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

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