45497-1

Align Timing Marks

14. Inspect the gear teeth and the three tabs on the gears for wear.

15. Install the new springs into the grooves of the cam gear.

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. Note in photograph that the Tapered Pins (PU-45497-1) are

below flush with end of the springs. This helps to align the three gear tabs during the next step.

16. Insert the pointed dowels from the Tapered Pins (PU45497-1) into the cam gear.

Cam Gear Spring Installation Tool Kit:

(PU-45497)

Tapered Pins:

(PU-45497-1)

Cam Gear Tooth Align Tool:

(PU-45497-2)

18. Line up the two gears using the timing marks and the three gear tabs that were referenced earlier. Push the gears back together, using both hands and hold securely.

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ENGINE

PU-45497-2

PU-45498

2871043

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.

20. After the tapered pins are removed, be sure the cam gear assembly is held together tightly. Place the cam gear assembly on a flat surface. Use the Cam Gear Tooth Alignment Tool (PU-45497-2) to align the teeth of the cam gears, as shown in the picture.

NOTE: Install the Cam Gear Alignment Tool (PU45497-2) into one assembly hole counter clockwise from the timing mark.

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.

NOTE: This Cam Spanner Wrench (PU-45498) is only needed to rotate the camshaft when the entire valve train is assembled. If the rocker arms are removed, the cam-shaft can be turned by hand.

22. Remove the bolt and nut from the balance shaft gear. Try to remove the balance shaft gear. If the gear does not come off manually, use the Flywheel Puller (PN 2871043) to remove the balance shaft gear.

NOTE: For ease of installing the Cam Gear Alignment Tool (PU-45497-2), use a twisting motion when pushing down on the tool.

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ENGINE

2871043

Mark Rotors

Max Tip Clearance

0.006” (0.15 mm)

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).

24. Install the two puller bolts (R). Tighten the puller bolts up so that the bolts are at equal length.

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.

27. Inspect the oil pump rotors for wear. Mark the rotors with a white pen to ensure upon reassembly that the correct sides of the rotors are installed and mesh with the same edges as previously installed.

25. Install the Flywheel Puller (PN 2871043) and remove the

crankshaft gear, if needed.

NOTE: If replacing the old rotors, new replacement rotors will fit into the original oil/water pump housing.

28. Use a feeler gauge to measure the clearance between the two rotors. Measure the gap between the two rotor tips as shown below. The clearance should not exceed 0.006" (0.15 mm).

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ENGINE

= T

22 ± 2 ft. lbs.

(30 ± 3 Nm).

Chamfer

End First

CAUTION

Press Off Gear

Press out shaft

and bearing

assembly.

Bearing

Retaining Ring

Press Off Bearing

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.

30. Reinstall the valve (dowel chamfered end first). Install the spring, washer, and bolt. Torque to specification.

31. Carefully press the gear off the assembly while supporting the housing assembly.

Wear appropriate safety gear during this

procedure. Protective gloves, clothing and eye

wear are required.

32. Remove the snap ring from the assembly. Place the housing in a support and press out the bearing/shaft assembly.

NOTE: Be sure to place the tapere d end of the valve (dowel) in first. If the valve is installed incorrectly, oil pressure and oil priming problems will occur.

3.44

22  2 ft. lbs. (30  3 Nm)

33. Place the shaft in a press to remove the bearing.

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ENGINE

Press On Bearing

Press Bearing / Shaft

Assembly using

outer race only

Separate

Crankcase Halves

34. Press shaft into the new bearing.

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.

37. Remove thrust plate (U).

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.

36. Press gear onto shaft while supporting the housing.

NOTE: Only remove the oil baffle if the baffle is damaged. When removing the oil baffle bolts, use a heat gun to heat the bolts and loosen the Loctite This will prevent any possible damage to the bo lts o r to the crankcase casting.

9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual

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Polaris RZR, RZR 4, RZR S User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual