POLARIS RZR User Manual

GENERAL INFORMATION

CHAPTER 1 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

Emissions &

Model Option

Designation

Basic Chassis

Engine Designation

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

Vehicle Description

Vehicle Identifier

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

}

Model

Engine

Year

Individual

Serial No.

Body Style

Emissions

Plant

No.

* This could be either

Powertrain

Check Digit

a number or a letter

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

GENERAL INFORMATION

Unit Serial Number (VIN) Location

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.

A

A

1

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

B

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 service parts be sure to use the correct parts manual.

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

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		Series#	Part Number
		20	4010278
P/N 5533534
		21	4010278
		22	4010321
		23	4010321
Key Series		27	4010321
		28	4010321
Number
		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 INFORMATION

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	25 lbs. / 11.3 kg
	Capacity
	Cargo Box Dimension	42 in. x 22 in. / 107 cm x 56 cm
	Cargo Box Capacity	300 lbs. / 136 kg
	Maximum Weight	740 lbs. / 336.4 kg
		(Includes rider(s), cargo, accessories
	Capacity (Payload)
		and trailer tongue weight)
	Hitch Towing Capacity	1500 lbs. / 680 kg
	Hitch Tongue Capacity	150 lbs. / 68 kg

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	25 lbs. / 11.3 kg
	Capacity
	Cargo Box Dimension	42 in. x 22 in. / 107 cm x 56 cm
	Cargo Box Capacity	300 lbs. / 136 kg
	Maximum Weight	740 lbs. / 336.4 kg
		(Includes rider(s), cargo, accessories
	Capacity (Payload)
		and trailer tongue weight)
	Hitch Towing Capacity	1500 lbs. / 680 kg
	Hitch Tongue Capacity	150 lbs. / 68 kg

1

1.5

GENERAL INFORMATION

MODEL: 2009 RANGER RZR

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

	Engine
	Platform	Polaris Domestic Twin Cylinder,
		Liquid Cooled, 4-Stroke
	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
	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	7 gal. (26.5 liters)
		87 Octane (minimum)
	Electrical
	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	Champion RC7YC3 /
		.035 in. (0.9 mm)
	Battery	Yuasa YTX20HL /
		18 Amp Hr. / 310 CCA / 12 Volt
	Instrument Type	Analog Speedometer
		with Multifunction LCD
	DC Outlet	Standard 12 V
	Relays	EFI / Fan
	Circuit Breaker	Fan Motor: 20 Amp
		Chassis: 20 Amp
		EFI: 15 Amp
	Fuses	Lights: 15 Amp
		Accessory: 15 Amp
		Speedo/ECU: 5 Amp

				Drivetrain
	Transmission Type					Polaris Automatic PVT
	Gear Ratio: Front / Rear
		High				3.14:1
		Low				8.71:1
		Rev				5.94:1
	Drive Ratio - Front					3.82:1
	Drive Ratio - Final					3.70:1
		Shift Type			In Line Shift - H / L / N / R / P
	Front Gearcase Oil Requirements					Polaris Demand Drive LT
						Premium Fluid
						6.75 oz. (200 ml)
	Transmission Oil Requirements				Polaris High Performance AGL
		Main Gearcase				24 oz. (710 ml)
	Transmission Oil Requirements				Polaris High Performance AGL
		Transfer Case				14 oz. (414 ml)
	Rear Gearcase Oil Requirements					Polaris Premium ADF
						26 oz. (769 ml)
		Belt				3211113
		Steering /			Suspension
		Front Suspension				Independent Dual A-arm
						w/Anti-Sway Bar
		Front Travel				9 in. / 23 cm
		Rear Suspension			Rolled IRS w/Anti-Sway Bar
		Rear Travel				9.5 in. / 24 cm
	Shock Preload Adjustment					Cam Adjustment
		Front / Rear
		Toe Out				1/8-1/4 in. / 3-6.35 mm
				Wheels	/ Brakes
		Front Wheel Size				12 x 6 / 10 gauge
		Front Tire Size				Maxxis / 25 x 8 R12
		Rear Wheel Size				12 x 8 / 10 gauge
		Rear Tire Size				Maxxis / 25 x 10 R12
	Tire Air Pressure - Front / Rear					8 psi (55 kPa)
	Brake - Front / Rear					Foot Actuated - 4 Wheel
						Hydraulic Disc
		Brake Fluid				DOT 4
CLUTCH CHART
	Altitude			Shift Weight		Drive Spring	Driven
							Spring
		0-1500		20-62		Blue / Red	Red or Yellow
	Meters	(0-5000)		(5631700)		(7043199)	(3234452)
	(Feet)	1500-3700		20-58		Blue / Red	Red or Yellow
		(5000 - 12000)		(5631216)		(7043199)	(3234452)

1.6

GENERAL INFORMATION

MODEL: 2009 RANGER RZR “S”
						Drivetrain				1
MODEL NUMBER: R09VH76AX			Transmission Type					Polaris Automatic PVT
ENGINE MODEL: EH076OLE072			Gear Ratio: Front / Rear
				High				3.14:1
Engine
				Low				8.71:1
Platform	Polaris Domestic Twin Cylinder,			Rev				5.94:1
	Liquid Cooled, 4-Stroke
			Drive Ratio - Front					3.82:1
Engine Model Number	EH076OLE072
			Drive Ratio - Final					3.70:1
Engine Displacement	760cc HO
				Shift Type			In Line Shift - H / L / N / R / P
Number of Cylinders	2
								Polaris Demand Drive LT
Bore & Stroke (mm)	80 x 76.5 mm		Front Gearcase Oil Requirements					Premium Fluid
Compression Ratio	11:1							6.75 oz. (200 ml)
			Transmission Oil Requirements				Polaris High Performance AGL
Compression Pressure	165-185 psi
				Main Gearcase				24 oz. (710 ml)
Engine Idle Speed	1250 ± 100 RPM
			Transmission Oil Requirements				Polaris High Performance AGL
Engine Max Operating RPM	6600 ± 200 RPM
				Transfer Case				14 oz. (414 ml)
Lubrication	Pressurized Wet Sump
			Rear Gearcase Oil Requirements					Polaris Premium ADF
Oil Requirements	PS-4 PLUS / 2W-50 Synthetic
								26 oz. (769 ml)
Oil Capacity	2 qts. / 1.9 liters
				Belt				3211130
Coolant Capacity	4.8 qts. / 4.5 liters
				Steering / Suspension
Overheat Warning	Instrument Cluster Indicator
			Front Suspension / Shock					Independent Dual A-arm
Exhaust System	Dual Headpipe / Single Silencer							FOX™ PODIUM X
Fuel	System			Front Travel				12 in. / 30.5 cm
Fuel System Type	Bosch Electronic Fuel Injection		Rear Suspension / Shock				Rolled IRS w/Anti-Sway Bar
								FOX™ PODIUM X
Fuel Delivery	Electronic Fuel Pump (in tank)
				Rear Travel				12 in. / 30.5 cm
Fuel Pressure	39 psi
			Shock Preload Adjustment				Threaded Shock Adjustment
Fuel Filters	See Chapter 4
				Front / Rear				with Spanner Wrench
Fuel Capacity / Requirement	7 gal. (26.5 liters)
	87 Octane (minimum)			Toe Out				1/8-1/4 in. / 3-6.35 mm
Electrical						Wheels / Brakes
Alternator Max Output	500 Watts @ 3000 RPM			Front Wheel Size				12 x 6 / Cast Aluminum
				Front Tire Size			Maxxis Bighorn / 26 x 9 R12
Lights: Main Headlights	2 - Single Beam 55 W / Halogen
				Rear Wheel Size				12 x 8 / Cast Aluminum
Tail / Brake	2 - 5 Watts / 2 - 5 Watts
				Rear Tire Size			Maxxis Bighorn / 26 x 12 R12
Starting System	Electric Start
			Tire Air Pressure - Front / Rear					8 psi (55 kPa)
Ignition System	Bosch EFI (ECU Controlled)
			Brake - Front / Rear					Foot Actuated - 4 Wheel
Ignition Timing	13° BTDC @ 1200 RPM
								Hydraulic Disc
	Champion RC7YC3 /
Spark plug / Gap				Brake Fluid				DOT 4
	.035 in. (0.9 mm)
			CLUTCH CHART
Battery	Yuasa YTX20HL /
	18 Amp Hr. / 310 CCA / 12 Volt
Instrument Type	Analog Speedometer		Altitude			Shift Weight		Drive Spring	Driven
									Spring
	with Multifunction LCD
				0-1500		21-74		Red / White	Red or Yellow
DC Outlet	Standard 12 V
			Meters	(0-5000)		(5632117)		(7043349)	(3234452)
Relays	EFI / Fan
			(Feet)
				1500-3700		21-70		Red / White	Red or Yellow
Circuit Breaker	Fan Motor: 20 Amp			(5000 - 12000)		(5632127)		(7043349)	(3234452)
	Chassis: 20 Amp
	EFI: 15 Amp
Fuses	Lights: 15 Amp
	Accessory: 15 Amp
	Speedo/ECU: 5 Amp

1.7

GENERAL INFORMATION

MISC. SPECIFICATIONS AND CHARTS

Conversion Table

°C to °F: 9/5(°C + 32) = °F

°F to °C: 5/9(°F - 32) = °C

1.8

GENERAL INFORMATION

Standard Torque Specifications

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

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 windings. 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

1.11

GENERAL INFORMATION

NOTES

1.12

MAINTENANCE

CHAPTER 2

MAINTENANCE

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PERIODIC MAINTENANCE CHART	. . . . . . .	2.3	2
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.

2

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

Severe Use Definition

•Frequent immersion in mud, water or sand

•Racing or race-style high RPM use

•Prolonged low speed, heavy load operation

•Extended idle

•Short trip cold weather operation

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

Break-In Period

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

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

•Pull only light loads.

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

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

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

Maintenance Chart Key

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

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

= SEVERE USE ITEM: See information provided above.

E = Emission Control System Service (California).

NOTE: Inspection may reveal the need for replacement parts. Always use genuine Polaris parts.

WARNING

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

2.3

MAINTENANCE

Pre-Ride - 25 Hour Maintenance Interval

				Maintenance Interval
		Item		(whichever comes first)		Remarks
			Hours	Calendar	Miles
					(KM)
		Steering	-	Pre-Ride	-
		Front Suspension	-	Pre-Ride	-
		Rear Suspension	-	Pre-Ride	-
		Tires	-	Pre-Ride	-
		Brake Fluid Level	-	Pre-Ride	-	Make adjustments as needed.
		Brake Pedal Travel	-	Pre-Ride	-
						See Pre-Ride Checklist on Page 2.9.
		Brake Systems	-	Pre-Ride	-
		Wheels / Fasteners	-	Pre-Ride	-
		Frame Fasteners	-	Pre-Ride	-
	E	Engine Oil Level	-	Pre-Ride	-
	E	Air Filter / Pre-Filter	-	Pre-Ride	-	Inspect; clean often; replace as needed
		Coolant Level	-	Daily	-	Check level daily, change coolant every 2
						years
		Head Lamp / Tail Lamp	-	Daily	-	Check operation; apply dielectric grease if
						replacing
		Air Filter,	-	Weekly	-	Inspect; replace as needed
	E	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	25 H	Monthly	250 (400)	Inspect level; change yearly
		(Demand Drive Fluid LT)
		Rear Gearcase Oil	25 H	Monthly	250 (400)	Inspect level; change yearly
		(ATV Angle Drive Fluid)
		Transmission - Main	25 H	Monthly	250 (400)	Inspect level; change yearly
		(AGL Gearcase Lubricant)
		Transmission - Transfer	25 H	Monthly	250 (400)	Inspect level; change yearly
		(AGL Gearcase Lubricant)
		Engine Breather	25 H	Monthly	250 (400)	Inspect; replace if necessary
	E	Filter (if equipped)
		Engine Oil Change	25 H	1 M	250 (400)	Perform a break-in oil change at one month
	E	(Break-In Period)

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		(whichever comes first)			Remarks
		Hours	Calendar	Miles
				(KM)			2
	Throttle Cable / Throttle					Inspect; adjust; lubricate; replace if
		50 H	6 M	300	(500)
E	Pedal					necessary
E	Throttle Body Air Intake	50 H	6 M	300	(500)	Inspect ducts for proper sealing / air leaks
	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)	Inspect coolant strength seasonally;
						pressure test system yearly
						Check for leaks at tank cap, fuel line, fuel
E	Fuel System	100 H	12 M	600 (1000)		pump, and fuel rail.
						Replace lines every two years.
E	Spark Plug	100 H	12 M	600 (1000) Inspect; replace as needed
						Perform a break-in oil change at 25 hours or
E	Engine Oil & Filter Change	100 H	6 M	1000	(1600)	one month / always replace oil filter when
						changing engine oil
	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
						Inspect for wear, routing, security; apply
	Wiring	100 H	12 M	1000	(1600)	dielectric grease to connectors subjected to
						water, mud, etc.
	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		-			Inspect periodically; adjust when parts are
						replaced
	Headlight Aim		-			Adjust as needed

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

EEmission 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

Standard RZR Shown

2.6

RH and LH Side Views

Standard RZR Shown

Standard RZR Shown

*Standard RZR Only

MAINTENANCE

2

2.7

MAINTENANCE

LUBRICANTS / SERVICE PRODUCTS

Polaris Lubricants, Maintenance and Service

Products

	Part No.	Description
		Engine Lubricant
	2870791	Fogging Oil (12 oz. Aerosol)
	2876244	PS-4 PLUS Performance Synthetic 2W-50
		4-Cycle Engine Oil (Quart)
	2876245	PS-4 PLUS Performance Synthetic 2W-50
		4-Cycle Engine Oil (Gallon)
	Gearcase / Transmission Lubricants
	2873602	AGL - Synthetic ATV Gearcase Lubricant
		(1 Qt.) (12 Count)
	2873603	AGL - Synthetic ATV Gearcase Lubricant
		(1 Gal.) (4 Count)
	2873604	AGL - Synthetic ATV Gearcase Lubricant
		(2.5 Gal.) (2 Count)
	2871653	ATV Angle Drive Fluid
		(8 oz.) (12 Count)
	2872276	ATV Angle Drive Fluid
		(2.5 Gal) (2 Count)
	2871654	Premium Demand Drive Fluid LT
		(1 Qt.) (12 Count)
	2870465	Oil Pump for 1 Gallon Jug

Grease / Specialized Lubricants

	2871312	Grease Gun Kit
	2871322	Premium All Season Grease
		(3 oz. cartridge) (24 Count)
	2871423	Premium All Season Grease
		(14 oz. cartridge) (10 Count)
	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™)
		Coolant
	2871323	60/40 Coolant (Gallon) (6 Count)
	2871534	60/40 Coolant (Quart) (12 Count)

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

Part No.	Description

Additives / Sealants / Thread Locking Agents / Misc.

	2870585	Loctite™ Primer N, Aerosol, 25 g
	2871956	Loctite™ Thread Sealant 565
		(50 ml.) (6 Count)
	2871949	Loctite™ Threadlock 242
		(50 ml.) (10 Count)
	2871950	Loctite™ Threadlock 242
		(6 ml.) (12 Count)
	2871951	Loctite™ Threadlock 262
		(50 ml.) (10 Count)
	2871952	Loctite™ Threadlock 262
		(6 ml.) (12 Count)
	2871953	Loctite™ Threadlock 271
		(6 ml.) (12 Count)
	2871954	Loctite™ Threadlock 271
		(36 ml.) (6 Count)
	2870584	Loctite™ 680-Retaining Compound
		(10 ml.)
	2870587	Loctite™ 518 Gasket Eliminator / Flange
		Sealant (50 ml.) (10 Count)
	2871326	Premium Carbon Clean
		(12 oz.) (12 Count)
	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)

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

2.8

					MAINTENANCE
	MAINTENANCE REFERENCES
	Item	Ref.	Rec. Lube / Fluid	Method	Frequency*
					Change after 25 hrs, and then
			Polaris PS-4 PLUS		6 months or 100 hours	2
				Add oil to proper level on	thereafter; Change more
	Engine Oil	Page 2.7	Performance Synthetic
				dipstick.	often in extremely dirty
			2W-50 4-Cycle Engine Oil
					conditions, or short trip cold
					weather operation.
	Engine Coolant	Page 2.6	Polaris Antifreeze 60/40	Fill recovery bottle between	Fill as required. Change
			(PN 2871534)	MAX and MIN lines.	coolant every 2 years.
	Brake Fluid	Page 2.7	DOT 4 (PN 2872189)	Fill reservoir between MAX	Fill as required. Change
				and MIN lines.	brake fluid every 2 years.
	Transmission	Page 2.7	AGL Synthetic Gearcase	Add lube to bottom of fill	Change annually***
	(Main Gearcase)		Lubricant (PN 2873602)	plug threads. 24 oz. (710 ml)
	Transmission		AGL Synthetic Gearcase	Add lube to bottom of level
		Page 2.7		check plug threads.	Change annually***
	(Transfer Case)		Lubricant (PN 2873602)
				14 oz. (414 ml)
			Premium Demand Drive	Add fluid to bottom of fill
	Front Gearcase	Page 2.7		plug threads.	Change annually***
			Fluid LT (PN 2876251)
				6.75 oz. (200 ml)
	Rear Gearcase	Page 2.7	ATV Angle Drive Fluid	Add lube to bottom of fill	Change annually***
			(PN 2871653)	plug threads. 26 oz. (769 ml)
	Prop Shaft	Page 2.7	Polaris Premium U-Joint	Locate fitting and grease with	Semi-annually**
			Lube (PN 2871551)	grease gun.
				Locate grease fittings on the
				upper and lower A-arms of
	ControlArmPivot	Page 2.6	Polaris Premium All Season	the front and rear suspension	Semi-annually**
	Bushings, FT / RR		Grease (PN 2871423)	and grease with grease gun.
				(4) Front A-arms
				(6) Rear A-arms
				Locate grease fittings on the
	Stabilizer Bar		Polaris Premium All Season	front and rear stabilizer bars
		Page 2.7		and grease with grease gun.	Semi-annually**
	Bushings, FT / RR		Grease (PN 2871423)	(2) Front Stabilizer Bar
				(2) Rear Stabilizer Bar

* 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.

Frame, Nuts, Bolts, and Fasteners

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

Shift Cable Inspection / Adjustment

Shift cable adjustment may be necessary if symptoms include:

•No AWD or gear position display on instrument cluster

•Ratcheting noise on deceleration

•Inability to engage into a gear

•Excessive gear clash (noise)

•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

Dust Boot

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

JamNut

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.

2.10

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.

Fuel Line

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

2.Be sure fuel line is routed properly.

IMPORTANT: Make sure line is not kinked or pinched.

3.Replace fuel line every two years.

Fuel Pump / Fuel Filters	2
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

Preliminary Filter

	Injector Rail
Fuel Line	Connector

Fuel Pump

Connector

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

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

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.

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.

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

2.12

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 throttle cable bracket to the frame support.

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

2

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

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 cable 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 insert 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.

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.

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 proper throttle operation.

Air Filter Service

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

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

2.14

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	2
	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

	Front
Intake Box	Foam Seal

	Air Intake Duct
Foil		Primary
Breather		Foam Seal
Hose		Intake Seal
T-MAP
Sensor	Fitting	Seal
		Breather
		Filter
Boot

Cap

	Pre-Filter	Seal
Air Filter	Sleeve

Clip (3)

Clamps

Air Box Can

Filter Ring

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.

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

Dipstick

Lever Lock

Lever Lock

Dipstick

SAFE

ADD 8 OZ

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

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

7.Remove 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 the dipstick as it is being removed, regardless of the level marks being on top or on bottom (see the next illustration).

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.

2.16

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: 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.

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	2
	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.

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 positioned in PARK (P).

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

17.Stop the engine and inspect for leaks.

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

19.Dispose of used oil and oil filter properly.

2.17

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

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.

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.

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

2.18