POLARIS RZR User Manual

GENERAL INFORMATION

CHAPTER 1

GENERAL INFORMATION

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

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

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

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

ENGINE SERIAL NUMBER LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.2

UNIT SERIAL NUMBER (VIN) LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.3

VEHICLE INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4

PUBLICATION NUMBERS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.4

PAINT CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.4

REPLACEMENT KEYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.4

SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4

GENERAL SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5

GENERAL: 2009 RANGER RZR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.5

GENERAL: 2009 RANGER RZR “S” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.5

DETAILED: 2009 RANGER RZR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.6

DETAILED: 2009 RANGER RZR “S” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.7

MISC. SPECIFICATIONS AND CHARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8

CONVERSION TABLE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.8

STANDARD TORQUE SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.9

SAE TAP / DRILL SIZES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.10

METRIC TAP / DRILL SIZES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.10

DECIMAL EQUIVALENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.10

GLOSSARY OF TERMS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.11

1.1

GENERAL INFORMATION

MODEL INFORMATION

Model Identification

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

Machine Model Number Identification

R 0 9 V H 7 6 A D

Model Year Designation

Basic Chassis

Designation

Engine Designation Number

EH076OLE022........................................................................Twin Cylinder, Liquid Cooled, OHV 4 Stroke, Electric Start (RZR)

EH076OLE072.................................................................Twin Cylinder, Liquid Cooled, OHV 4 Stroke, Electric Start (RZR “S”)

VIN Identification

World

Mfg. ID

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 4 X A V H 7 6 A * 9 P 0 0 0 0 0 0

Vehicle Description

}

Emissions & Model Option

Engine Designation

Vehicle Identifier

Model

Year

Check Digit

Plant No.

Individual Serial No.

* This could be either

a number or a letter

Body Style

Powertrain

Engine

Emissions

Engine Serial Number Location

Whenever corresponding about an engine, be sure to refer to the engine model number and serial number. This information can be found on the sticker applied to the cylinder head on the side of engine.

1.2

Unit Serial Number (VIN) Location

GENERAL INFORMATION

The machine model number and serial number (VIN) are important for vehicle identification. The VIN number (A) is stamped on a portion of the front left frame rail close to the left front wheel.

The VIN and model number are also located on a decal (B) attached to the frame support accessible through the front right wheel well.

1.3

GENERAL INFORMATION

VEHICLE INFORMATION

Publication Numbers

Model Model No. Owner’s Manual PN Parts Manual PN

2009 RANGER RZR R08VH76AD, AG, AH, AO 9921878 9921879

2009 RANGER RZR “S” R08VH76AX 9921878 9922130

NOTE: When ordering se rvic e part s 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.

Paint Codes

Painted Part Color Description Polaris Number

Frame / Bumpers / Racks Gloss Black P-067

Frame / Bumpers / Racks Matte Black P-458 Plastic - Hood / Dash / Fenders Indy Red P-293 Plastic - Hood / Dash / Fenders Sage Brush Green Metallic P-498

Replacement Keys

Replacement keys can be made from the original key. To 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.

KEY COVER P/N 5533534

Key Series 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/

1.4

GENERAL SPECIFICATIONS

MODEL: 2009 RANGER RZR

MODEL NUMBER: R09VH76AD, AG, AH, AO ENGINE MODEL: EH076OLE022

Category Dimension / Capacity

Length 102 in. / 259 cm Width 50 in. / 127 cm Height 68.5 in. / 174 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. / 336.4 kg

and trailer tongue weight)

GENERAL INFORMATION

MODEL: 2009 RANGER RZR “S”

MODEL NUMBER: R09VH76AX ENGINE MODEL: EH076OLE072

Category Dimension / Capacity

Length 106 in. / 269 cm Width 60.5 in. / 154 cm Height 70.5 in. / 179 cm Wheel Base 77 in. / 196 cm Ground Clearance 12 in. / 30.5 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. / 336.4 kg

and trailer tongue weight)

1.5

GENERAL INFORMATION

MODEL: 2009 RANGER RZR

MODEL NUMBER: R09VH76AD, AG, AH, AO ENGINE MODEL: EH076OLE022

Engine

Platform

Engine Model Number EH076OLE022

Engine Displacement 760cc Number of Cylinders 2

Bore & Stroke (mm) 80 x 76.5 mm

Compression Ratio 9.78:1

Compression Pressure 150-170 psi

Engine Idle Speed 1150 ± 100 RPM

Engine Max Operating RPM 6500 ± 200 RPM

Lubrication Pressurized Wet Sump

Oil Requirements PS-4 PLUS / 2W-50 Synthetic

Oil Capacity 2 qts. / 1.9 liters

Coolant Capacity 4.8 qts. / 4.5 liters

Overheat Warning Instrument Cluster Indicator

Exhaust System Single Headpipe / Single Silencer

Fuel System Type Bosch Electronic Fuel Injection

Fuel Delivery Electronic Fuel Pump (in tank)

Fuel Pressure 39 psi

Fuel Filters See Chapter 4

Fuel Capacity / Requirement

Alternator Max Output 500 Watts @ 3000 RPM

Lights: Main Headlights 2 - Single Beam 55 W / Halogen

Tail / Brake 2 - 5 Watts / 2 - 5 Watts Starting System Electric Start Ignition System Bosch EFI (ECU Contr olled) Ignition Timing 13° BTDC @ 1200 RPM

Spark plug / Gap

Battery

Instrument Type

DC Outlet Standard 12 V

Relays

Circuit Breaker Fan Motor: 20 Amp

Fuses

Polaris Domestic Twin Cylinder,

Liquid Cooled, 4-Stroke

Fuel System

7 gal. (26.5 liters)

87 Octane (minimum)

Electrical

Champion RC7YC3 /

.035 in. (0.9 mm)

Yuasa YTX20HL /

18 Amp Hr. / 310 CCA / 12 Volt

Analog Speedometer

with Multifunction LCD

EFI / Fan

Chassis: 20 Amp

EFI: 15 Amp

Lights: 15 Amp

Accessory: 15 Amp

Speedo/ECU: 5 Amp

Drivetrain

Transmission Type Polaris Automatic PVT

Gear Ratio: Front / Rear

High

Low

Rev Drive Ratio - Front 3.82:1 Drive Ratio - Final 3.70:1

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

Polaris Demand Drive LT

Front Gearcase Oil Requirements

Transmission Oil Requirements

Main Gearcase

Transmission Oil Requirements

Transfer Case

Rear Gearcase Oil Requirements

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. / 3-6.35 mm

Wheels / Brakes

Front Wheel Size

Front Tire Size

Rear Wheel Size

Rear Tire Size

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

Brake - Front / Rear

Brake Fluid DOT 4

Polaris High Performance AGL

Independent Dual A-arm

Foot Actuated - 4 Wheel

3.14:1

8.71:1

5.94:1

Premium Fluid

6.75 oz. (200 ml)

24 oz. (710 ml)

14 oz. (414 ml)

Polaris Premium ADF

26 oz. (769 ml)

w/Anti-Sway Bar

Cam Adjustment

12 x 6 / 10 gauge

Maxxis / 25 x 8 R12

12 x 8 / 10 gauge

Maxxis / 25 x 10 R12

Hydraulic Disc

CLUTCH CHART

Altitude Shift Weight Drive Spring

Meters

(Feet)

0-1500

(0-5000)

1500-3700

(5000 - 12000)

20-62

(5631700)

20-58

(5631216)

Blue / Red

(7043199)

Blue / Red

(7043199)

Driven Spring

Red or Yellow

(3234452)

Red or Yellow

(3234452)

1.6

GENERAL INFORMATION

MODEL: 2009 RANGER RZR “S”

MODEL NUMBER: R09VH76AX ENGINE MODEL: EH076OLE072

Engine

Platform

Engine Model Number EH076OLE072

Engine Displacement 760cc HO 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 ± 200 RPM

Lubrication Pressurized Wet Sump

Oil Requirements PS-4 PLUS / 2W-50 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 Electronic Fuel Injection

Fuel Delivery Electronic Fuel Pump (in tank) Fuel Pressure 39 psi

Fuel Filters See Chapter 4

Fuel Capacity / Requirement

Alternator Max Output 500 Watts @ 3000 RPM

Lights: Main Headlights 2 - Single Beam 55 W / Halogen

Tail / Brake 2 - 5 Watts / 2 - 5 Watts Starting System Electric Start Ignition System Bosch EFI (ECU Controlled) Ignition Timing 13° BTDC @ 1200 RPM

Spark plug / Gap

Battery

Instrument Type

DC Outlet Standard 12 V

Relays

Circuit Breaker Fan Motor: 20 Amp

Fuses

Polaris Domestic Twin Cylinder,

Liquid Cooled, 4-Stroke

Fuel System

7 gal. (26.5 liters)

87 Octane (minimum)

Electrical

Champion RC7YC3 /

.035 in. (0.9 mm)

Yuasa YTX20HL /

18 Amp Hr. / 310 CCA / 12 Volt

Analog Speedometer

with Multifunction LCD

EFI / Fan

Chassis: 20 Amp

EFI: 15 Amp

Lights: 15 Amp

Accessory: 15 Amp

Speedo/ECU: 5 Amp

Drivetrain

Transmission Type Polaris Automatic PVT

Gear Ratio: Front / Rear

High

Low

Rev Drive Ratio - Front 3.82:1 Drive Ratio - Final 3.70:1

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

Polaris Demand Drive LT

Front Gearcase Oil Requirements

Transmission Oil Requirements

Main Gearcase

Transmission Oil Requirements

Transfer Case

Rear Gearcase Oil Requirements

Belt 3211130

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. / 3-6.35 mm

Wheels / Brakes

Front Wheel Size

Front Tire Size

Rear Wheel Size

Rear Tire Size

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

Brake - Front / Rear

Brake Fluid DOT 4

Polaris High Performance AGL

Independent Dual A-arm

Rolled IRS w/Anti-Sway Bar

Threaded Shock Adjustment

12 x 6 / Cast Aluminum

Maxxis Bighorn / 26 x 9 R12

12 x 8 / Cast Aluminum

Maxxis Bighorn / 26 x 12 R12

Foot Actuated - 4 Wheel

3.14:1

8.71:1

5.94:1

Premium Fluid

6.75 oz. (200 ml)

24 oz. (710 ml)

14 oz. (414 ml)

Polaris Premium ADF

26 oz. (769 ml)

FOX™ PODIUM X

with Spanner Wrench

Hydraulic Disc

CLUTCH CHART

Altitude Shift Weight Drive Spring

Meters

(Feet)

0-1500

(0-5000)

1500-3700

(5000 - 12000)

21-74

(5632117)

21-70

(5632127)

Red / White

(7043349)

Red / White

(7043349)

Driven Spring

Red or Yellow

(3234452)

Red or Yellow

(3234452)

1.7

GENERAL INFORMATION

MISC. SPECIFICATIONS AND CHARTS

Conversion Table

1.8

°C to °F:

9/5

(°C + 32) = °F °F to °C:

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.

1.9

GENERAL INFORMATION

SAE Tap / Drill Sizes

Decimal Equivalents

Metric Tap / Drill Sizes

1.10

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 wind ings.

Mechanical energy is converted to electrical energy in the stator.

mi.: Mile/miles. mm: Millimeter. Unit of length in the metric system. 1 mm = approximately .040". 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 cylinder 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.

1.11

GENERAL INFORMATION

NOTES

1.12

MAINTENANCE

CHAPTER 2

MAINTENANCE

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

PERIODIC MAINTENANCE OVERVIEW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.3

BREAK-IN PERIOD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.3

MAINTENANCE CHART KEY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.3

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

50 - 300 HOUR MAINTENANCE INTERVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.5

COMPONENT INSPECTION / SERVICE LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6

FRONT AND REAR VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.6

RH AND LH SIDE VIEWS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.7

LUBRICANTS / SERVICE PRODUCTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.8

MAINTENANCE REFERENCES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.11

FUEL LINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.11

FUEL PUMP / FUEL FILTERS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.11

VENT LINES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.11

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

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

THROTTLE CABLE REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.12

AIR FILTER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.14

ENGINE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.16

ENGINE OIL LEVEL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.16

ENGINE OIL AND FILTER SERVICE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.17

ENGINE BREATHER HOSE INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.18

ENGINE AND TRANSMISSION MOUNT LOCATIONS. . . . . . . . . . . . . . . . . . . . . . . . .2.18

COMPRESSION AND LEAKDOWN TEST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.18

EXHAUST - SPARK ARRESTOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.18

TRANSMISSION AND GEARCASES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.19

TRANSMISSION / GEARCASE SPECIFICATION CHART . . . . . . . . . . . . . . . . . . . . . .2.19

TRANSMISSION LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.19

FRONT GEARCASE LUBRICATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.21

REAR GEARCASE LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.22

COOLING SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.23

COOLING SYSTEM OVERVIEW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.23

COOLANT LEVEL INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.23

COOLANT STRENGTH / TYPE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.23

COOLING SYSTEM PRESSURE TEST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.24

COOLING SYSTEM HOSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.24

RADIATOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.24

COOLANT DRAIN / RADIATOR REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.24

FINAL DRIVE / WHEEL AND TIRE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.25

WHEEL, HUB, AND SPINDLE TORQUE TABLE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.25

WHEEL REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.25

WHEEL INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.25

TIRE INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.26

TIRE PRESSURE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.26

DRIVE SHAFT BOOT INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.26

2.1

MAINTENANCE

ELECTRICAL AND IGNITION SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.27

BATTERY MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.27

BATTERY REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.27

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

BATTERY OFF SEASON STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.28

BATTERY CHARGING (SEALED BATTERY) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.28

SPARK PLUG SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.28

ENGINE TO FRAME GROUND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.29

STEERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.29

STEERING INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.29

STEERING WHEEL FREEPLAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.29

STEERING INSPECTION / TIE ROD ENDS AND HUBS . . . . . . . . . . . . . . . . . . . . . . . 2.30

TOE ALIGNMENT INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.30

TOE ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.31

SUSPENSION (RZR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.31

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

SUSPENSION (RZR “S”). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.32

SPRING PRELOAD ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.32

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

BRAKE SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.33

BRAKE FLUID INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.33

BRAKE PAD / DISC INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.33

BRAKE HOSE AND FITTING INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.33

2.2

MAINTENANCE

PERIODIC MAINTENANCE CHART

Periodic Maintenance Overview

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

genuine Pure Polaris parts available from your Polaris dealer.

NOTE: Service and adjustments are critical. 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 frequent ly.

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 dail y pre-ride inspecti on 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.

WARNING

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

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 -



Air Filter / Pre-Filter - Pre-Ride - Inspect; clean often; replace as needed

Coolant Level - Daily -

Head Lamp / Tail Lamp - Daily Air Filter,



Main Element



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 Fluid LT)

 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

(whichever comes first)

Miles

(KM)

Make adjustments as needed. See Pre-Ride Checklist on Page 2.9.

Check level daily, change coolant every 2 years

Check operation; apply dielectric grease if replacing

- Weekly - Inspect; replace as needed

Remarks

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

MAINTENANCE

50 - 300 Hour Maintenance Interval

Maintenance Interval

Item

Hours Calendar



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



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

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

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

 Toe Adjustment -

Headlight Aim - Adjust as needed

(whichever comes first)

Miles

(KM)

50 H 6 M 300 (500)

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

Inspect; adjust; lubricate; replace if necessary

Inspect coolant strength seasonally; pressure test system yearly Check for leaks at tank cap, fuel line, fuel pump, and fuel rail. 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

Inspect for wear, routing, security; apply dielectric grease to connectors subjected to water, mud, etc.

Inspect periodically; adjust when parts are replaced

Remarks

 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.

2.5

MAINTENANCE

COMPONENT INSPECTION / SERVICE LOCATIONS

Front and Rear View

Standard RZR Shown

2.6

RH and LH Side Views

MAINTENANCE

Standard RZR Shown

*Standard RZR Only

2.7

MAINTENANCE

LUBRICANTS / SERVICE PRODUCTS

Polaris Lubricants, Maintenance and Service Products

Part No. Description

Engine Lubricant

2870791 Fogging Oil (12 oz. Aerosol)

2876244

2876245

2873602

2873603

2873604

2871653

2872276

2871654 2870465 Oil Pump for 1 Gallon Jug

2871312 Grease Gun Kit 2871322

PS-4 PLUS Performance Synthetic 2W-50 4-Cycle Engine Oil (Quart)

PS-4 PLUS Performance Synthetic 2W-50 4-Cycle Engine Oil (Gallon)

Gearcase / Transmission Lubricants

AGL - Synthetic ATV Gearcase Lubricant (1 Qt.) (12 Count)

AGL - Synthetic ATV Gearcase Lubricant (1 Gal.) (4 Count)

AGL - Synthetic ATV Gearcase Lubricant (2.5 Gal.) (2 Count)

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

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

Premium Demand Drive Fluid LT (1 Qt.) (12 Count)

Grease / Specialized Lubricants

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

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

Part No. Description

Additives / Sealants / Thread Locking Agent s / Misc.

2870585 Loctite™ Primer N, Aerosol, 25 g 2871956

2871949

2871950

2871951

2871952

2871953

2871954

2870584

2870587

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

2872189 DOT 4 Brake Fluid (12 Count) 2871557 Crankcase Sealant, 3-Bond 1215 (5oz.) 2872893 Engine Degreaser (12oz.) (12 Count)

Loctite™ Thread Sealant 565 (50 ml.) (6 Count)

Loctite™ Threadlock 242 (50 ml.) (10 Count)

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

Loctite™ Threadlock 262 (50 ml.) (10 Count)

Loctite™ Threadlock 262 (6 ml.) (12 Count)

Loctite™ Threadlock 271 (6 ml.) (12 Count)

Loctite™ Threadlock 271 (36 ml.) (6 Count)

Loctite™ 680-Retaining Compound (10 ml.)

Loctite™ 518 Gasket Eliminator / Flange Sealant (50 ml.) (10 Count)

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

2871423 2871460 Starter Drive Grease (12 Count)

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

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

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

Coolant

2.8

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

MAINTENANCE

MAINTENANCE REFERENCES

Item Ref. Rec. Lube / Fluid Method Frequency*

Change after 25 hrs, and then

Polaris PS-4 PLUS

Engine Oil Page 2.7

Engine Coolant Page 2.6

Brake Fluid Page 2.7 DOT 4 (PN 287218 9) Transmission

(Main Gearcase) Transmission

(Transfer Case)

Front Gearcase Page 2.7

Rear Gearcase Page 2.7

Prop Shaft Page 2.7

Control Arm Pivot Bushings, FT / RR

Stabilizer Bar Bushings, FT / RR

Page 2.7

Page 2.6

Page 2.7

Performance Synthetic 2W-50 4-Cycle Engine Oil

Polaris Antifreeze 60/40 (PN 2871534)

AGL Synthetic Gearcase Lubricant (PN 2873602)

Premium Demand Drive Fluid LT (PN 2876251)

ATV Angle Drive Fluid (PN 2871653)

Polaris Premium U-Joint Lube (PN 2871551)

Polaris Premium All Season Grease (PN 2871423)

Add oil to proper level on dipstick.

Fill recovery bottle between MAX and MIN lines.

Fill reservoir between MAX and MIN lines.

Add lube to bottom of fill plug threads. 24 oz. (710 ml)

Add lube to bottom of level check plug threads. 14 oz. (414 ml)

Add fluid to bottom of fill plug threads.

6.75 oz. (200 ml) Add lube to bottom of fill

plug threads. 26 oz. (769 ml) Locate fitting and grease with

grease gun. Locate grease fittings on the

upper and lower A-arms of the front and rear suspension and grease with grease gun. (4) Front A-arms (6) Rear A-arms

Locate grease fittings on the front and rear stabilizer bars and grease with grease gun. (2) Front Stabilizer Bar (2) Rear Stabilizer Bar

6 months or 100 hours thereafter; Change more often in extremely dirty conditions, or short trip cold weather operation.

Fill as required. Change coolant every 2 years.

Fill as required. Change brake fluid every 2 years.

Change annually***

Semi-annually**

* More often under severe use, such as operated in water or under severe loads. **Semi-annually or 50 hours of operation (refer to Maintenance Schedule for additional information) ***Annually or 100 hours of operation (refer to Maintenance Schedule for additional information)

2.9

MAINTENANCE

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

• 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.

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)

• Gear selector moving out of desired range

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

Clevis Pin

Shift Cable

Mount

Shift Cable

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.

Upper

Jam Nut

Dust Boot

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.

2.10

Lower

Jam Nut

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

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

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

MAINTENANCE

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 engine 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.

FUEL SYSTEM AND AIR INTAKE

Fuel System

WARNING

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 loss of consciousness or death

in a short time.

Never drain the fuel when the engine is hot.

Severe burns may result.

2. Be sure fuel line is routed properly.

IMPORTANT: Make sure line is not kinked or pinched.

3. Replace fuel line every two years.

Fuel Pump / Fuel Filters

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

Fuel Pump Asm

NOTE: Neither filter is servicable.

Fuel Pump Asm

Located in Fuel Tank

Fine Filter

Fuel Line

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

Injector Rail

Fuel Line

Connector

Fuel Pump

Connector

Preliminary Filter

NOTE: For all other information related to the EFI System, refer to Chapter 4.

Vent Lines

1. Check fuel tank, front gear case, rear gear case 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

MAINTENANCE

Throttle Pedal Inspection

If the throttle pedal has excessive play due to cable stretch or cable misadjustment, it will cause a delay in throttle speed. Also, the throttle may not open fully. If the throttle pedal has no play, the throttle may be hard to control, and the idle speed may be erratic.

Throttle Pedal

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

Throttle Freeplay Adjustment

3. Slide back the cable adjuster boot.

4. Using a 10 mm open-end wrench, loosen the adjustment jam nut.

5. Using an 8 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.

Throttle Body

Adjuster

Boot

Jam Nut

NOTE: While adjusting, lightly move the throttle pedal in and out.

6. Re-tighten the jam nut.

7. Apply a small amount of grease to the inside of the boot and slide it over the cable adjuster to its original position.

Inspection

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

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

3. Measure the 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. Locate the throttle cable adjuster at the throttle body.

Throttle Cable

Adjuster

Throttle Cable Replacement

1. Place the vehicle in PARK and stop the engine.

2. Remove the seats and rear service panel (see Chapter 5).

3. Remove the shift handle knob and center console (see Chapter 5).

4. Remove the rear cargo box and rear bumper as an assembly (see Chapter 5).

5. Remove the air intake box (see “Air Filter Service”).

6. Remove both PVT outlet and inlet ducts to allow access the throttle body cover (see Chapter 6).

7. Remove the throttle body cover.

NOTE: Upon removing the cable from the throttle plate arm, the brass retainer will become loose or separated from the cable. Take care not to drop brass retainer upon removal.

8. Pull back on the throttle plate arm and remove the throttle cable.

9. Using an 8 mm open-end wrench, remove the throttle cable from the throttle body.

2.12

10. Remove the rear floor and rocker panel fasteners to loosen the floor.

MAINTENANCE

11. Lift up on the floor and remove the panduit strap retaining the throttle cable and brake line to the frame.

12. Remove the cable end and retainer from the throttle foot pedal.

13. Remove the (2) screws retaining the thro ttle cable b racket to the frame support.

14. Remove the front upper cable clamp from the vertical frame tube.

20. Route the cable through the retainer at the botto m of the frame in the floor console opening.

21. Continue to route the cable towards the rear of the vehicle following the brake line routing.

22. Use the (2) cable ties to retain the throttle cable to the brake line.

NOTE: Be sure to route the throttle cable inside the boss on the rear portion of the floor.

15. Push the rear tabs together and remove the front lower cable retainer.

16. Pull the throttle cable out through the front left wheel well and discard the cable.

17. Install the new cable into the vehicle through the front left wheel well. Route the cable over the upper A-arm and between the front left-hand drive shaft and frame, and between the front gearcase and frame.

18. Install the front upper cabl e clamp making sure to allow enough cable slack to attach the cable bracket to the frame support.

19. Open the front lower cable retainer, place over the cable and reinstall retainer into the frame hole.

23. Insert the rosebud retainer as shown and route the throttle cable and brake line through the retainer.

2.13

MAINTENANCE

24. Route the cable around the circumference of the PVT cover up and over to the throttle body.

25. Apply pipe sealant or PTFE Teflon® tape to the threads at the end of the throttle cable.

NOTE: If using a liquid sealant, do not allow sealant to contact the internal throttle cable.

26. Screw the throttle cable end into the throttle body.

27. Pull back on the throttle plate arm and in sert the throttle cable and brass bushing. Pull slack out of the cable at the foot pedal end to ensure it stays in place.

28. Move to the front of the vehicle and route the upper portion of the cable inside of the brake line.

29. From the left side of the vehicle, hold and align the throttle cable bracket to the frame support with your left hand. Reach into the footwell area with your right hand and start the screws. NOTE: May require an assistant.

33. Install the throttle body cover and PVT inlet duct.

34. Verify the vehicle is still in PARK.

35. Start the engine and allow it to warm up.

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

• If freeplay is correct, proceed to next step.

• If adjustment is required , refer to “Throttle Freeplay

Adjustment” procedure.

37. Using a 10 mm open-end wrench, tighten the jam nut against the throttle body housing. Torque jam nut to 45 in. lbs. (5 Nm).

38. Apply a small amount of grease to the inside of the boot and slide it over the cable adjuster.

39. Reassemble the vehicle using the appropriate areas of the Service Manual as a reference if needed.

40. After reassembly, field test unit to ensure pro per throttle operation.

Air Filter Service

30. Torque the retaining screws to 50 in. lbs. (5.6 Nm).

31. Install the cable end and retainer into the throttle foot pedal.

32. Move back to the throttle body and check to see that the throttle plate arm is resting against the stop. If not, turn in the cable adjuster in (clockwise) until the throttle plate arm rests on the stop.

It is recommended that the air filter be inspected as part of pre-ride inspection. When riding in extremely dusty conditions, apply grease to the seal under the air box cap. In extremely dusty conditions, air filter replacement will be required more often.

The filter should be inspected using the following procedure.

Removal

1. The air box is located just above the rear LH wheel in the wheel well area.

2. Unlatch the (3) clips and remove the air box cap. Inspect the seal. It should adhere tightly to the cover and seal all the way around.

Air Box Location

2.14

3. Remove air filter assembly and remove the pre-filter sleeve.

MAINTENANCE

4. Inspect the main air filter element and replace if necessary. Do not clean the main filter, the filter should be replaced.

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

5. Wash pre-filter in warm soapy water and allow it to air dry.

NOTE: If unable to clean the pre-filter, replace it.

Seal

Cap

Pre-Filter

Sleeve

Air Filter

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

Installation

1. Clean the air box thoroughly.

2. Install a new or clean pre-filter over the main air filter element.

3. Place filter ring over the end of the filter and install the filter into the air box. Be sure the filter fits tightly in the air box.

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

4. Install air box cap and secure with clips.

Secure Clips

Breather

Hose

T-MAP Sensor

Boot

Clamps

Foil

Fitting

Air Intake Duct

Air Box Can

Intake Box

Seal

Breather

Filter

Clip (3)

Filter Ring

Air Filter

Front

Foam Seal

Primary

Foam Seal

Intake Seal

Pre-Filter

Sleeve

Cap

Seal

2.15

MAINTENANCE

ENGINE

Engine Oil Level

The twin cylinder engine is a wet-sump engine, meaning the oil is contained in the bottom of the crankcase. To check the oil level follow the procedure listed below.

Dipstick

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. Remove both seats and the rear service panel.

Lever Lock

Dipstick

SAFE

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 a ngle and de pth of dipstick consistent.

7. Remove the dipstick and check the oil level. Maintain the oil level 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 th e d ip stick a s it is being removed, regardless of the level marks being on top or on bottom (see the next illustration).

ADD 8 OZ

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

Dipstick

Lever Lock

2.16

Dipstick

Always read top side of dipstick to

properly check oil level in crankcase

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. Reinstall the dipstick and seat the lever lock.

MAINTENANCE

Engine Oil and Filter Service

Always change engine oil and filter at the intervals outlined in the Periodic Maintenance Chart. Always change the oil filter whenever changing the engine oil.

WARNING

Personal injury can occur when handling used

oil. Hot oil can cause burns or skin damage.

Recommended Engine Oil:

PS-4 PLUS 2W-50 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. Start 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. Remove both seats and rear service panel.

10. Place shop towels beneath oil filter. Using Oil Filter Wrench (PV-43527) and a 3/8” extension, turn the oil filter counter-clockwise to remove it.

Oil Filter

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

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

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

NOTE: Drain plug is accessed through the skid plate.

Drain Plug

CAUTION

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 drain plug.

6. Allow oil to drain completely.

7. Replace the sealing washer on drain plug.

14. Remove dipstick and fill sump with 2 quarts (1.9 l) of PS-4 PLUS 2W-50 Synthetic Engine Oil (PN 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:

(PV-43527)

15. Verify the transmission is still positi oned 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.

2.17

MAINTENANCE

Engine Breather Hose Inspection

The engine is equipped with a breather hose. Inspect the breather hose for possible kinks or wear. The hose is form fitted for a proper fit. Follow the breather hose from the side of the airbox to the engine valve cover.

Breather

Hose

NOTE: Make sure line is not kinked or pinched.

Engine and Transmission Mount Locations

Periodically inspect engine and transmission mounts for cracks or damage.

Rear Mount

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

800: 150-170 PSI

800 HO: 165-185 PSI

Cylinder Leakdown

Service Limit 15%

(Inspect for cause if test exceeds 15%)

Exhaust - Spark Arrestor

WARNING

Do not clean spark arrestor immediately after the

engine has been run, as the exhaust system

becomes very hot. Serious burns could result from

contact with the exhaust components. 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.

LH Mount

RH Mount

Compression and Leakdown Test

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

2.18

Periodically clean spark arrestor to remove accumulated carbon.

1. Remove the retaining screw and remove the 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. Reinstall the arrestor and torque the screw to 40 in. lbs. (4.5 Nm).

Arrestor

Screen

Silencer

Retaining

Screw

TRANSMISSION AND GEARCASES

Transmission / Gearcase S pecification Chart

MAINTENANCE

EARCASE LUBRICANT CAPACITY FILL PLUG TORQUE

Transmission

(Main Gearcase)

Transmission

(Transfer Case)

Front Gearcase

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

Transmission Lubrication

NOTE: It is important to follow the transmission and gearcase maintenance intervals described in the Periodic Maintenance Chart. Regular fluid level inspections on these components should be performed as well.

Transmission Specifications

AGL - Synthetic ATV

Gearcase Lubricant

AGL - Synthetic ATV

Gearcase Lubricant

Premium Demand Drive

Fluid LT

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

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

6.75 oz. (200 ml) 8- 1 0 ft. lbs. (11-14 Nm) 8-10 ft. lbs. (11-14 Nm)

Transfer Case - Lubricant Level Check:

1. Position vehicle on a level surface.

2. Remove the fill plug.

3. Remove the level check plug.

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

DRAIN / LEVEL CHECK

LUG TORQUE

Specified Lubricant:

AGL Synthetic Gearcase Lubricant

Fill Plug

(PN 2873602)

Approximate Capacity at Change:

Main Gearcase - 24 oz. (710 ml)

Transfer Case - 14 oz. (414 ml)

Drain / Level Plug Torque:

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

Fill Plug Torque:

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

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

• Be sure vehicle is positioned on a level surface when checking or changing fluid.

• Check vent hose to be sure it is routed properly and unobstructed.

Level Check Plug

Drain Plug

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

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

2.19

MAINTENANCE

Main Gearcase - Lubricant Level Check:

The fill plug is located on the side of the gearcase just below the shift lever bell crank. Maintain the fluid level even with the bottom of the fill plug hole.

1. Position vehicle on a level surface.

2. Remove the fill plug.

3. Check the fluid level.

Transfer Case

Drain Plug

Main Gearcase

Drain Plug

Transfer Case Lubricant Change:

Fill Plug /

Level Check Plug

4. If fluid level is not at fill plug hole, add the recom m e nded fluid as needed.

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

Trans mission 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.

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

2. Place a drain pan under the transfer case drain plug.

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

4. Clean the drain plug.

5. Reinstall the drain plug with a new o-ring and torque to

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

6. Add the recommended fluid through the fill plug hole until it begins to flow out the check plug hole. Do not overfill.

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

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

Main Gearcase Lubricant Change:

9. Remove the fill plug (refer to “Main Gearcase - Lubricant Level Check”).

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

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

12. Clean the drain plug.

13. Reinstall the drain pl ug with a new o-ring and torque to 30-45 in. lbs. (3-5 Nm).

14. Add the recommended fluid through the fill plug hole. Maintain the fluid level at the bottom of the fill plug ho le when filling the Main Gearcase. Do not overfill.

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

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

2.20

MAINTENANCE

Front Gearcase Lubrication

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

• Be sure vehicle is positioned on a level surface when checking or changing fluid.

• Check vent hose to be sure it is routed properly and unobstructed.

Front Gearcase Specifications

Specified Lubricant:

Premium Demand Drive Fluid LT

(PN 2876251)

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.

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.

Fill Plug

8-10 ft. lbs.

(11-14 Nm)

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.

Drain Plug

8-10 ft. lbs. (11-14 Nm)

1. Remove the fill plug.

2. Place a drain pan under the drain plug.

3. Remove the drain plug and allow fluid t o 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. Add the recommended fluid. Maintain the lubricant 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).

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

Fill Plug

8-10 ft. lbs.

(11-14 Nm)

2.21

MAINTENANCE

Rear Gearcase Lubrication

Rear Gearcase Specifications

Specified Lubricant:

ATV Angle Drive Fluid (PN 2871653)

Capacity: 26 oz. (769 ml)

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

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

Lubricant Level Check:

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

Fill Plug

40-50 ft. lbs.

(54-68 Nm)

Lubricant Change:

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

Fill Plug

Drain Plug

1. Remove the fill plug.

2. Place a drain pan under the drain plug.

Maintain Level at

Bottom of Threads

1. Position the vehicle on a level surface.

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

3. Add the recommended lubricant as needed.

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

(54-68 Nm)

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

4. Clean the drain plug.

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

Fill Plug

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

Maintain Level at

Bottom of Threads

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

Drain Plug

30-45 in. lbs.

(3-5 Nm)

2.22

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

8. Check for leaks. Discard used lubricant properly.

MAINTENANCE

COOLING SYSTEM

Cooling System Overview

The engine coolant level is controlled, or maintained, by the recovery system. The recovery system components are the recovery bottle, radiator filler neck, radiator pressure cap and connecting hose.

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

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

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

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

Coolant Level Inspection

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

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

NOTE: If overheating is evident, allow system to cool completely and check coolant level in the radiator and inspect for signs of trapped air in system.

WARNING

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.

Recovery Bottle

Pressure Cap

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 by lifting it straight up from the front cab to allow the inserts to disengage from the grommets.

3. View the coolant level in the recovery bottle.

Coolant Strength / Type

Tes t the strength of the coolant using an antifreeze hydrometer.

Antifreeze Hydrometer

• A 50/50 or 60/40 mixture of antifreeze and distilled water will provide the optimum cooling, corrosion protection, and antifreeze protection.

• Do not use tap water, straight antifreeze, or straight water in the system. Tap water contains minerals and impurities which build up in the system.

• Straight water or antifreeze may cause the system to freeze, corrode, or overheat.

Polaris 60/40 Anti-Freeze / Coolant

(PN 2871323)

2.23

MAINTENANCE

Cooling System Pressure Test

Refer to Chapter 3 for cooling system pressure test procedure.

Cooling System Hoses

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

Filler Neck

Recovery

Bottle

T-Fitting

2. Check tightness of all hose clamps.

CAUTION

Do not over-tighten hose clamps at radiator, or radiator fitting may distort, causing a restriction to coolant flow. Radiator hose clamp torque is

36 in. lbs. (4 Nm).

2. Carefully straighten any bent radiator fins.

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

CAUTION

Washing the vehicle with a high-pressure

washer could damage the radiator fins and impair the radiators effectiveness. Use of a high-pressure washer is not recommended.

Coolant Drain / Radiator Removal

Coolant Drain

1. Remove the front hood.

WARNING

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

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

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

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

Radiator

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

Flush radiator fins

in this direction

2.24

Drain Here

5. Allow coolant to completely drain.

MAINTENANCE

Radiator Removal

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

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

3. Remove the (2) upper radiator retaining bolts and the (4) bolts retaining the lower radiator mount bracket. 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.

5. Reverse procedure for installation.

Fan Motor Asm.

Recovery

Hose

Inserts

FINAL DRIVE / WHEEL AND TIRE

Wheel, Hub, and Spindle Torque Table

Item Nut Type Specification

Aluminum Wheels

(Cast)

Steel Wheels

(Black / Camo)

Hub Retaining Nuts

(Front & Rear)

Aluminum Wheel

90 ft. lbs. (122 Nm)

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

Wheel Removal

1. Position the vehicle on a level surface.

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

Lug Nut

Flange Nut

- 80 ft. lbs. (108 Nm)

90 ft. lbs. (122 Nm)

27 ft. lbs. (37 Nm)

Steel Wheel

27 ft. lbs. (37 Nm)

T-Fitting

Engine

Inlet Hose

Engine

Outlet Hose

Grommets

Radiator

Screws

3. Loosen 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. Install 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 rotation arrows on the tire point toward forward rotation.

4. Attach the wheel nuts and finger tighten them.

2.25

MAINTENANCE

5. Carefully lower the vehicle to the ground.

6. Torque the wheel nuts and/or hub nut to the proper torque specification listed in the torque table at the beginning of this section.

7. If hub nut was removed, install a new cotter pin after the hub nut has been tightened.

WARNING

Operating a RANGER with worn tires will

increase the possibility of the vehicle skidding

easily with possible loss of control.

Use a new

Note

Tire Rotation

Wheel Nuts (4)

cotter pin

Hub Nut

Valve stem

facing outward

CAUTION

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.

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.

Worn tires can cause an accident.

Always replace tires when the tread depth

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

Tire Pressure

CAUTION

Maintain proper tire pressure.

Refer to the warning tire pressure decal

applied to the vehicle.

Tire Pressure Inspection (Cold)

Front Rear

8 psi (55 kPa) 8 (55 kPa)

Drive Shaft Boot Inspection

Inspect the front and rear drive shaft boots for damage, tears, wear, or leaking grease. If the rubber boots exhibit any of these symptoms, replace the boot(s). Refer to Chapter 7 for drive shaft boot replacement.

Front Boots

Tire Tread Depth

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

Tread Depth 1/8" (3 mm)

2.26

Rear Boots

MAINTENANCE

ELECTRICAL AND IGNITION SYSTEM

Battery Maintenance

Keep battery terminals and connections free of corrosion. If cleaning is necessary, remove the corrosion with a stiff wire brush. W ash with a solution of one tablespoon baking soda and one cup water. Rinse well with tap water and dry off with clean shop towels. Coat the terminals with dielectric grease or petroleum jelly.

WARNING

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 f or 3-5 hours at a current equivalent to 1/10 of the battery’s rated amp/hour capacity. Do not use the vehicle’s stator/alternator to charge a new battery.

Battery Removal

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

Battery

2. Disconnect the black (negative) battery cable.

3. Disconnect the red (positive) battery cable.

4. Remove the rubber strap and lift the battery out of the vehicle.

CAUTION

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.

Battery Installation

IMPORTANT: Using a new battery that has not been fully charged can damage the battery and result in a shorter life. It can also hinder vehicle performance. Follow the battery charging procedure before installing the battery.

1. Ensure the battery is fully charged.

2. Place the battery in the battery holder and secure with rubber 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.

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

2.27

MAINTENANCE

Battery Off Season Storage

Whenever the vehicle is not used for a period of three months or more, remove the battery from the vehicle, ensure that it's fully charged, and store it out of the sun in a cool, dry place. Check battery voltage each month during storage and recharge as needed to maintain a full charge.

NOTE: Battery charge can be maintained by using a Polaris battery tender charger or by charging about once a month to make up for normal self-discharge. Battery tenders can be left connected during the storage period, and will automatically charge the battery if the voltage drops below a pre-determined point.

Battery Charging (Maintenance Free)

The sealed battery is already filled with electrolyte and has been sealed at the factory. Never pry the sealing strip of f or add any type of fluid to this battery.

The single most important thing about maintaining a sealed battery is to keep it fully charged. Since the battery is sealed and the sealing strip cannot be removed, you must use a voltmeter or multimeter to measure the DC voltage at the battery terminals.

Spark Plug Service

1. Remove both driver and passenger seats.

2. Remove the rear service panel.

WARNING

A hot exhaust system and engine can cause serious

burns. Allow engine to cool or wear protective

gloves when removing the spark plugs

3. The PTO side spark plug can be accessed with the service panel removed. The MAG side spark plug can be accessed through the rear RH wheel well area.

4. Remove both spark plug caps.

1. Check the battery voltage with a voltmeter or multimeter. The battery voltage should read 12.8 VDC or higher.

2. If the voltage is less than 12.8 volts, charge the battery at

1.2 amps or less until battery voltage is 12.8 VDC or greater.

NOTE: When using an automatic charger, refer to the charger manufacturer’s instructions for battery charging directions. When using a constant current charger, follow the guidelines in the following table:

State of

Charge

100% 12.8 - 13.0 VDC

75% - 100% 12.5 - 12.8 VDC

50% - 75% 12.0 - 12.5 VDC Needs Charge 5 - 11 hrs

25% - 50% 11.5 - 12.0 VDC Needs Charge

0% - 25% 11.5 VDC or less Needs Charge 20 hrs

Voltage Action

None, check

again in 3

months

May need slight

charge, check

again in 3

months

Charge

Time

None

Required

3 - 6 hrs

At least 13

hrs, verify

state of

charge

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

6. Remove spark plugs.

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

Inspect electrode for wear and buildup

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

2.28

MAINTENANCE

9. Measure gap with a wire gauge. Refer to specifications in the following illustration for proper spark plug type and gap. Adjust gap if necessary by carefully bending the side electrode.

Spark Plug Gap

Gap - .035" (0.90 mm)

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

11. Apply anti-seize compound to the spark plug threads.

12. Install spark plug and torque to specification.

Recommended Spark Plug:

Champion RC7YC3

Spark Plug Torque:

18 ft. lbs. (24 Nm)

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.

WARNING

Due to the critical nature of the procedures outlined in this chapter, Polaris recommends steering component repair and adjustment be performed by an authorized

Polaris MSD certified technician when replacing

worn or damaged steering parts.

Use only genuine Polaris replacement parts.

Engine To Frame Ground

Inspect engine ground cable connection. Be sure it is clean and tight. The ground cable runs from the engine starter motor to the ground terminal location under the driver’ s seat near the battery.

Ground

Terminal Location

Engine

Ground Strap

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

U-Joints

Tie Rod

Gearbox

2.29

MAINTENANCE

Steering Inspection / Tie Rod Ends and Hubs

• To check for play in the tie rod end, grasp the steering tie rod and pull in all directions feeling for movement.

Toe Alignment Inspection

1. Place machine on a smooth level surface.

2. Set steering wheel in a straight ahead position and secure the steering wheel in this position.

3. 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.

Measurement “B”

Chalk Mark

Measurement “A”

• Elevate front end of machine so front wheels are off the ground. Check for any looseness in front hub and 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.

Check for Loose Wheel or Hub

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

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

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

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

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

6. 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).

° by moving vehicle forward or

= In. / mm.

Wheel Toe-Out:

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

2.30

MAINTENANCE

Toe Adjustment

If toe alignment is incorrect, measure the distance between vehicle center and each wheel. This will tell you which tie rod needs adjusting.

NOTE: Be sure steering wheel is straight ahead before determining which tie rod(s) need adjustment.

CAUTION

During tie rod adjustment, it is very important that

the following precautions be taken when

tightening tie rod end jam nuts.

If the rod end is positioned incorrectly it will not

pivot, and may break.

To adjust toe alignment:

• Hold tie rod end to keep it from rotating.

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

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

SUSPENSION (RZR)

Spring Preload Adjustment

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

WARNING

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.

• IMPORTANT: When tightening the tie rod end jam

nuts, the rod ends must be held parallel to prevent rod end damage and premature wear. Damage may not be immediately apparent if done incorrectly.

• After alignment is complete, torque jam nuts to specification.

= T

Tie Rod Jam Nut Torque:

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

Cam

Decrease

Preload

Increase

Preload

Shock Spanner Wrench

(PN 2870872)

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

2.31

MAINTENANCE

SUSPENSION (RZR “S”)

Spring Preload Adjustment

The front and rear shocks have a preload adjustment. Suspension spring preload may be adjusted to suit different riding conditions or vehicle payloads.

WARNING

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. Loosen the upper jam nut adjustment ring. Turn the lower adjustment ring (1) clockwise to increase preload or counter-clockwise to decrease preload.

Factory Preload Setting

3.5 in. (8.9 cm)

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

Shock Compression Adjustment

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

Use a flat blade screwdriver to make damping adjustments.

NOTE: When the adjuster screw is turned clockwise until it stops, the damping is in the fully closed position.

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

NOTE: The factory setting is 8 clicks from closed (see “Compression Adjustment Table”).

Increase

Damping

Decrease

Damping

Decrease

Preload

Spring

Spacer

Decrease

Preload

Increase

Preload

Ride-In

Spring

Front Shock

Factory Preload Setting

5.4 in. (13.7 cm)

Increase

Preload

Clicker

Adjuster

Compression Adjustment Table

Setting Compression Damping

Softest 18 clicks from closed Factory 8 clicks from closed Firmest 2 clicks from closed

2.32

Rear Shock

MAINTENANCE

BRAKE SYSTEM

Brake Fluid Inspection

Always check the brake pedal travel and inspect the brake fluid reservoir level before each operation. If the fluid level is low, add DOT 4 brake fluid only.

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

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

1. Position the vehicle on a level surface.

2. Place the transmission in PARK (P).

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

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

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

Brake Pad / Disc Inspection

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

2. Inspect the brake pad wear surface for excessive wear.

3. Pads should be changed when the friction material is worn to .040” (1 mm).

Measure Pad Material

Thickness

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).

Measure Brake Disc Thickness

Service Limit:

.040" (1 mm)

Maximum

Minimum

Master Cylinder

Rear

Disc

Service Limit:

.170" (4.32 mm)

Front

Disc

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.

2.33

MAINTENANCE

MAINTENANCE LOG

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

2.34

ENGINE

CHAPTER 3

ENGINE

ENGINE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.2

CRANKCASE EXPLODED VIEWS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.2

ENGINE FASTENER TORQUE PATTERNS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.7

TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.8

800 EFI ENGINE SERVICE SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.9

SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.11

ENGINE COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.12

COOLING SYSTEM SPECIFICATIONS / PRESSURE TEST . . . . . . . . . . . . . . . . . . . .3.12

COOLING SYSTEM EXPLODED VIEW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.13

COOLING SYSTEM BLEEDING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.14

GENERAL ENGINE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.15

ENGINE LUBRICATION SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.15

ACCESSIBLE ENGINE COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.15

OIL PRESSURE TEST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.15

OIL FLOW CHART. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.16

ENGINE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.17

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

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

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

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

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

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

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

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

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

COMBUSTION CHAMBER / VALVE SEAT RECONDITIONING. . . . . . . . . . . . . . . . . .3.29

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

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

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

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

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

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

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

HONING TO DEGLAZE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.35

CLEANING THE CYLINDER AFTER HONING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.35

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.61

COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.62

3.1

ENGINE

ENGINE SPECIFICATIONS

Crankcase Exploded Views

3.2

Oil Pump / Water Pump / Engine Cover Exploded View

ENGINE

3.3

ENGINE

Stator Cover / Starter / Water Pump Oil Filter / Pressure Relief / Exploded View

3.4

Cylinder / Cylinder Head / Piston Exploded View

ENGINE

3.5

ENGINE

Engine EFI Sensors / Valve Cover / General Component Exploded View

3.6

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

Engine Fastener Torque Patterns

Crankcase Bolt Tighten Sequence

ENGINE

22  2 ft. lbs. (30  3 Nm)

Cylinder Head Bolt Tighten Sequence

Lubricate threads and between washer and underside of bolt with engine oil. Torque in sequence to spec provided, allow the gasket to set for 1 minute, th en

tighten in sequence 90

35  4 ft. lbs. (47.5  5.5 Nm)

 (1/4 turn).

+ 90

 (1/4 turn)

3.7

ENGINE

Torque Specifications

Engine Torque Specifications

Fastener Size in. lbs. (Nm) ft. lbs. (Nm)

Camshaft Gear 8 mm 22 ± 2 (30 ± 3) Camshaft Thrust Plate 6 mm 11 5 ± 12 (13 ± 1.35) 9.5 ± 1 (13 ± 1.35) Throttle Body Adaptor Bolts 8 mm 216 ± 24 (24.5-± 2.7) 18 ± 2 (24.5 ± 2.7) Counterbalance Gear 8 mm 22 ± 2 (30 ± 3) Crankcase Bolts 8 mm * 22 ± 2 (30 ± 3) Crankcase Breather 5 mm 20 ± 5 (2.5 ± 0.55) Cylinder Head Bolts 11 mm * 35 ± 4 (47.5 ± 5.5) Exhaust Manifold 8 mm 216 ± 24 (24.5 ± 2.70) 18 ± 2 (24.5 ± 2.7) Flywheel 14 mm 65 ± 7 (88 ± 9.50) Injector Rail 8 mm 216 ± 24 (24.5 ± 2.70) 1 8 ± 2 (24.5 ± 2.7) Magneto Cover 6 mm * 96 ± 3 (10.85 ± 0.35) Oil Baffle Weldment 5 mm 60 ± 6 (6.8 ± 0.68) Oil Drain Bolt (Crankcase) 12 mm 192 ± 24 (21.7 ± 2.7) 16 ± (21.7) Oil Fill Tube Bolt 5 mm 50 ± 5 (5.64 ± 0.56) Oil Filter Pipe Fitting 20 mm 35 ± 4 (47.5 ± 5.4) Oil Pick Up 5 mm 60 ± 6 (6.8 ± 0.68) Oil Pressure Relief Plug 10 mm 22 ± 2 (30 ± 3) Oil Pump Housing Screw 6 mm * 84 ± 8 (9.50 ± 0.90) Rocker Arm 8 mm * 22 ± 2 (30 ± 3) Rocker Cover 6 mm * 84 ± 8 (9.5 ± 0.9) Spark Plug 14 mm 216 ± 24 (24.5 ± 2.7) 18 ± 2 (24.5 ± 2.7) Starter Motor 6 mm * 84 ± 8 (9.5 ± 0.9) Stator Assembly 6 mm 96 ± 3 (10.85 ± 0.35) Stator Housing 6 mm * 96 ± 3 (10.85 ± 0.35) Temperature Switch 3/8 NPT 17 ± 2 (23 ± 3) Thermostat Housing 6 mm 84 ± 8 (9.5 ± 0.9) Timing Plug 3/4-16 7 - 9 (10 - 12) Trigger Coil/Stator Wire Holddown 5 mm * 96 ± 3 (10.85 ± 0.35) Water Pump Housing Cover 6 mm * 96 ± 3 (10.85 ± 0.35) Water Pump Impeller Nut 8 mm 108 ± 3 (12 ± 0.35) -

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

3.8

800 EFI Engine Service Specifications

Cylinder Head - Engine Specifications

Main Component: Cylinder Head EH076OLE022 / EH076OLE072

Cam Lobe Height - Intake 1.333” (33.867 mm) / 1.357” (34.477 mm) Cam Lobe Height - Exhaust 1.333” (33.867 mm) / 1.342” (34.096 mm) Camshaft Journal Outer Diameter - Mag 1.654"  0.00039" (42  0.010 mm)

ENGINE

Camshaft Journal Outer Diameter - Center 1.634" 0.00039" (41.50  0.010 mm)

Camshaft

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

Cylinder Head

Valve Seat

Valve Guide

Camshaft Journal Outer Diameter - PTO 1.614"  0.00039" (41  0.010 mm) Camshaft Journal Bore Inner Diameter - Mag 1.656"  0.00039" (42.07  0.010 mm) Camshaft Journal Bore Inner Diameter - Center 1.637"  0.00039" (41.58  0.010 mm) Camshaft Journal Bore Inner Diameter - PTO 1.617"  0.00039" (41.07  0.010 mm) Camshaft Oil Clearance 0.00276"  0.00079" (0.07  0.02 mm) Camshaft End Play 0.0167"  0.0098" (0.425  0.25 mm)

Cylinder Head - Surface warp limit 0.00394" (0.1 mm)

Valve Seat - Contacting Width - Intake

Valve Seat - Contacting Width - Exhaust

Valve Seat Angle 45.5  0.255 Valve Guide Inner diameter 0.2367"  0.00029" (6.012  0.007 mm) Valve Guide Protrusion Above Head 0.807"  0.0039" (20.50  0.01 mm)

0.0472"  0.00787" - 0.0039" (1.20  0.20 - 0.10mm)

0.0591"  0.00787" - 0.0039" (1.50  0.20 - 0.10 mm)

Valve

Valve Spring

Valve Stem Diameter - Intake 0.2356"  0.00039" (5.985  0.01 mm) Valve Stem Diameter - Exhaust 0.2351"  0.00039" (5.972  0.01 mm) Valve Stem Oil Clearance - Intake 0.00228"  0.00098" (0.058  0.025 mm) Valve Stem Oil Clearance - Exhaust 0.00275" Valve Stem Overall Length - Intake 4.51"  0.01476" (114.5550  0.375 mm) Valve Stem Overall Length - Exhaust 4.5453"  .01496" (115.45  0.38 mm) Valve Spring Overall Length - Free Length 1.735" (46.069 mm)

Valve Spring Overall Length - Installed Height

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

 0.00098" (0.0870  0.025mm)

3.9

ENGINE

Cylinder / Piston - Engine Specifications

Main Components: Cylinder / Piston / Connecting Rod EH076OLE022 / EH076OLE072

Cylinder

Lifter

Piston

Piston Pin

Cylinder - Surface warp limit (mating with cylinder head)

Cylinder Bore - Standard 3.1495" (80 mm) Cylinder Taper Limit 0.00031" (0.008 mm) Cylinder Out of Round Limit 0.00030" (0.0075 mm) Cylinder to Piston Clearance .0015"  .00059" (.040  .015mm)

Lifter Outer Diameter Standard 0.84245"  0.00025" (21.39 8  0.00635 mm) Lifter Block Bore 0.8438"  0.00062" (21.4322  0.0157 mm) Piston - Standard 3.14803"  .00028" (79.960  .007mm) Piston Standard Inner Diameter of

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

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

0.004" (0.10 mm)

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

0.00047"  0.00024" (0.012  0.006 mm)

Piston / Connecting Rod / Crankshaft - Engine Specifications

Main Components: Piston / Connecting Rod EH076OLE022 / EH076OLE072

T op Ring - Standard 0.0059 0.138" (0.15 0.35mm) Top Ring - Limit > 15% Leakdown

Installed

Gap

Piston Ring

Ring to Groove

Clearance

Connecting Rod

Crankshaft Crankshaft Runout Limit 0.00236" (0.060mm)

Second Ring - Standard 0.0098  0.197" (0.25 0.50mm) Second Ring - Limit > 15% Leakdown Oil Ring - Standard 0.0196 0.00984" (0.50 0.25mm) Oil Ring - Limit > 15% Leakdown T op Ring - Standard 0.0024"  0.0008" (0.060  0.020 mm) Top Ring - Limit > 15% Leakdown Second Ring - Standard 0.0028"  0.0008" (0.070  0.020 mm) Second Ring - Limit > 15% Leakdown

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

Connecting Rod Small End

Radial Clearance

Connecting Rod Big End

Side Clearance

Connecting Rod Big End

Radial Clearance

0.0098" 0.00039" (0.025  0.010mm)

0.01181" 0.00591" (0.030  0.015mm)

0.0015" 0.00006" (0.0038  0.0015mm)

3.10

Special Tools

ENGINE

Part Number Tool Description

PV-43527 OIL FILTER WRENCH PU-45257 VALVE SPRING COMPRESSOR PU-45652 VALVE PRESSURE HOSE

2871043 FLYWHEEL PULLER

2870390 PISTON SUPPORT BLOCK PU-45497-1 CAM GEAR SPRING INSTALLATION KIT PU-45497-2 CAM GEAR TOOTH ALIGNMENT TOOL

PU-45498 CAM SPANNER WRENCH PU-45838 GEAR HOLDER

PA-44995 WA TER PUMP MECHANICAL SEAL INSTALLER

PU-45543 UNIVERSAL DRIVER HANDLE

PA-45483 MAIN SEAL INSTALLER

PU-45658 CRANKSHAFT MAIN SEAL SAVER

PA-45401 WATER PUMP SEAL SAVER

2870975 MITY VAC™

PU-45778 OIL SYSTEM PRIMING TOOL

PRESSURE TEST TOOL

3.11

ENGINE

ENGINE COOLING SYSTEM

Cooling System Specifications

Condition Specification

Thermostat Open 180° F (82° C) Thermostat Full Open Lift 6 mm at 203° F (95° C) Thermostat Closed 171° F (77° C) System Capacity 4.8 Quarts (4.5 liters) Pressure Cap Relief 13 PSI

Polaris Premium Antifreeze

2871534 - Quart

2871323 - Gallon

Recommended Coolant

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

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

Pressure Cap Test

WARNING

Never remove pressure cap when engine is

warm or hot. The cooling system is under

pressure and serious burns may result.

Allow the engine and cooling system to cool

before servicing.

1. Remove pressure cap and test cap using a commercially available pressure cap tester.

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

Pressure Cap

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 dam age. 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 front hood.

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

Remove

Cap

Test Here

3.12

Cooling System Exploded View

Engine Outlet Hose

(Thermostat Housing)

ENGINE

Radiator

Inlet Hose

Engine Inlet Hose

(Water Pump Cover)

Pressure Cap

Filler Neck

Recovery Bottle

To Bottle

Radiator

Outlet Hose

Fan Motor

Shroud

To Filler Neck

Coolant Flow Diagram

Engine

Water Pump

Engine

Thermostat Housing

Filler Neck

Recovery Bottle

Radiator

3.13

ENGINE

Cooling System Bleeding Procedure

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.

CAUTION

Use caution when performing these procedures.

Coolant may be hot and may cause

severe injury or burns.

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

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

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

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

3. Remove pressure cap and top off coolant.

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

Recovery Bottle

Pressure Cap

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. Slightly loosen the bleed screw (C) on the thermostat cover 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.

Pressure Cap

CAUTION

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.

Top LH Side

of Engine

8. Tighten the bleed screw to 70 ± 10 in.lbs. (8 ± 1.13 Nm) on the thermostat housing and properly install the pressure cap.

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

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

3.14

ENGINE

10. Add Polaris Premium Antifreeze to the radiator filler neck if the level goes down. If no bubbles are seen at the filler neck, the system should be purged of air

WARNING

Be sure to install the pressure cap before

shutting off the engine.

Coolant may spit out of the radiator.

11. Stop the engine and let cool, top off the radiator filler neck with coolant. 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 2W-50 Synthetic

Filter Wrench - PV-43527 or equivalent

- Oil Pressure Specification -

27-35 psi @ 6000 RPM, Polaris 2W-50

Synthetic, Engine at operating temperature.

Accessible Engine Components

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

• Starter Motor / Drive

• Cylinder Head

• Cylinder

• Piston / Rings

• Rocker Arms

• Water Pump

The following components require engine removal for service:

• Flywheel

• Alternator (Stator)

• Counterbalance Shaft or Bearings

• Gear Train Components

• Camshaft

• Oil Pump / Oil Pump Drive Gear

• Connecting Rod

• Crankshaft

• Crankshaft Main Bearings

• Crankcase

Oil Pressure Test

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

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

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

Oil Pressure at Idle: 6 psi

Oil Pressure at 6000 RPM (Engine Hot):

Minimum: 27 psi

Standard: 31 psi

Maximum: 35 psi

3.15

ENGINE

Oil Flow Chart

This chart describes the flow of oil through the 800 EFI engine. Beginning in the crankcase sump, the oil is drawn through an oil galley to the feed side of the oil pump. The oil is then pumped through th e 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 first 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. The oil pressure switch is fed off the main oil galley.

3.16

ENGINE

Engine Removal

Because of its design configuration, 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 RZR engine assembly from the vehicle. Refer to “Accessible Engine Components” on Page 3.15 for further information.

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.

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.

WARNING

8. Remove the (2) push rivets from the rear of the center console.

9. Remove the (2) fasteners from the rear seat base and remove the assembly from the vehicle.

Always wear safety glasses and proper shop

clothing when performing the procedures in th is

manual. Failing to do so may lead to possible

injury or death.

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

2. Clean work area.

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 and passenger seats (see Chapter 5).

6. Disconnect (-) negative battery cable.

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

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

7. Remove the rear service panel (see Chapter 5).

Remove

Push Rivets

3.17

ENGINE

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 vehicl e and engin e .

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

Outlet Duct

PVT Cover

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

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.

Frame Brace

Ignition

Coil

PVT Duct

19. Remove the upper nut and grommet from the stabilizer bar linkage on both sides of the vehicle.

16. Remove the high tension leads from the spark pl ugs and disconnect the ignition coil harness.

Harness

Connection

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

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

3.18

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

ENGINE

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

Loosen

Clamp

23. Disconnect the T-MAP and TPS harnesses (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.

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

NOTE: The Bosch harness connector and locking spring is bonded to the fuel injectors with an epoxy mix. DO NOT attempt to disconnect the Bosch 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.

Fuel

Injector

Disconnect Here

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

Harness

DO NOT

Disconnect Here

27. Disconnect the fuel line from the fuel injector rail.

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

Remove

Clip

3.19

ENGINE

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

Mark Upper

Jam Nut

Lower

Jam Nut

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.

32. Disconnect the stator / alternator harness.

Stator

Connector

33. Disconnect the transmission speed sensor harness.

Speed Sensor

Connector

Gear Switch

Connector

31. Disconnect the CPS harness.

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

CPS

Connector

Castle Nut

3.20

ENGINE

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

36. Pivot the A-arms up ward and rear hub carriers downw ard and remove the drive shafts from the hub carriers.

Hub Carrier

38. Disconnect the engine coolant temperature (ECT) sensor harness.

ECT

Connector

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

37. 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.

40. 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.

41. 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.

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

43. Remove the outer PVT cover.

3.21

ENGINE

44. Remove RH engine mount fastener.

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

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

Engine/Transmission

Mount Plate

Transmission/Gearcase

Mount Plate

Remove

(2) Lower Bolts

46. 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.

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.

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

Allow valve cover

to clear frame

3.22

ENGINE

49. Remove propshaft from the transmission output shaft.

50. 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.

51. Then lift assembly high enough to clear vehicle frame and completely remove it from the vehicle to a work bench.

Engine / Transmission Separation

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

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

Once the engine / transmission / rear gearcase assembly has been removed from the vehicle, the engine and transmission will need to be separated to allow engine servicing. Use the following procedure to separate the engine from the assembly.

1. Remove the drive belt, drive clutch and driven clutch (see Chapter 6).

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

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

3.23

ENGINE

ENGINE DISASSEMBLY AND INSPECTION

Cylinder Head Assembly Exploded View

Rocker Arms

Retainer Locks (keepers)

Spring Retainers

Springs

Push Rods

Valve Spring Seats

Cylinder Head

Valves

Valve Seals

Hydraulic Lifters

3.24

ENGINE

Rocker Arms

1. Remove the valve cover.

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

3. Inspect the wear pad at the valve end of the rocker arm for indications of scuffing or abnormal wear. If the pad is grooved, replace the rocker arm.

NOTE: Do not attempt to true this surface by grinding.

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

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

Cylinder Head Removal

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

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

2. Remove bolts (A) and tap cylinder head (B) ligh tly 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 solvent. 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.

WARNING

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).

3.25

ENGINE

Cylinder Head Inspection

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

CAUTION

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.

WARNING

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.

Measure at different

points on the surface.

Cylinder Head Warp Limit:

.004" (.1016 mm) max

= In. / mm.

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).

PU-45257

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.

ENGINE

Cylinder Head Disassembly

1. Carefully remove the cylinder components.

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

4. Remove valve guide seals.

IMPORTANT: It is recommended to replace seals whenever the cylinder head is disassembled. Hardened, cracked or worn valve seals will cause excessive oil consumption and carbon buildup.

5. Mark the valves with a white pen. Remove the valves from the cylinder head. This will ensure that the valves are properly placed during engine reassembly.

Mark the Valves

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

V alve Spring

Free Length

= In. / mm.

Valve Spring Free Length:

Std: 1.735" (44.069 mm)

3.27

ENGINE

Valve Inspection

1. Remove all carbon from valves with a soft wire 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).

= In. / mm.

Valve Stem Diameter:

Intake: 0.2356" + 0.00039"

(5.985 + 0.01 mm)

Exhaust: 0.2351" + 0.00039"

(5.972 + 0.01 mm)

6. 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.

4. Inspect split keeper groove for wear or flaring of the keeper seat area (B).

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

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

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

= In. / mm.

Valve Guide I.D.:

0.23672" + 0.000295" (6.0617 + 0.0075 mm)

7. 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.

3.28

ENGINE

Combustion Chamber

1. Clean all accumulated carbon deposits from combustion chamber and valve seat area with carbon cleaner and a soft plastic scraper.

IMPORTANT: Do not use a wire brush, metal scraper, or abrasive cleaners to clean the bottom of the cylinder head. Extensive damage to the cy linder head may result. Wear safety glasses during cleaning.

Combustion Area

NOTE: Valve seat width and point of contact on the valve face is very important for proper sealing. The valve must contact the valve seat over the entire circumference of the seat, a nd 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 overheat and warp, resulting in burnt valves.

Valve Seat Reconditioning

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

NOTE: The cylinder head valve guides cannot be replaced.

WARNING

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 Cylinder Head Reconditioning Kit (PN

2200634). 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.

3.29

ENGINE

4. Inspect the cut area of the seat: * If the contact area is less than 75% of the circumference of the

seat, rotate the pilot 180

* 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).

Proper Seat Contact

on Valve Face

Bottom 60

Seat 45

Top 30

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 an d 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-



Seat

Width

= In. / mm.

Valve Seat Width:

Intake Std: .028" (.7 mm)

Limit: .055" (1.4 mm)

Exhaust Std: .039I (1.0 mm)

Limit: .071" (1.8 mm)

3.30

ENGINE

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

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 in to its respective guide and lap using a lapping tool or a section of fuel line connected to the valve stem.

Cylinder Head Reassembly

NOTE: Assemble the valves one at a time to maintain proper order.

1. Apply engine oil to valve guides and seats.

2. Coat valve stem with molybdenum disulfide grease or 2W-50 Synthetic engine oil.

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

4. Valve seals should 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.

PU-45257

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).

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.

3.31

ENGINE

Valve Sealing Test

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

2. Pour 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 exhaust valves by pouring fluid into exhaust port.

Cylinder Removal

1. Follow 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 cylinder forward and backward while lifting it from the crankcase, supporting pistons and connecting rods. Support pistons with Piston Support Block (PN 2870390).

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

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

Mark Hydraulic Lifter

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.

3.32

Inspect Hydraulic Lifter

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.

ENGINE

Piston Removal

1. Remove circlip (A). 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.

Compression

Rings

Oil Ring

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

ENGINE

Cylinder Inspection

1. Remove all gasket material from the 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.

Measure at different

points on surface.

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

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

1/2” Down From Top of Cylinder

= In. / mm.

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

1/2” Up From Bottom

= In. / mm.

Cylinder Taper Limit: .002" (9.05mm) Max.

Cylinder Out of Round:

Limit: .002" (.0 mm) Max.

3.34

Standard Bore Size

(Both Cylinders): 3.1496" (80 mm)

Cylinder Hone Selection and Honing Procedure

Cylinders may be wet or dry honed depending upon the hone manufacturer’s recommendations. Wet honing removes more material faster and leaves a more distinct pattern in the bore.

CAUTION

ENGINE

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.

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

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.

Example of Cross Hatch Pattern

IMPORTANT: Clean the cylinder after honing

Cleaning the Cylinder After Honing

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

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

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

3.35

ENGINE

Piston-to-Cylinder Clearance

Measure piston outside diameter at a point 5 mm up from the bottom of the piston at a right angle to the direction of the piston pin.

Subtract this measurement from the maximum cylinder measurement obtained in Step 5.

5 mm

Piston

Piston Pin

Piston to Cylinder Clearance:

See “800 EFI Engine Service

Specifications” on page 3.9

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

Piston Pin Measurement Locations

Piston Pin O.D.:

See “800 EFI Engine Service

Specifications” on page 3.9

3. Measure connecting rod small end ID.

Piston O.D.:

See “800 EFI Engine Service

Specifications” on page 3.9

Piston / Rod Inspection

1. Measure piston pin bore.

Piston Pin Bore:

See “800 EFI Engine Service

Specifications” on page 3.9

Connecting Rod Small End I.D.:

See “800 EFI Engine Service

Specifications” on page 3.9

3.36

ENGINE

4. Measure piston ring to groove clearance by placing the ring in the ring land and measuring with a thickness gauge. Replace piston and rings if ring-to-groove clearance exceeds service limits.

Piston

Ring

Feeler Gauge

See “800 EFI Engine Service

Specifications” on page 3.9

Piston Ring Installed Gap

1. Place each piston ring (A) inside cylinder (B) using 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.

25-50 mm

Piston Ring Installed Gap

See “800 EFI Engine Service

Specifications” on page 3.9

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.

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

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

3.37

ENGINE

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

7. Inspect the bendix bushing (C) in the mag cover for wear. Replace as needed.

Flywheel / Stator Removal / Inspection

1. Remove stator housing bolts and remove housing.

Remove Stator

Cover

2871043

4. Use caution when removing the wire holddown (B) and th e

stator assembly (D). Do not tap or bump the gear /stator housing cover or the stator. This could cause the seal around the gear/stator housing cover and the crankcase to break, causing a leak.

5. Remove the bendix (E) if necessary.

2. Remove flywheel nut and washer.

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

CAUTION

Do not thread the puller bolts into the flywheel

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

3.38

Engine Crankcase Disassembly / Inspection

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

ENGINE

2. Remove the nylok nut (C), washer (D), and water pump impeller (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).

CAUTION

5. Remove the starter bendix (G), wire holddown plate (H), and the woodruff key (I) from the crankshaft. The stator does not have to be removed at this point.

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.

2871043

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

Camshaft Gear

Crank Gear

Counterbalance Gear

3.39

ENGINE

8. Use a white pen to accent the timing marks on the following gears: camshaft gear (K), crankshaft gear (M), or counterbalance gear (N) This will ensure proper gear alignment and timing during reassembly of the gears.

Water Pump Gear

Timing Marks

CAUTION

Wear safety glasses at all times. Use caution

when working with the top gear.

The springs could cause injury or become lost

should they pop out.

12. Remove all three springs using one of the tapered pins from

the Tapered Pins (PU-45497-1).

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) (O) to align the cam split gear assembly. With the split gear aligned, remove the bolt and cam gear assembly.

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

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.

3 Loaded Springs

PU-45497-1

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

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

mark side facing up.

• While holding both gears together, lightly work a small

flathead screwdriver between the two gears.

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

3.40

Accent Timing Marks

ENGINE

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

Inspect Teeth & Tabs

Replace 3 Springs

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

Install Springs

To Assemble:

• Hold the spring with one finger.

• Start the pointed end of the tapered pin into the cam gear hole. Slowly push the dowel through the hole until the end of the dowel is almost flush with the spring.

• Perform this procedure with all three tapered pins.

• Do not push the pins too far through or the springs will pop out.

NOTE: Do not remove the tapered pins at this time.

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

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

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

PU-45497-1

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.

Align Timing Marks

3.41

ENGINE

19. Once the gears are pressed together, firmly hold the gears together with one hand. Carefully remove the Tapered Pins (PU-45497-1) by pulling them out one at a time with the other hand.

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.

PU-45498

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 an d 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.

PU-45497-2

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

2871043

3.42

ENGINE

23. Inspect the crankshaft gear (Q) for broken or worn teeth. If the crankshaft gear does not need to be replaced, it does not need to be removed. If the crankshaft gear is damaged, remove the crankshaft gear with the Flywheel Puller

(PN 2871043).

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

26. Rotate the water/oil pump gear (S), so that all four bolts are visible though the gear. Remove the four bolts with a hex wrench. Pull out the pump.

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

Mark Rotors

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

crankshaft gear, if needed.

2871043

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).

Max Tip Clearance

0.006” (0.15 mm)

3.43

ENGINE

29. Remove the oil pressure relief. The oil pressure relief consists of a bolt, washer, spring, and valve (dowel). Inspect the valve (dowel) for signs of possible obstructions. Use compressed air to blow out any debris.

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

22 ± 2 ft. lbs. (30 ± 3 Nm).

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

Press Off Gear

CAUTION

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.

Chamfer End First

= T

22  2 ft. lbs. (30  3 Nm)

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

Press out shaft

and bearing

assembly.

Bearing

Retaining Ring

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

Press Off Bearing

3.44

ENGINE

34. Press shaft into the new bearing..

Press On Bearing

35. Press the bearing/shaft assembly using the bearing's outer race. Do not use the shaft to press the assembly into the housing, as bearing damage may result. Install retaining ring.

Press Bearing / Shaft

Assembly using

outer race only

37. Remove thrust plate (U).

38. Remove PTO end engine mount. Remove crankcase bolts. Tap on the reinforced areas on the cases using soft hammer. Carefully separate the two crankcase halves.

Separate

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 bolt s or to the crankcase casting.

.

3.45

ENGINE

39. Remove and clean oil pick up (V) and oil baffle weldment (W).

40. Remove balance shaft and crankshaft.

Camshaft Inspection

1. Thoroughly clean the cam shaft.

2. Visually inspect each cam lobe for wear, chafing or damage.

3. Measure height of each cam lobe using a micrometer. Compare to specification.

Cam Lobe Height

41. Remove and inspect crankshaft m ain journal bearings for

abnormal wear. It is recommended to replace the bearings anytime the engine is disassembled.

= In. / mm.

Cam Lobe Height

Intake (Std):

800 EFI: 1.334" (33.867 mm)

800 H.O. EFI: 1.357” (34.477 mm)

Exhaust (std.):

800 EFI: 1.334" (33.867 mm)

800 H.O. EFI: 1.342” (34.096 mm)

3.46

ENGINE

4. Measure camshaft journal outside diameters (O.D.).

= In. / mm.

Camshaft Journal O.D. :

A. (Mag): 1.654" ± .00039" (42 ± .010 mm)

B. (Ctr.): 1.634" ± .00039" (41.50 ± .010 mm)

C. (PTO): 1.614" ± .00039" (41 ± .010 mm)

ENGINE REASSEMBLY

Crankcase Reassembly

CAUTION

After any reassembly or rebuild, the engine

must be primed using the Oil Priming Adapter

(PU-45778) and a 3/4-full oil filter before initial

start-up (see “Oil Pump Priming”).

NOTE: Before assembly, clean the bolts and bolt holes with Primer N (PN 2874275) to remove any debris. This will ensure proper sealing when installing bolts.

1. Install oil pick up (A), if removed. Torque to specification.

5. Measure ID of camshaft journal bores.

= In. / mm.

Camshaft Journal Bore I.D.:

(Mag): 1.656" ± 0.00039" (42.07± 0.010 mm)

(Ct r. ) 1.637" ± 0 .00039" (4 1.58 ± 0.01 0 m m)

(PTO) 1.617" ± 0.00039" (41.07 ± 0.010 mm)

6. Calculate oil clearance by subtracting journal O.D.s from journal bore I.D.s. Compare to specificati o n.

= In. / mm.

Calculated Camshaft Oil Clearance:

Std: 0.0027" (.070mm) Limit: .0039" (.10 mm)

NOTE: Replace camshaft if damaged or if any part is worn past the service limit.

2. Install oil baffle weldment (B). Torque bolts to specification.

= T

Oil Baffle Weldment & Oil Pick Up Bolt Torque:

60 ± 6 in. lbs. (6.8 ± 0.68 Nm)

3. Install the balance shaft. Inspect balance shaft clearance (C) in both gearcase halves. Rotate balance shaft to ensure there is clearance between it and the oil baffle weldment.

NOTE: Replace engine block if camshaft journal bores are damaged or worn excessively.

3.47

ENGINE

NOTE: Always install new balance shaft bearings.

4. Apply assembly lube to cam journals and balance shaft bearing surfaces of the MAG case halve. Install camshaft and balance shaft.

5. Install crankshaft assembly and apply engine oil to crank pins and rods (D). Apply assembly lube to the main journals and bearings.

7. Assemble the crankcase halves. Apply LocTite™ 242 (PN

2871949) to the threads and pipe sealant to the bolt flanges. Torque bolts to specification following torque pattern at beginning of this chapter.

= T

Crankcase Bolt Torque:

22 + 2 ft. lbs. (30 + 3 Nm)

Torque in sequence

8. Lubricate cam lobes and valve lifters with Moly Lube Grease.

Apply Moly Lube

Cam Lobes

6. Apply Crankcase Sealant (PN 2871557) to the top gearcase

halve.

NOTE: Do not apply sealant to cam relief hole (E).

Lifters

9. Lubricate lifters with engine oil and install in the original order as removed in disassembly. Apply Lubricant or Moly Lube to the ends of the lifters.

NOTE: Always re place the camshaft and lifters as a set.

3.48

ENGINE

10. Lubricate connecting rods with 2W-50 synthetic engine oil.

11. Install new cylinder gasket on crankcase. Align gasket on the dowel pins for proper gasket alignment.

13. Install piston assemblies into cylinder alig ning the piston pin holes, to ensure proper alignment of the pistons to the connecting rods upon assembly. Partially install the piston pins into the pistons.

NOTE: To help align the pistons, slide a rod that is close to the same diameter as the wrist pin holes to properly align them in the cylinder.

14. Position cylinder and piston assemblies onto the connecting rods and push the piston pins through the piston and connecting rods.

12. Orientate the piston rings on the piston before inst allation into the cylinders. Set the gaps of the rings every 120° (See Illustration Below).

Piston Ring

Orientation

1. Top Ring

2. Second Ring

3. Oil Ring

2 3

Push in Piston Pins

15. Install the piston pin circlips. The circlip ends should be installed at the 12 O'clock position.

Piston Pin Cirlcip in

12 O’clock position

3.49

ENGINE

NOTE: While installing in piston circlips, cover all engine passages. The clip could fall into the engine during installation.

16. Install camshaft thrust plat e (G) with new bolts. Torque bolts to specification.

NOTE: New bolts have patch lock on the threads and do not require Loctite™.

17. Assemble rotors as marked when disassembled. Use a cleaner to remove the marks previously made on the rotors.

Line Up Marks

18. Apply assembly lube or oil to the rotors on the oil pump shaft.

NOTE: The application of lubrication aids in priming the oil pump during initial engine start up.

Lubricate Rotors

= T

Thrust Plate Screw Torque:

115 ± 12 in.lbs. (13 ± 1.35 Nm)

19. Align the bolt holes and install oil pump assembly into crankcase. Rotate the rotors in the housing during installation, as this checks for binding if new rotors are used.

NOTE: For assembly of the gears, the cam gear and the crankshaft gear are stamped with “This Side Out." This indicates the side of the gear that faces outward or away from the case.

3.50

NOTE: Before assembly, clean the bolts and bolt holes with Primer N (PN 2874275) to remove any debris. This will ensure proper sealing when installing bolts and new Loctite™.

ENGINE

20. Install oil pump housing bolts (H). The new bolts contain patch lock, so Loctite Torque bolts to specification and follow the torque sequence at beginning of the chapter.

 is not needed on the new bolts.

NOTE: Occasionally spin the oil pump when installing bolts to check for binding of the rotors.

= T

Oil Pump Bolt Torque:

84  8 in.lbs. (9.50  0.90 Nm)

* Torque in Sequence

21. Apply Loctite 242 (PN 2871949) to the crankshaft.

22. Before installing the crankshaft gear (I), heat the crankshaft gear to 250

 F (121C) on a hot plate (J).

CAUTION

The crankshaft gear is extremely hot! Severe

burns or injury can occur if the gear is not

handled with extreme care and caution. Follow

the procedure below to help ensure safety.

23. Use extreme caution when removing the crankshaft gear from the hot plate. Use a pair of pliers and leather gloves when handling the crankshaft gear.

24. Install the crankshaft gear (I) onto the crankshaft.

NOTE: For assembly of the gears, the cam gear and the crankshaft gear are stamped with This Side Ou t." This indicates the side of the gear that f aces outwar d or away from the case.

3.51

ENGINE

25. Install counter balance shaft gear (J) with new key, aligning timing marks with crankshaft gear (I). Install washer and bolt. Use the Gear Holder (PU-45838). Torque to specification.

PU-45838

= T

Balance Shaft Gear Bolt Torque:

22  2 ft. lbs. (30  3 Nm)

NOTE: Cam Spanner Wrench (PU-45498) is only needed to rotate the camshaft when the entire valve train is assembled.

PU-45498

27. Reinstall the camshaft gear; so the timing marks are properly aligned. Install the washer and bolt. Torque to specification.

NOTE: Be sure all of the timi ng marks are properly aligned.

26. Use the Cam Gear Alignment Tool (PU-45497-2) to align

the teeth of the cam gear (M). Install the cam gear (M) (with the Cam Gear Alignment Tool still in place) onto the camshaft. The timing marks on the camshaft gear should align with the keyway on the balance shaft gear.

PU-45497-2

NOTE: If the timing mark on the camshaft gear does not align properly, remove the camshaft gear and tool. Use the Cam Spanner Wrench (PU-45498) to rotate the cam to the proper position.

Timing Marks

Water Pump Gear

Timing Marks

3.52

= T

Counterbalance Gear and Camshaft

Gear Bolt Torque:

22  2 ft. lbs. (30  3 Nm)

ENGINE

28. Before installing the gear / stator housing, replace the seals in the cover. Install a new water pump seal (N) into the gear / stator housing. Use the Water Pump Mechanical Seal Installer (PA-44995) to properly install the seal to the correct depth in the cover.

PA-44995

IMPORTANT: Due to seal design and construction, seals MUST be installed DRY (no lubricant) during assembly. Use of lubricants (oil, soapy water, etc.) will not allow the seal to wear-in and seal properly. Do not touch seal surface or allow seal surface to come in contact with contaminates during installation. Thoroughly clean parts, tools and hands before installation.

NOTE: Install the crankshaft seal (P) with the seal lip facing out (towards the crankcase).

Seal lip goes towards the crankcase.

30. Once the crankshaft seal is installed into the gear / stator housing cover, set the direction of the paper lip by sliding the Main Crankshaft Seal Saver (PA-45658) into the crankshaft seal from the rubber lipped side to the paper lip side (Back to Front). Remove the tool.

Important: Set the direction

of the paper lip seal

PU-45658

NOTE: To remove the water pump seal, the gear/ stator housing must be removed. The water pump seal cannot be removed or installed with the gear/ stator housing attached to the engine. Shaft damage will occur.

NOTE: Install the water pump seal (N) with the seal lip facing out (towards the crankcase). Use of a hydraulic press is recommended for this procedure.

29. Install a new crankshaft seal (P) into the gear/stator housing

cover. Use the Universal Driver Handle (PU-45543) and the Main Seal Installer (PA-45483) to seat the crankshaft seal into place.

PU-45543

PA-45483

31. Carefully install the tapered end of the Crankshaft Seal Protection Tool (PA-45658) through the paper side of the crankshaft seal (Back to Front). Leave the seal protector installed in the crankshaft seal. Check the crankshaft seal lips to verify they have not been rolled or damaged.

PU-45658

3.53

ENGINE

32. Before installing the gear/stator housing cover, inst all the

Water Pump Seal Saver (PA-45401) onto the water pump shaft.

PA-45401

33. Install a NEW gasket to the gear/stator housing cover and crankcase. With the tools installed, carefully place the gear/stator housing cover over the protection tools.

35. Install the gear/stator housing gasket onto he crankcase.

Gear / Stator

Housing Gasket

34. Apply Crankcase Sealant (PN 2871557) to the outside edges of the crankcase halves (see arrows), where the crankcases mate (see the following photos). This helps to prevent coolant leakage.

36. Secure the gear / stator housing cover to the crankcase with the cover bolts. Torque bolts in proper sequence to specification. Remove seal protectors from the shaft ends once the cover is secure.

PA-45401

PA-45658

= T

Gear/Stator Housing Bolt Torque:

96  3 in. lbs. (10.85  0.35 Nm)

*Torque in proper sequence

3.54

POLARIS RZR User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

GENERAL INFORMATION

GENERAL INFORMATION

MODEL INFORMATION

Model Identification

Engine Designation Number

VIN Identification

Engine Serial Number Location

Unit Serial Number (VIN) Location

VEHICLE INFORMATION

Publication Numbers

Paint Codes

Replacement Keys

SPECIAL TOOLS

GENERAL SPECIFICATIONS

MODEL: 2009 RANGER RZR

MODEL: 2009 RANGER RZR

MISC. SPECIFICATIONS AND CHARTS

Conversion Table

Standard Torque Specifications

SAE Tap / Drill Sizes

Decimal Equivalents

Metric Tap / Drill Sizes

Glossary of Terms

MAINTENANCE

MAINTENANCE

PERIODIC MAINTENANCE CHART

Periodic Maintenance Overview

Break-In Period

Maintenance Chart Key

Pre-Ride - 25 Hour Maintenance Interval

50 - 300 Hour Maintenance Interval

COMPONENT INSPECTION / SERVICE LOCATIONS

Front and Rear View

RH and LH Side Views

LUBRICANTS / SERVICE PRODUCTS

Polaris Lubricants, Maintenance and Service Products

MAINTENANCE REFERENCES

GENERAL VEHICLE INSPECTION AND MAINTENANCE

Pre-Ride / Daily Inspection

Shift Cable Inspection / Adjustment

Frame, Nuts, Bolts, and Fasteners

FUEL SYSTEM AND AIR INTAKE

Fuel System

Fuel Pump / Fuel Filters

Fuel Line

Vent Lines

Throttle Pedal Inspection

Throttle Freeplay Adjustment

Throttle Cable Replacement

Air Filter Service

ENGINE

Engine Oil Level

Engine Oil and Filter Service

Engine Breather Hose Inspection

Engine and Transmission Mount Locations

Exhaust - Spark Arrestor

Compression and Leakdown Test

TRANSMISSION AND GEARCASES

Transmission / Gearcase S pecification Chart

Transmission Lubrication

Front Gearcase Lubrication

Rear Gearcase Lubrication

COOLING SYSTEM

Cooling System Overview

Coolant Level Inspection

Coolant Strength / Type

Cooling System Pressure Test

Cooling System Hoses

Coolant Drain / Radiator Removal

Radiator

FINAL DRIVE / WHEEL AND TIRE

Wheel, Hub, and Spindle Torque Table

Wheel Removal

Wheel Installation

Tire Inspection

Tire Pressure