Polaris Rzr4 2011 Rzr4

Polaris RZR, RZR 4, RZR S User Manual

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2011 RANGER RZR / RZR S / RZR 4

SERVICE MANUAL

PN 9923142

2011 RZR / RZR S / RZR 4RANGER

SERVICE MANUAL

FOREWORD

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



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

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

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

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

technicians in a properly

Publication Printed September 2010 (PN 9923142) Rev 1

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

UNDERSTANDING MANUAL SAFETY LABELS AND DIRECTIONS

WARNING

CAUTION

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

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

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

CAUTION

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

NOTE:

NOTE provides key information by clarifying instructions.

IMPORTANT:

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

TRADEMARKS

POLARIS ACKNOWLEDGES THE FOLLOWING PRODUCTS MENTIONED IN THIS MANUAL: Loctite, Registered

Trademark of the Loctite Corporation Nyogel, Trademark of Wm. F. Nye Co. Fluke, Registered Trademark of John Fluke Mfg.

Co. Mity-Vac, Registered Trademark of Neward Enterprises, Inc. Torx, Registered Trademark of Textron Hilliard, Trademark of

the Hilliard Corporation Warn, Trademark of Warn Industries FOX, Registered Trademark of FOX RACING SHOX RydeFX,

Registered Trademark of ArvinMeritor Some Polaris factory publications can be downloaded from www.polarisindustries.com,

purchased from www.purepolaris.com or

by contacting the nearest Polaris dealer.

GENERAL INFORMATION

MAINTENANCE

ENGINE

ELECTRONIC FUEL INJECTION

BODY / STEERING / SUSPENSION

CLUTCHING

FINAL DRIVE

TRANSMISSION

BRAKES

ELECTRICAL

GENERAL INFORMATION

CHAPTER 1

GENERAL INFORMATION

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

9923142 - 2011 RZR / RZR S / RZR 4 Service ManualRANGER

1.1

GENERAL INFORMATION

}

Machine Model Number Identification

}

Model Year Designation

Basic Chassis

Designation

Engine Designation

Emissions & Model Option

R 1 1 V H 7 6 A D

}

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

}

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

World

Mfg. ID

Engine

Vehicle Description

Vehicle Identifier

Check Digit

Model

Year

Body Style

Plant No.

Individual Serial No.

* This could be either

a number or a letter

Powertrain

Emissions

VIN

Figure 1-1

Engine Serial

Figure 1-2

Number

MODEL INFORMATION

Model Identification

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

Engine Designation Number

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

VIN Identification

V e hicle and Engine Serial Number Location

Whenever corresponding about a Polaris ORV, refer to the vehicle identification number (VIN) and the engine serial number.

The VIN can be found stamped on a portion of the front left frame rail, close to the left front wheel (see Figure 1-1). The

engine model and serial number can be found on a decal applied to the cylinder on the side of the engine (see Figure 1-2).

1.2

9923142 - 2011 RZR / RZR S / RZR 4 Service ManualRANGER

GENERAL INFORMATION

VEHICLE INFORMATION

Publication Numbers

Model Model No. Owner’s Manual Parts Manual

2011 RZR R11VH76AA, AD, AF, AH 9922973 9922974

2011 RZR EPS R11VY76AO 9922973 9922974

2011 RZR S R11VE76AC, AD, AW 9922973 9923141

2011 RZR S EPS INT’L R11VM76FX 9922973 9922977

2011 RZR 4 R11XH76AW 9923148 9923149

2011 RZR 4 EPS R11XY76AA 9923148 9923149

RANGER

NOTE: When ordering service parts be sure to use the correct parts manual. NOTE: Polaris factory

publications can be found at www.polarisindustries.com or purchased from www.purepolaris.com.

Replacement Keys

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

Key Series Number

KEY COVER P/N 5533534

key and refer to the chart to the right for the proper part number.

Series# Part Number

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

SPECIAL TOOLS

Special tools may be required while servicing this vehicle. Some of the tools listed or depicted are mandatory, while other tools maybe substituted with a similar tool, if available. Polaris recommends the use of Polaris Special Tools when servicing any Polaris product. Dealers may order special tools through Polaris’ official tool supplier, SPX Corporation, by phone at 1-800-3286657 or on-line at http://polaris.spx.com/.

1.3

9923142 - 2011 RZR / RZR S / RZR 4 Service ManualRANGER

GENERAL INFORMATION

GENERAL SPECIFICATIONS

MODEL: 2011 RZRRANGER

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

Category Dimension / Capacity

Length 103 in. / 261.6 cm

Width 50 in. / 127 cm

Height 69 in. / 175.3 cm

Wheel Base 77 in. / 196 cm

Ground Clearance 10 in. / 25.4 cm

Dry Weight 945 lbs. / 429 kg

Gross Vehicle Weight 1727 lbs. / 783 kg

Front Storage Capacity Cargo Box Dimension 42 in. x 22 in. / 107

cm x 56 cm Cargo Box Capacity 300 lbs. /

136 kg

Maximum Weight Capacity (Payload)

Hitch Towing Capacity 1500 lbs. / 680 kg

Hitch Tongue Capacity 150 lbs. / 68 kg

(Includes rider(s), cargo, accessories

25 lbs. / 11.3 kg

740 lbs. / 335.6 kg

and trailer tongue weight)

MODEL: 2011 RZR EPSRANGER

MODEL NUMBER: R11VY76AO ENGINE NUMBER: 1204276

Category Dimension / Capacity

Length 103 in. / 261.6 cm

Width 50 in. / 127 cm

Height 69 in. / 175.3 cm

Wheel Base 77 in. / 196 cm

Ground Clearance 10 in. / 25.4 cm

Dry Weight 961 lbs. / 436 kg

Gross Vehicle Weight 1727 lbs. / 783 kg

Front Storage Capacity Cargo Box Dimension 42 in. x 22 in. / 107

cm x 56 cm Cargo Box Capacity 300 lbs. /

136 kg

Maximum Weight Capacity (Payload)

Hitch Towing Capacity 1500 lbs. / 680 kg

Hitch Tongue Capacity 150 lbs. / 68 kg

(Includes rider(s), cargo, accessories

25 lbs. / 11.3 kg

740 lbs. / 335.6 kg

and trailer tongue weight)

1.4

9923142 - 2011 RZR / RZR S / RZR 4 Service ManualRANGER

GENERAL INFORMATION

MODEL: 2011 RZR / EPSRANGER

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

Drivetrain

Transmission Type Polaris Automatic PVT

Drive Ratio - Front 3.82:1

Drive Ratio - Final 3.70:1

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Polaris Rzr4 2011 Rzr4

Specifications and Main Features

Frequently Asked Questions

User Manual