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
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
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
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.
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
MODEL NUMBER: R11VH76AA, AD, AF, AH
ENGINE NUMBER: 1204276
CategoryDimension / Capacity
Length103 in. / 261.6 cm
Width50 in. / 127 cm
Height69 in. / 175.3 cm
Wheel Base77 in. / 196 cm
Ground Clearance10 in. / 25.4 cm
Dry Weight945 lbs. / 429 kg
Gross Vehicle Weight1727 lbs. / 783 kg
Front Storage
Capacity
Cargo Box Dimension42 in. x 22 in. / 107 cm x 56 cm
Cargo Box Capacity300 lbs. / 136 kg
Maximum Weight
Capacity (Payload)
Hitch Towing Capacity1500 lbs. / 680 kg
Hitch Tongue Capacity150 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
CategoryDimension / Capacity
Length103 in. / 261.6 cm
Width50 in. / 127 cm
Height69 in. / 175.3 cm
Wheel Base77 in. / 196 cm
Ground Clearance10 in. / 25.4 cm
Dry Weight961 lbs. / 436 kg
Gross Vehicle Weight1727 lbs. / 783 kg
Front Storage
Capacity
Cargo Box Dimension42 in. x 22 in. / 107 cm x 56 cm
Cargo Box Capacity300 lbs. / 136 kg
Maximum Weight
Capacity (Payload)
Hitch Towing Capacity1500 lbs. / 680 kg
Hitch Tongue Capacity150 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
MODEL NUMBER: R11VE76AC, AD, AW
ENGINE NUMBER: 1204276
CategoryDimension / Capacity
Length104 in. / 264.2 cm
Width60.5 in. / 154 cm
Height70.5 in. / 179 cm
Wheel Base77 in. / 196 cm
Ground Clearance12.5 in. / 32 cm
Dry Weight1000 lbs. / 454 kg
Gross Vehicle Weight1782 lbs. / 808 kg
Front Storage
Capacity
Cargo Box Dimension42 in. x 22 in. / 107 cm x 56 cm
Cargo Box Capacity300 lbs. / 136 kg
Maximum Weight
Capacity (Payload)
Hitch Towing Capacity1500 lbs. / 680 kg
Hitch Tongue Capacity150 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
CategoryDimension / Capacity
Length104 in. / 264.2 cm
Width60.5 in. / 154 cm
Height70.5 in. / 179 cm
Wheel Base77 in. / 196 cm
Ground Clearance12.5 in. / 32 cm
Dry Weight1016 lbs. / 461 kg
Gross Vehicle Weight1782 lbs. / 808 kg
Front Storage
Capacity
Cargo Box Dimension42 in. x 22 in. / 107 cm x 56 cm
Cargo Box Capacity300 lbs. / 136 kg
Maximum Weight
Capacity (Payload)
Hitch Towing Capacity1500 lbs. / 680 kg
Hitch Tongue Capacity150 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
Length130 in. / 330 cm
Width60.5 in. / 154 cm
Height75 in. / 190.5 cm
Wheel Base103 in. / 262 cm
Ground Clearance11.5 in. / 29 cm
Dry Weight1255 lbs. / 569 kg
Gross Vehicle Weight2155 lbs. / 978 kg
Front Storage
Capacity
Cargo Box Dimension42 in. x 22 in. / 107 cm x 56 cm
Cargo Box Capacity300 lbs. / 136 kg
Maximum Weight
Capacity (Payload)
Hitch Towing Capacity1500 lbs. / 680 kg
Hitch Tongue Capacity150 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
CategoryDimension / Capacity
Length130 in. / 330 cm
Width60.5 in. / 154 cm
Height75 in. / 190.5 cm
Wheel Base103 in. / 262 cm
Ground Clearance11.5 in. / 29 cm
Dry Weight1271 lbs. / 577 kg
Gross Vehicle Weight2171 lbs. / 985 kg
Front Storage
Capacity
Cargo Box Dimension42 in. x 22 in. / 107 cm x 56 cm
Cargo Box Capacity300 lbs. / 136 kg
Maximum Weight
Capacity (Payload)
Hitch Towing Capacity1500 lbs. / 680 kg
Hitch Tongue Capacity150 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
The following torque specifications are to be used only as a general guideline. There are exceptions in the steering, suspension, and
engine areas. Always consult the exploded views or each manual section for torque values of fasteners before using standard torque.
1
9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual
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.
1
9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual
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
2
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.
9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual
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
2Engine CoolantPolaris 60/40 Coolant
3Brake FluidPolaris 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
9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual
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.
ItemRecommended LubeMethodFrequency
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
9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual
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
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.
2
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
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
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.
2
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
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).
2
• 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
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).
2
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%)
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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).
2
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
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
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)
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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
ItemNut TypeSpecification
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
#1
Flange Nut
#2
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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9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual
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
2
Tire Pressure
Maintain proper tire pressure.
Refer to the warning tire pressure decal
applied to the vehicle.
Tire Pressure Inspection (Cold)
FrontRear
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.
9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual
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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9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual
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.
2
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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9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual
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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9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual
• 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.
2
• 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.
9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual
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.
2
Shock Spanner Wrench
(PN 2871095)
4. Each notch of the adjustment will add 6% - 8% more
preload to the spring over the primary position.
9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual
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.
2
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
SettingCompression Damping
SoftestFull counter-clockwise position
Factory6 clicks from softest position
FirmestFull clockwise position
9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual
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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9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual
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.
Second Ring - Standard0.0098 - 0.0197" (0.25 - 0.50 mm)
Second Ring - Limit> 15% Leakdown
Oil Ring - Standard0.0197 0.0098" (0.50 0.25 mm)
Oil Ring - Limit> 15% Leakdown
Top Ring - Standard0.0024" 0.0008" (0.060 0.020 mm)
Top Ring - Limit> 15% Leakdown
Second Ring - Standard0.0028" 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)
9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual
PU-50105OIL FILTER WRENCH
PU-45257VALVE SPRING COMPRESSOR
PU-45652VALVE PRESSURE HOSE
2871043FLYWHEEL PULLER
2870390PISTON SUPPORT BLOCK
PU-45497-1CAM GEAR SPRING INSTALLATION KIT
PU-45497-2CAM GEAR TOOTH ALIGNMENT TOOL
PU-45498CAM SPANNER WRENCH
PU-45838GEAR HOLDER
PA-44995WATER PUMP MECHANICAL SEAL INSTALLER
PU-45543UNIVERSAL DRIVER HANDLE
PA-45483MAIN SEAL INSTALLER
PU-45658CRANKSHAFT MAIN SEAL SAVER
PA-45401WAT ER PUMP SEAL SAVER
2870975MITY VAC™
PU-45778OIL SYSTEM PRIMING TOOL
PRESSURE TEST TOOL
3.10
9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual
Room Temperature68F (20C)
Thermostat Closed175° F (79° C)
Thermostat Open180° 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 Off194F (90C)
Thermostat Full Open Lift202° F (94° C)
Fan On205 F (96C)
Engine Temperature
Overheat Indicator
Engine Protection
Ignition Misfire
Engine Protection
Shutdown
ItemSpecification
Cooling System Capacity
Pressure Cap Relief13 PSI
Moving Vehicle: 235
Idle Vehicle:241F (116C)
Moving Vehicle: 239
Idle Vehicle:244F (118C)
Moving Vehicle: 257
Idle Vehicle:262F (128C)
RZR / RZR S4.8 qts. (4.5 l)
RZR 45.5 qts. (5.2 l)
F (113 C)
F (115C)
F (125C)
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
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
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.
3
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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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
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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.
3
9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual
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).
A
10. Remove the rear bumper, rear cargo box and box supports
from the vehicle (see Chapter 5).
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9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual
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.
3
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
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
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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.
3
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.
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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.
3
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.
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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.
3
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.
9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual
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.
3
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).
9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual
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.
9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual
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
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)
9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual
Measure valve stem in several places.
Rotate the valve 90 degrees and measure
for wear.
= In. / mm.
= In. / mm.
C
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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9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual
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.
3
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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9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual
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-
3.30
9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual
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.
3
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.
9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual
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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9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual
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.
3
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.
3.33
9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual
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.
3.34
9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual
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.
3
IMPORTANT: Clean the cylinder after honing
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.
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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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.
3
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.
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 /statorhousing 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).
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.
3
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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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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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.
3
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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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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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.
3
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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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.
9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual
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).
3
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