Polaris RZR, RZR 4, RZR S User Manual

2011 RANGER RZR / RZR S / RZR 4

SERVICE MANUAL

PN 9923142

2011 RANGER RZR / RZR S / RZR 4

SERVICE MANUAL

FOREWORD

The information printed within this publication includes the latest product information at time of print. The most recent version of this Service Manual is available in electronic format at www.polarisdealers.com.



This Service Manual is designed primarily for use by certified Polaris Master Service Dealer equipped shop and should be kept available for reference. All references to left and right side of the vehicle are from the operator's perspective when seated in a normal riding position.

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

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

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

technicians in a properly

Publication Printed September 2010 (PN 9923142) Rev 1

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

UNDERSTANDING MANUAL SAFETY LABELS AND DIRECTIONS

WARNING

CAUTION

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

SAFETY ALERT WARNING indicates a potential hazard that may result in severe injury or death to the operator, bystander or person(s) inspecting or servicing the vehicle.

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

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

NOTE:

NOTE provides key information by clarifying instructions.

IMPORTANT:

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

TRADEMARKS

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

by contacting the nearest Polaris dealer.

GENERAL INFORMATION

MAINTENANCE

ENGINE

ELECTRONIC FUEL INJECTION

BODY / STEERING / SUSPENSION

CLUTCHING

FINAL DRIVE

TRANSMISSION

BRAKES

ELECTRICAL

GENERAL INFORMATION

CHAPTER 1

GENERAL INFORMATION

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

1.1

GENERAL INFORMATION

}

Machine Model Number Identification

}

Model Year Designation

Basic Chassis

Designation

Engine Designation

Emissions & Model Option

R 1 1 V H 7 6 A D

}

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

}

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

World

Mfg. ID

Engine

Vehicle Description

Vehicle Identifier

Check Digit

Model

Year

Body Style

Plant No.

Individual Serial No.

* This could be either

a number or a letter

Powertrain

Emissions

VIN

Figure 1-1

Engine Serial

Figure 1-2

Number

MODEL INFORMATION

Model Identification

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

Engine Designation Number

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

VIN Identification

V e hicle and Engine Serial Number Location

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

1.2

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

GENERAL INFORMATION

Key Series Number

KEY COVER P/N 5533534

VEHICLE INFORMATION

Publication Numbers

Model Model No. Owner’s Manual Parts Manual

2011 RANGER RZR R11VH76AA, AD, AF, AH 9922973 9922974 2011 RANGER RZR EPS R11VY76AO 9922973 9922974 2011 RANGER RZR S R11VE76AC, AD, AW 9922973 9923141 2011 RANGER RZR S EPS INT’L R11VM76FX 9922973 9922977 2011 RANGER RZR 4 R11XH76AW 9923148 9923149 2011 RANGER RZR 4 EPS R11XY76AA 9923148 9923149

NOTE: When ordering service parts be sure to use the correct parts manual. NOTE: Polaris factory publications can be found at www.polarisindustries.com or purchased from

www.purepolaris.com.

Replacement Keys

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

Series# Part Number

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

SPECIAL TOOLS

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

1.3

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

GENERAL INFORMATION

GENERAL SPECIFICATIONS

MODEL: 2011 RANGER RZR

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

Category Dimension / Capacity

Length 103 in. / 261.6 cm Width 50 in. / 127 cm Height 69 in. / 175.3 cm Wheel Base 77 in. / 196 cm Ground Clearance 10 in. / 25.4 cm Dry Weight 945 lbs. / 429 kg Gross Vehicle Weight 1727 lbs. / 783 kg Front Storage

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

Maximum Weight Capacity (Payload)

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

(Includes rider(s), cargo, accessories

25 lbs. / 11.3 kg

740 lbs. / 335.6 kg

and trailer tongue weight)

MODEL: 2011 RANGER RZR EPS

MODEL NUMBER: R11VY76AO ENGINE NUMBER: 1204276

Category Dimension / Capacity

Length 103 in. / 261.6 cm Width 50 in. / 127 cm Height 69 in. / 175.3 cm Wheel Base 77 in. / 196 cm Ground Clearance 10 in. / 25.4 cm Dry Weight 961 lbs. / 436 kg Gross Vehicle Weight 1727 lbs. / 783 kg Front Storage

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

Maximum Weight Capacity (Payload)

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

(Includes rider(s), cargo, accessories

25 lbs. / 11.3 kg

740 lbs. / 335.6 kg

and trailer tongue weight)

1.4

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

GENERAL INFORMATION

MODEL: 2011 RANGER RZR / EPS

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

Engine

Platform

Engine Number 1204276

Engine Displacement 760cc H.O.

Number of Cylinders 2

Bore & Stroke (mm) 80 x 76.5 mm

Compression Ratio 11:1

Compression Pressure 165 - 185 psi

Engine Idle Speed 1250 ± 100 RPM

Engine Max Operating RPM 6600 RPM

Lubrication Pressurized Wet Sump

Oil Requirements PS-4 Plus Synthetic

Oil Capacity 2 qts. / 1.9 liters

Coolant Capacity 4.8 qts. / 4.5 liters

Overheat Warning Instrument Cluster Indicator

Exhaust System Dual Headpipe / Single Silencer

Fuel System Type Bosch M17 EFI

Fuel Delivery Electronic Fuel Pump (in tank)

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

Fuel Filters See Chapter 4

Fuel Capacity / Requirement

Alternator Max Output 500 Watts @ 3000 RPM

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

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

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

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

Battery (RZR)

Battery (RZR EPS)

Instrument Type Multifunction Instrument Cluster

DC Outlet Standard 12 Volt

Relays

Circuit Breaker Fan Motor: 20 Amp

Fuses (Fuse/Relay Box)

Fuses (Power Fuse Holder)

H.O. Domestic Twin Cylinder,

Liquid Cooled, 4-Stroke

Fuel System

7.25 gal. (27.4 liters)

87 Octane (minimum)

Electrical

Yuasa YTX20HL /

18 Amp Hr. / 310 CCA / 12 Volt

Deka ETX30L / 30 AH

365 CCA / 12 Volt

Chassis / EFI / Fan

Fuel Pump / EPS

Drive / Fuel Pump: 10 Amp

Lights / EFI / Accessory: 20 Amp

EFI: 20 Amp

Chassis / EPS: 30 Amp

Drivetrain

Transmission Type Polaris Automatic PVT

Drive Ratio - Front 3.82:1

Drive Ratio - Final 3.70:1

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

Front Gearcase

Fluid Type / Capacity

Transmission: Main Gearcase

Fluid Type / Capacity

Transmission: Transfer Case

Fluid Type / Capacity

Rear Gearcase

Fluid Type / Capacity

Belt 3211113

Steering / Suspension

Front Suspension

Front Travel 9 in. / 23 cm

Rear Suspension Rolled IRS w/Anti-Sway Bar

Rear Travel 9.5 in. / 24 cm

Shock Preload Adjustment

Front / Rear

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

Wheels / Brakes

Front Wheel Size

Front Tire Type / Size

Rear Wheel Size

Rear Tire Type / Size

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

Brake - Front / Rear

Brake Fluid DOT 4

Polaris Demand Drive Plus

6.75 oz. (200 ml) Polaris AGL Plus

24 oz. (710 ml)

Polaris AGL Plus

14 oz. (414 ml)

Polaris Premium ADF

26 oz. (769 ml)

Independent Dual A-arm

w/Anti-Sway Bar

Standard: Cam Adjustment

Walker Evans: Threaded

Spanner Wrench Adjustment

12 x 6 / Steel

12 x 6 / Cast Aluminum

Maxxis / 25 x 8 R12

12 x 8 / Steel

12 x 8 / Cast Aluminum

Maxxis / 25 x 10 R12

Foot Actuated - 4 Wheel

Hydraulic Disc

CLUTCH CHART

Meters

(Feet)

Altitude

0-1500

(0-5000)

1500-3700

(5000 - 12000)

Shift

Weight

23-62

(5632337)

23-58 (B)

(1322911)

Drive

Spring

Black

(7043594)

Black

(7043594)

(B) = Bushed Shift Weight

Driven Spring

Blk / Almond

(7043167)

Blk / Almond

(7043167)

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

1.5

GENERAL INFORMATION

MODEL: 2011 RANGER RZR S

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

Category Dimension / Capacity

Length 104 in. / 264.2 cm Width 60.5 in. / 154 cm Height 70.5 in. / 179 cm Wheel Base 77 in. / 196 cm Ground Clearance 12.5 in. / 32 cm Dry Weight 1000 lbs. / 454 kg Gross Vehicle Weight 1782 lbs. / 808 kg Front Storage

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

Maximum Weight Capacity (Payload)

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

(Includes rider(s), cargo, accessories

25 lbs. / 11.3 kg

740 lbs. / 335.6 kg

and trailer tongue weight)

MODEL: 2011 RANGER RZR S EPS INT’L

MODEL NUMBER: R11VM76FX ENGINE NUMBER: 1204276

Category Dimension / Capacity

Length 104 in. / 264.2 cm Width 60.5 in. / 154 cm Height 70.5 in. / 179 cm Wheel Base 77 in. / 196 cm Ground Clearance 12.5 in. / 32 cm Dry Weight 1016 lbs. / 461 kg Gross Vehicle Weight 1782 lbs. / 808 kg Front Storage

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

Maximum Weight Capacity (Payload)

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

(Includes rider(s), cargo, accessories

25 lbs. / 11.3 kg

740 lbs. / 335.6 kg

and trailer tongue weight)

1.6

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

GENERAL INFORMATION

MODEL: 2011 RANGER RZR S / EPS INT’L

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

Engine

Platform

Engine Number 1204276

Engine Displacement 760cc H.O.

Number of Cylinders 2

Bore & Stroke (mm) 80 x 76.5 mm

Compression Ratio 11:1

Compression Pressure 165 - 185 psi

Engine Idle Speed 1250 ± 100 RPM

Engine Max Operating RPM 6750 RPM

Lubrication Pressurized Wet Sump

Oil Requirements PS-4 Pl us Synthetic

Oil Capacity 2 qts. / 1.9 liters

Coolant Capacity 4.8 qts. / 4.5 liters

Overheat Warning Instrument Cluster Indicator

Exhaust System Dual Headpipe / Single Silencer

Fuel System Type Bosch M17 EFI

Fuel Delivery Electronic Fuel Pump (in tank)

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

Fuel Filters See Chapter 4

Fuel Capacity / Requirement

Alternator Max Output 500 Watts @ 3000 RPM

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

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

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

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

Battery (RZR S)

Battery (RZR S EPS)

Instrument Type Multifunction Instrument Cluster

DC Outlet Standard 12 Volt

Relays

Circuit Breaker Fan Motor: 20 Amp

Fuses (Fuse/Relay Box)

Fuses (Power Fuse Holder)

H.O. Domestic Twin Cylinder,

Liquid Cooled, 4-Stroke

Fuel System

7.25 gal. (27.4 liters)

87 Octane (minimum)

Electrical

Yuasa YTX20HL /

18 Amp Hr. / 310 CCA / 12 Volt

Deka ETX30L / 30 AH

365 CCA / 12 Volt

Chassis / EFI / Fan

Fuel Pump / EPS

Drive / Fuel Pump: 10 Amp

Lights / EFI / Accessory: 20 Amp

EFI: 20 Amp

Chassis / EPS: 30 Amp

Drivetrain

Transmission Type Polaris Automatic PVT

Drive Ratio - Front 3.82:1

Drive Ratio - Final 3.70:1

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

Front Gearcase

Fluid Type / Capacity

Transmission: Main Gearcase

Fluid Type / Capacity

Transmission: Transfer Case

Fluid Type / Capacity

Rear Gearcase

Fluid Type / Capacity

Rear Gearcase (INT’L)

Fluid Type / Capacity

Belt 3211133

Steering / Suspension

Front Suspension / Shock

Front Travel 12 in. / 30.5 cm

Rear Suspension / Shock

Rear Travel 12 in. / 30.5 cm

Shock Preload Adjustment

Front / Rear

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

Wheels / Brakes

Front Wheel Size

Front Tire Type / Size

Rear Wheel Size

Rear Tire Type / Size

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

Brake - Front / Rear

Brake Fluid DOT 4

Polaris Demand Drive Plus

6.75 oz. (200 ml) Polaris AGL Plus

24 oz. (710 ml)

Polaris AGL Plus

14 oz. (414 ml)

Polaris Premium ADF

26 oz. (769 ml)

Polaris Premium ADF

22 oz. (650 ml)

Independent Dual A-arm

Standard: Monotube

FOX™: PODIUM X

Rolled IRS w/Anti-Sway Bar

Standard: Monotube

FOX™: PODIUM X

Standard: Cam Adjustment

FOX™: Threaded Spanner

Wrench Adjustment

12 x 6 / Cast Aluminum

Maxxis Bighorn / 26 x 9 R12

ITP “900XCT” / 27 x 9 R12

12 x 8 / Cast Aluminum

Maxxis Bighorn / 26 x 12 R12

ITP “900XCT” / 27 x 11 R12

Foot Actuated - 4 Wheel

Hydraulic Disc

CLUTCH CHART

Meters

(Feet)

Altitude

0-1500

(0-5000)

1500-3700

(5000 - 12000)

Shift

Weight

23-62

(5632337)

23-58 (B)

(1322911)

Drive

Spring

Black

(7043594)

Black

(7043594)

(B) = Bushed Shift Weight

Driven Spring

Blk / Almond

(7043167)

Blk / Almond

(7043167)

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

1.7

GENERAL INFORMATION

MODEL: 2011 RANGER RZR 4

MODEL NUMBER: R11XH76AW ENGINE NUMBER: 1204276

Category Dimension / Capacity

Length 130 in. / 330 cm Width 60.5 in. / 154 cm Height 75 in. / 190.5 cm Wheel Base 103 in. / 262 cm Ground Clearance 11.5 in. / 29 cm Dry Weight 1255 lbs. / 569 kg Gross Vehicle Weight 2155 lbs. / 978 kg Front Storage

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

Maximum Weight Capacity (Payload)

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

(Includes rider(s), cargo, accessories

25 lbs. / 11.3 kg

900 lbs. / 408 kg

and trailer tongue weight)

MODEL: 2011 RANGER RZR 4 EPS

MODEL NUMBER: R11XY76AA ENGINE NUMBER: 1204276

Category Dimension / Capacity

Length 130 in. / 330 cm Width 60.5 in. / 154 cm Height 75 in. / 190.5 cm Wheel Base 103 in. / 262 cm Ground Clearance 11.5 in. / 29 cm Dry Weight 1271 lbs. / 577 kg Gross Vehicle Weight 2171 lbs. / 985 kg Front Storage

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

Maximum Weight Capacity (Payload)

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

(Includes rider(s), cargo, accessories

25 lbs. / 11.3 kg

900 lbs. / 408 kg

and trailer tongue weight)

1.8

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

GENERAL INFORMATION

MODEL: 2011 RANGER RZR 4 / EPS

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

Engine

Platform

Engine Number 1204276

Engine Displacement 760cc H.O.

Number of Cylinders 2

Bore & Stroke (mm) 80 x 76.5 mm

Compression Ratio 11:1

Compression Pressure 165 - 185 psi

Engine Idle Speed 1250 ± 100 RPM

Engine Max Operating RPM 6750 RPM

Lubrication Pressurized Wet Sump

Oil Requirements PS-4 Pl us Synthetic

Oil Capacity 2 qts. / 1.9 liters

Coolant Capacity 5.5 qts. / 5.2 liters

Overheat Warning Instrument Cluster Indicator

Exhaust System Dual Headpipe / Single Silencer

Fuel System Type Bosch M17 EFI

Fuel Delivery Electronic Fuel Pump (in tank)

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

Fuel Filters See Chapter 4

Fuel Capacity / Requirement

Alternator Max Output 500 Watts @ 3000 RPM

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

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

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

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

Battery

Instrument Type Multifunction Instrument Cluster

DC Outlets (2) Standard 12 Volt

Relays

Circuit Breaker Fan Motor: 20 Amp

Fuses (Fuse/Relay Box)

Fuses (Power Fuse Holder)

H.O. Domestic Twin Cylinder,

Liquid Cooled, 4-Stroke

Fuel System

7.25 gal. (27.4 liters)

87 Octane (minimum)

Electrical

Deka ETX30L / 30 AH

365 CCA / 12 Volt

Chassis / EFI / Fan

Fuel Pump / EPS

Drive / Fuel Pump: 10 Amp

Lights / EFI / Accessory: 20 Amp

EFI: 20 Amp

Chassis / EPS: 30 Amp

Drivetrain

Transmission Type Polaris Automatic PVT

Drive Ratio - Front 3.82:1

Drive Ratio - Final 3.70:1

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

Front Gearcase

Fluid Type / Capacity

Transmission: Main Gearcase

Fluid Type / Capacity

Transmission: Transfer Case

Fluid Type / Capacity

Rear Gearcase

Fluid Type / Capacity

Belt 3211133

Steering / Suspension

Front Suspension / Shock

Front Travel 12 in. / 30.5 cm

Rear Suspension / Shock

Rear Travel 12 in. / 30.5 cm

Shock Preload Adjustment

Front / Rear

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

Wheels / Brakes

Front Wheel Size

Front Tire Type / Size

Rear Wheel Size

Rear Tire Type / Size

Tire Air Pressure

Brake - Front / Rear

Brake Fluid DOT 4

Polaris Demand Drive Plus

6.75 oz. (200 ml) Polaris AGL Plus

24 oz. (710 ml)

Polaris AGL Plus

14 oz. (414 ml)

Polaris Premium ADF

26 oz. (769 ml)

Independent Dual A-arm

FOX™ 2.0 Piggyback

Rolled IRS w/Anti-Sway Bar

FOX™ 2.0 Piggyback

Threaded Spanner Wrench

Adjustment

12 x 6 / Cast Aluminum

Maxxis Bighorn / 26 x 9 R12

12 x 8 / Cast Aluminum

Maxxis Bighorn / 26 x 12 R12

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

Foot Actuated - 4 Wheel

Hydraulic Disc

CLUTCH CHART

Meters

(Feet)

Altitude

0-1500

(0-5000)

1500-3700

(5000 - 12000)

Shift

Weight

23-62

(5632337)

23-58 (B)

(1322911)

Drive

Spring

Black

(7043594)

Black

(7043594)

(B) = Bushed Shift Weight

Driven Spring

Blk / Almond

(7043167)

Blk / Almond

(7043167)

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1.9

GENERAL INFORMATION

MISC. SPECIFICATIONS AND CHARTS

Conversion Table

1.10

°C to °F:

9/5

(°C + 32) = °F °F to °C:

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

5/9

(°F - 32) = °C

Standard Torque Specifications

GENERAL INFORMATION

The following torque specifications are to be used only as a general guideline. There are exceptions in the steering, suspension, and engine areas. Always consult the exploded views or each manual section for torque values of fasteners before using standard torque.

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1.11

GENERAL INFORMATION

SAE Tap / Drill Sizes

Decimal Equivalents

Metric Tap / Drill Sizes

1.12

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GENERAL INFORMATION

Glossary of Terms

ABDC: After bottom dead center. ACV: Alternating current voltage. Alternator: Electrical generator producing voltage alternating current. ATDC: After top dead center. BBDC: Before bottom dead center. BDC: Bottom dead center. BTDC: Before top dead center. CC: Cubic centimeters. Center Distance: Distance between center of crankshaft and center of driven clutch shaft. Chain Pitch: Distance between chain link pins (No. 35 = 3/8" or 1 cm). Polaris measures chain length in number of pitches. CI: Cubic inches. Clutch Buttons: Plastic bushings which aid rotation of the movable sheave in the drive and driven clutch. Clutch Offset: Drive and driven clutches are offset so that drive belt will stay nearly straight as it moves along the clutch face. Clutch Weights: Three levers in the drive clutch which relative to their weight, profile and engine RPM cause the drive clutch to

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

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

cylinder bore.

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

touching the chassis).

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

Mechanical energy is converted to electrical energy in the stator.

mi.: Mile/miles.

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

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

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1.13

GENERAL INFORMATION

NOTES

1.14

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

MAINTENANCE

CHAPTER 2

MAINTENANCE

PERIODIC MAINTENANCE CHART. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3

BREAK-IN PERIOD / MAINTENANCE CHART KEY . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.3

PRE-RIDE - 25 HOUR MAINTENANCE INTERVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.4

50 - 500 HOUR MAINTENANCE INTERVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5

MAINTENANCE QUICK REFERENCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.6

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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MAINTENANCE

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

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

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

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

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

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

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

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

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

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

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

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

2.2

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

MAINTENANCE

WARNING

PERIODIC MAINTENANCE CHART

Periodic Maintenance Overview

Inspection, adjustment and lubrication of important components are explained in the periodic maintenance chart. Inspect, clean, lubricate, adjust and replace parts as necessary. When inspection reveals the need for replacement parts, use

genuine Pure Polaris parts available from your Polaris dealer.

NOTE: Service and adjustments are critical. If you’re not familiar with safe service and adjustment procedures, have a qualified dealer perform these operations.

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

Severe Use Definition

• Frequent immersion in mud, water or sand

• Racing or race-style high RPM use

• Prolonged low speed, heavy load operation

• Extended idle

• Short trip cold weather operation

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

Break-In Period

The break-in period consists of the first 25 hours of operation, or the time it takes to use 14 gallons (53 liters) of fuel. Careful treatment of a new engine and drive components will result in more efficient performance and longer life for these components.

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

• Pull only light loads.

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

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

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

Maintenance Chart Key

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

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

= SEVERE USE ITEM: See information provided above.

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

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

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2.3

MAINTENANCE

Pre-Ride - 25 Hour Maintenance Interval

Maintenance Interval

Item

Hours Calendar

 Steering - Pre-Ride -

Front Suspension - Pre-Ride -



Rear Suspension - Pre-Ride -



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



Brake Pedal Travel - Pre-Ride -



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



Engine Oil Level - Pre-Ride -

(whichever comes first)

Miles

Remarks

(KM)

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



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

Coolant Level - Daily -

Head Lamp / Tail Lamp - Daily -



Air Filter - Weekly - Inspect; replace as needed



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



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



(Demand Drive Plus)

 Rear Gearcase Oil

(ATV Angle Drive Fluid) Transmission - Main



(AGL Gearcase Lubricant) Transmission - Transfer



(AGL Gearcase Lubricant)



Engine Breather Filter

(if equipped)



Engine Oil Change

(Break-In Period)

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

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

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

Check level daily , change coolan t every 2 years

Check operation; apply dielectric grease if replacing

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

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

2.4

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

MAINTENANCE

50 - 500 Hour Maintenance Interval

Maintenance Interval

Item



Throttle Cable / Throttle

Pedal Throttle Body Air Intake

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



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

 Steering 50 H 6 M 500 (800) Lubricate

Front Suspension 50 H 6 M 500 (800) Lubricate



Rear Suspension 50 H 6 M 500 (800) Lubricate



Cooling System 50 H 6 M 500 (800)



Fuel System 100 H 12 M 600 (1000)



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



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

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



(whichever comes first)

Hours Calendar

50 H 6 M 300 (500)

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

Miles

(KM)

Inspect; adjust; lubricate; replace if necessary

Inspect coolant strength seasonally; pressure test system yearly

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

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

Remarks

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



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



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

Inspect for wear, routing, security; apply

Wiring 100 H 12 M 1000 (1600)



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

Shocks 100 H - - Visually inspect shock seals



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

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



Shocks 500 H 12 M - Change shock oil and seals



 Toe Adjustment -

Headlight Aim - Adjust as needed

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

Inspect periodically; adjust when parts are replaced

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

E Emission Control System Service (California)

 Have an authorized Polaris dealer perform these services.

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MAINTENANCE

Maintenance Quick Reference

III. # Item Lube Rec. Method Frequency*

Change after 1st month or first 25 hours of operation, 100 hours thereafter; Change more often (25 hours) in severe duty conditions or short trip cold weather operation

1Engine Oil

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

Add oil to proper level on dipstick

2 Engine Coolant Polaris 60/40 Coolant

3 Brake Fluid Polaris DOT 4 Brake Fluid

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

Maintain coolant level in coolant reservoir bottle.

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

Check level daily, change coolant every 2 years

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

2.6

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MAINTENANCE

Maintenance Quick Reference, Continued.....

III. # Item Lube Rec. Method Frequency*

4 Front Gearcase Polaris Demand Drive Plus

5 Rear Gearcase

6 Transmission

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

Polaris ATV Angle Drive Fluid (ADF)

Polaris AGL Plus Gearcase Lubricant

Add lubricant until it is visible at the fill hole threads

Check level every 25 hours; change fluid yearly

Check level every 25 hours; change lubricant yearly

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MAINTENANCE

Grease Lubrication Points

There are grease fittings at each A-arms pivot point, each front or rear stabilizer bushing, and on the front propshaft yoke. Apply grease until all traces of water have been purged out at each of these areas.

Item Recommended Lube Method Frequency

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

Polaris Premium U-Joint Grease

Grease fittings every 500 miles (800 km).

Grease before long periods of storage, and after thoroughly washing or submerging the vehicle.

2.8

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MAINTENANCE

LUBRICANTS / SERVICE PRODUCTS

Polaris Lubricants, Maintenance and Service Products

Part No. Description

Engine Lubricant

2870791 Fogging Oil (12 oz. Aerosol) 2876244

2876245

2878068

2878069

2878070

2876160

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

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

Gearcase / Transmission Lubricants

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

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

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

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

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

Part No. Description

Additives / Sealants / Thread Locking Agent s / Misc.

2871950

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

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

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

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

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

2872276

2877922

2877923 2870465 Oil Pump for 1 Gallon Jug

2871312 Grease Gun Kit 2871322

2871423 2871460 Starter Drive Grease (12 Count)

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

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

Demand Drive Plus (Quart)

Demand Drive Plus (2.5 Gallon)

Grease / Specialized Lubricants

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

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

Coolant

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

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

2.9

MAINTENANCE

Shift Cable

Mount

Dust Boot

Clevis Pin

Shift Cable

Lower

Jam Nut

Upper

Jam Nut

GENERAL VEHICLE INSPECTION AND MAINTENANCE

Pre-Ride / Daily Inspection

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

• Tires - check condition and pressures

• Fuel tank - fill to proper level

• All brakes - check operation and adjustment

• Throttle - check for free operation and closing

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

• Ignition switch - check for proper function

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

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

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

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

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

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

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

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

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

Frame, Nuts, Bolts, and Fasteners

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

Shift Cable Inspection / Adjustment

Shift cable adjustment may be necessary if symptoms include:

• No AWD or gear position display on instrument cluster

• Ratcheting noise on deceleration

• Inability to engage into a gear

• Excessive gear clash (noise)

4. Adjust the shift cable so there is the same amount of cable travel when shifting slightly past the detents of HIGH (H) gear and PARK (P).

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

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

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

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

• Gear selector moving out of desired range

2.10

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

MAINTENANCE

WARNING

Injector Rail

Connector

Fuel Pump

Connector

Fuel Line

Fuel Pump Asm

FUEL SYSTEM AND AIR INTAKE

Fuel System

Gasoline is extremely flammable and explosive

under certain conditions.

Always stop the engine and refuel outdoors or in

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

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

gasoline, seek medical attention immediately.

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

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

can result in loss of consciousness or

death in a short time.

Never drain the fuel when the engine is hot.

Severe burns may result.

Fuel Pump / Fuel Filters

The RZR 800 EFI engine uses a serviceable, high-volume, highpressure, fuel pump that includes a preliminary filter and an internal fine filter located before the pump regulator.

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

Fuel Line

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

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

IMPORTANT: Make sure line is not kinked or pinched.

3. Replace fuel line every two years.

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

Vent Lines

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

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

IMPORTANT: Ensure lines are not kinked or pinched.

2.11

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

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