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 to Slingshot Dealers in electronic format at www.polarisdealers.com.
This Service Manual is designed primarily for use by trained Slingshot service technicians in a properly equipped shop
and should be kept available for reference in the shop area. 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. 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 Slingshot dealer for service.
Comments or suggestions about this manual should be submitted via Ask Polaris. Consumers can direct comments or
suggestions to: Service Publications Department, Polaris Sales Inc., 2100 Hwy 55, Medina, MN 55340.
Publication Printed July 2013 (PN 9924882)
Page 2
Copyright Info
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 components, some minor discrepancies may result
between the actual vehicle and the information presented in this 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
Throughout this manual, important information is brought to your attention by the following symbols:
WARNING
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.
CAUTION
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.
Page 3
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.
2008–2013 RZR vehicles use model numbers beginning with “R”. Beginning with the 2014 model year, all RZR model
numbers begin with “Z”.
2008–2013 Example: R13XT9EAK
GROUP
1st2nd3rd4th*5th*6th*7th*8th*9th**10th
R13XT9EAK
* = digits that would transfer to 17 digit VIN and are used in digits 4-8 respectively
** = 9th digit will be used on color/featured versions of models (not including the base)
First 3 digits and 9th digit are used in model number only. They are not used with the 17 digit VIN.
Digits 1 through 8 determine Digital Wrench calibration.
2014 Example: Z14VH76AD
GROUP
1st2nd3rd
Z14VH76AD
* = digits that would transfer to 17 digit VIN and are used in digits 4-8 respectively
** = 9th digit will be used on color/featured versions of models (not including the base)
First 3 digits and 9th digit are used in model number only. They are not used with the 17 digit VIN.
Digits 1 through 8 determine Digital Wrench calibration.
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.
R13VH76AC, AD, AN, AS
R13VE76AD, AI, AS, AW
R13VE76FI, FX
Z14VH76AC, AD
Z14VH7EAI, AJ, AK, AL, AW
Z14VE76AD, AL, AS, AV, AW
Z14VE76FI, FX
99240999924104
99240999924100
99240999924101
99247079924712
99247079924712
99247079924709
99247079924708
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.
Special tools may be required while servicing this
vehicle. Some of the tools listed or depicted are
mandatory, while other tools may be 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, Bosch Automotive Service Solutions, by
phone at 1-800-328-6657 or on-line at http://polaris.service-solutions.com/.
Inspection, adjustment and lubrication of important components are explained in the periodic maintenance chart.
Inspect, clean, lubricate, adjust and replace parts as necessary. When inspection reveals the need for replacement
parts, use genuine Pure Polaris parts available from your Polaris dealer.
NOTE: Service and adjustments are critical. If you’re not familiar with safe service and adjustment
procedures, have a qualified dealer perform these operations.
Maintenance intervals in the following chart are based upon average riding conditions and an average vehicle speed of
approximately 10 miles per hour. Vehicles subjected to severe use must be inspected and serviced more frequently.
Severe Use Definition
• Frequent immersion in mud, water or sand
• Racing or race-style high RPM use
• Prolonged low speed, heavy load operation
• Extended idle
• Short trip cold weather operation
Pay special attention to the oil level. A rise in oil level during cold weather can indicate contaminants collecting in the
oil sump or crankcase. Change oil immediately if the oil level begins to rise. Monitor the oil level, and if it continues to
rise, discontinue use and determine the cause or see your dealer.
2
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.
Maintain coolant level in
coolant reservoir bottle.
Maintain fluid level between
“MAX and “MIN” lines on the
master cylinder reservoir
Frequency*
Change after 1st month or first
25 hours of operation, 100
hours thereafter; Change more
often (25 hours) in severe duty
conditions or short trip cold
weather operation
Check level daily, change
coolant every two years
Check level during pre-ride
inspection; change fluid every
two years
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 - alsocheck
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.
• Gear selector moving out of desired range
1. Locate the shift cable in the rear LH wheel well area.
2. Inspect shift cable, clevis pin, pivot bushings, and
dust boot. Replace if worn or damaged.
3. If adjustment is required, loosen the lower jam nut
and pull the cable out of the mount to move the
upper jam nut.
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
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.
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.
Page 35
MAINTENANCE
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 in
loss of consciousness or
death in a short time.
Never drain the fuel when the engine is hot.
Severe burns may result.
3. Replace fuel line every two years.
Fuel Pump / Fuel Filters
The RZR 800 EFI engine uses a serviceable, highvolume, high-pressure, fuel pump that includes a
preliminary filter and an internal fine filter located before
the pump regulator.
NOTE: Neither filter is servicable individually. Must
replace the fuel pump as an assembly.
2
Fuel Line
1. Check the quick-connect fuel line for signs of wear,
deterioration, damage or leakage. Replace if
necessary.
2. Be sure fuel line is routed and retained properly.
IMPORTANT: Make sure line is not kinked or
pinched.
NOTE: Refer to Chapter 4 for fuel pump replacement
and all other information related to the EFI System.
2.11
Page 36
MAINTENANCE
Vent Lines
1. Check fuel tank, front gearcase, rear gearcase and
transmission ventlines for signsof 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.
Throttle Pedal Inspection
This vehicle is equipped with a Throttle Release Switch
(TRS) used to detect when the throttle pedal has
returned to the rest position.
NOTE: The throttle pedal lever is designed to have a
few degrees of freeplay prior to engaging the throttle
arm that pulls the throttle cable.
Alwayscheckthatthethrottlepedalmoves
independently of the cable pull lever at the start of throttle
pedal travel and that the throttle pedal returns normally
before starting the engine.
There should be minimal freeplay between the throttle
cable and the cable pull lever. If there is excessive play
due to cable stretch or misadjustment, it will cause a
delay in throttle response, especially at low engine
speed. The throttle may also not open fully. If the throttle
cable has no freeplay, the throttle may be hard to control,
and the idle speed may be erratic.
Throttle Freeplay Adjustment
Inspection
1. Place the transmission in PARK.
2. Start the engine and warm it up thoroughly.
3. Measure the distance the throttle arm (A) moves
before the engine begins to pick up speed. Throttle
cable freeplay should be 1/16” - 1/8” (1.5 - 3 mm).
NOTE: The throttle pedal lever (B) is designed to
have a few degrees of freeplay prior to engaging the
throttle arm (A) that pulls the throttle cable.
Adjustment
1. Remove both seats and rear service panel.
2. Remove cargo box as an assembly (see Chapter 5).
Check throttle pedal freeplay periodically in accordance
with the Periodic Maintenance Chart. Adjust the freeplay
if necessary (see “Throttle Freeplay Adjustment”).
3. Remove the (2) push rivets retaining the air intake
box and remove the box from the frame.
4. Loosen the hose clamp retaining the PVT intake duct
and remove the duct from the vehicle to access the
throttle cable freeplay adjustment.
6. Using a 14 mm open-end wrench, loosen the
adjustment jam nut. Using a 12 mm open-end
wrench, move the cable adjuster until 1/16” - 1/8”
(1.5 - 3 mm) of freeplay is achieved at the throttle
pedal.
NOTE: While adjusting, lightly move the throttle
pedal in and out.
7. Re-tighten the jam nut after final adjustment is made.
8. Apply a small amount of grease to the inside of the
boot and slide it over the cable adjuster to its original
position.
9. Reinstall the PVT intake duct and tighten the hose
clamp.
10. Reinstall the air intake box and (2) push rivets.
11. Reinstall the cargo box, all fasteners and reconnect
the taillight harness.
12. Reinstall the rear service panel and seats.
Air Filter Service
It is recommended that the air filter be inspected as part
of pre-ride inspection. Always apply grease to the seal
under the air box cap and on the sealing edges of the air
filter when servicing. 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 left rear 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.
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:
1. Position vehicle on a level surface.
2. Place the transmission in Park (P).
3. Stop the engine and allow it to cool down before
removing the dipstick.
IMPORTANT: Do not run the machine and then
check the dipstick.
4. Locate the engine oil dipstick:
• RZR / RZR S: Remove both seats and the rear
service panel to access the dipstick.
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 dipstick and check to see that the oil level is
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).
2
• RZR 4: Remove the right rear passenger seat to
access the dipstick.
5. Lift the lever lock, remove dipstick and wipe dry with
a clean cloth.
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 lock the lever.
2.15
Page 40
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 / Filter:
PS-4 Synthetic 4-Cycle Engine Oil
(PN 2876244) (Quart)
Engine Oil Filter (PN 2540086)
Capacity: 2 Quarts (1.9 L)
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.
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 specification.
Crankcase Drain Plug:
16 ft-lbs (22 Nm)
9. Place shop towels beneath oil filter. Using Oil Filter
Wrench (PU-50105) and a 3/8” extension, turn the oil
filter counter-clockwise to remove it.
CAUTION
Oil may be hot. Do not allow hot oil to come into contact
10. Using a clean dry cloth, clean filter sealing surface
on the crankcase.
11. Lubricate O-ring on new filter with a film of fresh
engine oil. Check to make sure the O-ring is in good
condition.
Page 41
MAINTENANCE
12. Install new filter to specification.
Oil Filter:
Turn by hand until filter O-ring contacts sealing
surface, then turn an additional 1/2 turn
13. Remove the engine oil dipstick (see “Engine Oil
Level”).
14. Fill the sump with 2 qts. (1.9 L) of PS-4 Synthetic
Engine Oil (2876244).
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.
Engine Breather Hose Inspection
The engine is equipped with a breather hose. Inspect the
breather hose for possible kinks or wear. The hose is
formed for a proper fit. Follow the breather hose from the
side of the airbox to the engine valve cover.
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:
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.
2
NOTE: Make sure line is not kinked or pinched.
Engine and Transmission Mounts
Periodically inspect engine and transmission mounts for
cracks or damage.
Refer to Chapter 3 “Engine Assembly and Installation” for
mounting fastener torque values.
5. Reinstall level check plug and torque to specification.
Level Check Plug:
30-45 in-lbs (3-5 Nm)
2.19
Page 44
MAINTENANCE
6. Reinstall the fill plug and torque to specification.
Fill Plug:
40-50 ft-lbs (54-68 Nm)
Main Gearcase - Lubricant Level Check:
The fill plug is located on the side of the gearcase just
below the shift lever bell crank. Maintain the fluid level
even with the bottom of the fill plug hole.
1. Position vehicle on a level surface.
2. Remove the fill / level plug and check the fluid level.
Transmission Lubricant Change:
The lubricant change procedure is relatively the same for
the main gearcase and the transfer case. To minimize
confusion, perform the lubricant change on only one
gearcase at a time. Access the drain plugs through the
drain holes in the skid plate.
Transfer Case Lubricant Change:
1. Remove the fill plug and the level check plug (refer to
“Transfer Case - Lubricant Level Check”).
2. Place a drain pan under the transfer case drain plug.
3. Remove the drain plug and allow to drain completely.
4. Clean and reinstall the drain plug with a new O-ring.
Torque drain plug to specification.
Drain Plug:
30-45 in-lbs (3-5 Nm)
5. Add the recommended fluid through the fill plug hole
until it begins to flow out the level plug hole. Do not
overfill.
6. Reinstall level check plug and torque to specification.
3. If fluid level is not at fill plug hole, add the
recommended fluid as needed.
4. Reinstall the fill / level plug and torque to
specification.
7. Reinstall the fill plug and torque to specification.
Fill Plug:
40-50 ft-lbs (54-68 Nm)
Main Gearcase Lubricant Change:
1. Remove the fill / level plug (refer to “Main Gearcase Lubricant Level Check”).
2. Place a drain pan under the main gearcase drain
plug.
3. Remove the drain plug and allow to drain completely.
Page 45
MAINTENANCE
4. Clean and reinstall the drain plug with a new O-ring.
Torque drain plug to specification.
Drain Plug:
30-45 in-lbs (3-5 Nm)
5. Add the recommended fluid through the fill plug hole.
Maintain the fluid level at the bottom of the fill plug
hole when filling the Main Gearcase. Do not overfill.
6. Reinstall the fill / level plug and torque to
specification.
Fill / Level Plug:
40-50 ft-lbs (54-68 Nm)
7. Check for leaks. Dispose of used lubricant properly.
Front Gearcase Lubrication
The front gearcase lubricant level should be checked and
changed in accordance with the maintenance schedule.
• Be sure vehicle is positioned on a level surface
when checking or changing fluid.
• Check vent hose to be sure it is routed properly
and unobstructed.
Front Gearcase Specifications
Specified Lubricant:
Polaris Demand Drive (PN 2877922)
Capacity: 6.75 oz. (200 ml)
Fill Plug: 8-10 ft-lbs (11-14 Nm)
Drain Plug: 8-10 ft-lbs (11-14 Nm)
Lubricant Level Check:
The fill plug is located on the bottom right side of the front
gearcase. Maintain the lubricant level even with the
bottom threads of the fill plug hole.
2
1. Position vehicle on a level surface.
2. Remove the fill plug and check the fluid level.
The engine coolant level is controlled, or maintained, by
the recovery system. The recovery system components
are the recovery bottle, radiator filler neck, radiator
pressure cap and connecting hose.
As coolant operating temperature increases, the
expanding (heated) excess coolant is forced out of the
radiator past the pressure cap and into the recovery
bottle. As engine coolant temperature decreases the
contracting (cooled) coolant is drawn back up from the
tank past the pressure cap and into the radiator.
NOTE: Some coolant level drop on new machines is
normal as the system is purging itself of trapped air.
Observe coolant levels often during the break-in
period.
IMPORTANT: Overheating of engine could occur if
air is not fully purged from system.
Polaris Premium 60/40 coolant is already premixed and
ready to use. Do not dilute with water.
Coolant Level Inspection
The pressure cap and recovery bottle are located under
the front hood of the vehicle. The coolant level must be
maintained between the minimum and maximum levels
indicated on the recovery bottle.
4. If the coolant level is below the MIN line, inspect the
coolant level in the radiator.
NOTE: If overheating is evident, allow system to
cool completely and check coolant level in the
radiator and inspect for signs of trapped air in
system.
WARNING
Never remove the pressure cap when the engine is
warm or hot. Escaping steam can cause severe burns.
The engine must be cool before removing the pressure
cap.
5. Remove the pressure cap. Using a funnel, add
coolant to the top of the filler neck.
6. Reinstall the pressure cap.
NOTE: Use of a non-standard pressure cap will
not allow the recovery system to function
properly.
7. Remove recovery bottle cap and add coolant using a
funnel.
8. Fill recovery bottle to MAX level with Polaris 60/40
premix Anti Freeze/Coolant or 50/50 or 60/40
mixture of antifreeze and distilled water as required
for freeze protection in your area.
9. Reinstall the recovery bottle cap.
10. If coolant was required, start engine and check for
leaks. Make sure radiator fins are clean to prevent
overheating.
With the engine at operating temperature, the coolant
level should be between the upper and lower marks on
the coolant recovery bottle. If not, perform the following
procedure:
Washing the vehicle with a high-pressure washer could
damage the radiator fins and impair the radiators
effectiveness. Use of a high-pressure washer is not
recommended.
Coolant Drain
1. Remove the hood from the front cab.
WARNING
Never drain the coolant when the engine and radiator
are warm or hot. Hot coolant can cause severe burns.
Allow engine and radiator to cool.
2. Slowly remove the pressure cap to relieve any
cooling system pressure.
3. Place a suitable drain pan underneath the radiator
fitting on the front RH side of the vehicle.
2.25
Page 50
MAINTENANCE
4. Drain the coolant from the radiator by removing the
lower coolant hose from the radiator as shown.
Properly dispose of the coolant.
5. Allow coolant to completely drain.
FINAL DRIVE / WHEEL AND TIRE
Wheel and Hub Torque Table
Item
Aluminum
Wheels (Cast)
Steel Wheels
(Black / Camo)
Hub Retaining
Nuts
NOTE: Do not lubricate the stud or the lug nut.
Nut Type
Lug Nut
#1
Flange
Nut #2
-80 ft-lbs (108 Nm)
Specification
30 ft-lbs + 90° (1/4
turn)
27 ft-lbs (37 Nm)
Wheel Removal
1. Position the vehicle on a level surface.
2. Place the transmission in PARK (P) and stop the
engine.
3. Loosen the wheel nuts slightly. If wheel hub removal
is required, remove the cotter pin and loosen the hub
nut slightly.
4. Elevate the appropriate side of the vehicle by placing
a suitable stand under the frame.
5. Remove the wheel nuts and remove the wheel.
6. If hub removal is required, remove the hub nut and
washers.
Wheel Installation
1. Verify the transmission is still in PARK (P).
2. Install the wheel hub, washers, and hub nut, if
previously removed.
3. Place the wheel in the correct position on the wheel
hub. Be sure the valve stem is toward the outside
and rotation arrows on the tire point toward forward
rotation.
Inspect the drive shaft boots for damage, tears, wear or
leaking grease. If the boots exhibit any of these
symptoms, they should be replaced. Refer to Chapter 7
for drive shaft boot replacement.
ELECTRICAL AND IGNITION SYSTEM
Battery Maintenance
Keep battery terminals and connections free of
corrosion. If cleaning is necessary, remove the corrosion
with a stiff wire brush. Wash with a solution of one
tablespoon baking soda and one cup water. Rinse well
with tap water and dry off with clean shop towels. Coat
the terminals with dielectric grease or petroleum jelly.
WARNING
CALIFORNIA PROPOSITION 65 WARNING:
Batteries, battery posts, terminals and related
accessories contain lead and lead compounds, and
other chemicals known to the State of California to
cause cancer and birth defects or other reproductive
harm.
WASH HANDS AFTER HANDLING.
WARNING
Battery electrolyte is poisonous. It contains sulfuric
acid. Serious burns can result from contact with skin,
eyes or clothing. Antidote:
External: Flush with water.
Internal: Drink large quantities of water or milk. Follow
with milk of magnesia, beaten egg, or vegetable oil. Call
physician immediately.
Eyes: Flush with water for 15 minutes and get prompt
medical attention.
Batteries produce explosive gases.
Keep sparks, flame, cigarettes, etc. away. Ventilate
when charging or using in an enclosed space. Always
shield eyes when
working near batteries.
KEEP OUT OF REACH OF CHILDREN.
2.28
NOTE: Batteries must be fully charged before use or
battery life will be reduced by 10-30% of full
potential. Charge battery according to “Charging
Procedure” provided in Chapter 10. Do not use the
vehicle’s stator/alternator to charge a new battery.
1. Remove the driver’s seat to access the battery.
Battery Installation
IMPORTANT: Using a new battery that has not been
fully charged can damage the battery and result in a
shorter life. It can also hinder vehicle performance.
Follow the battery charging procedure in Chapter 10
“Electrical” before installing the battery.
1. Ensure the battery is fully charged.
2. Place the battery in the battery holder and secure
with hold-down strap.
3. Coat the terminals with dielectric grease or
petroleum jelly.
4. Connect and tighten the red (positive) cable first.
5. Connect and tighten the black (negative) cable last.
2
2. Disconnect the black (negative) battery cable.
3. Disconnect the red (positive) battery cable.
4. Remove the hold-down strap and lift the battery out
of the vehicle.
CAUTION
To reduce the chance of sparks: Whenever removing
the battery, disconnect the black (negative) cable first.
When reinstalling the battery, install the black (negative)
Inspect ground cable connections. Be sure they are
clean and tight. The engine ground cable runs from the
starter motor to the chassis ground terminal.
STEERING
Steering Inspection
The steering components should be checked periodically
for loose fasteners, worn tie rod ends, ball joints, and
damage. Also check to make sure all cotter pins are in
place. If cotter pins are removed, they must not be
reused. Always use new cotter pins.
Replace any worn or damaged steering components.
Steering should move freely through the entire range of
travel without binding. Check routing of all cables, hoses,
and wiring to be sure the steering mechanism is not
restricted or limited.
NOTE:Wheneversteeringcomponentsare
replaced, check front end alignment.
WARNING
Due to the critical nature of the procedures outlined in
this chapter, Polaris recommends steering component
repair and adjustment be performed by an authorized
Polaris
MSD certified technician.
Use only genuine Polaris replacement parts.
2
Steering Wheel Freeplay
Check steering wheel for specified freeplay and
operation.
1. Position the vehicle on level ground.
2. Lightly turn the steering wheel left and right.
3. There should be 0.8”-1.0” (20-25 mm) of freeplay.
4. If there is excessive freeplay or the steering feels
rough, inspect the following components.
• Tie Rod Ends
• Steering Shaft U-Joints
• Steering Gearbox
Tie Rod End / Wheel Hub Inspection
• To check for play in the tie rod end, grasp the
steering tie rod, pull in all directions feeling for
movement.
• Elevate front end of machine so front wheels are
off the ground. Check for any looseness in front
hub/wheel assembly by grasping the tire firmly at
top and bottom first, and then at front and rear. Try
to move the wheel and hub by pushing inward and
pulling outward.
• If abnormal movement is detected, inspect the hub
and wheel assembly to determine the cause (loose
wheel nuts or loose front hub nut).
• Refer to Chapter 7 “Final Drive” for front hub
service procedures.
• Replace any worn steering components. Steering
should move freely through entire range of travel
without binding.
1. Place machine on a smooth level surface and set
steering wheel in a straight ahead position. Secure
the steering wheel in this position.
2. Place a chalk mark on the center line of the front tires
approximately 10” (25.4 cm) from the floor or as
close to the hub/axle center line as possible.
NOTE: It is important the height of both marks
be equally positioned to get an accurate
measurement.
Wheel Toe Adjustment
If toe alignment is incorrect, measure the distance
between vehicle center and each wheel. This will tell you
which tie rod needs adjusting.
2
3. Measure the distance between the marks and record
the measurement. Call this measurement “A”.
4. Rotate the tires 180° by moving the vehicle forward.
Position chalk marks facing rearward, even with the
hub/axle center line.
5. Again measure the distance between the marks and
record. Call this measurement “B”. Subtract
measurement “B” from measurement “A”. The
difference between measurements “A” and “B” is the
vehicle toe alignment. The recommended vehicle toe
tolerance is 1/8” to 1/4” (0.3 to 0.6 cm) toe out. This
means the measurement at the front of the tire (A) is
1/8” to 1/4” (0.3 to 0.6 cm) wider than the
measurement at the rear (B).
NOTE: Be sure steering wheel is straight ahead
before determining which tie rod needs adjustment.
CAUTION
During tie rod adjustment, it is very important that the
following precautions be taken when tightening tie rod
end jam nuts.
If the rod end is positioned incorrectly it will not pivot,
and may break.
To adjust toe alignment:
• Hold tie rod end to keep it from rotating.
• Loosen jam nuts at both end of the tie rod.
• Shorten or lengthen the tie rod until alignment is as
required to achieve the proper toe setting as
specified in “Wheel Toe Alignment”.
2.33
Page 58
MAINTENANCE
• IMPORTANT: When tightening the tie rod end jam
nuts, the rod ends must be held parallel to prevent
rod end damage and premature wear. Damage
may not be immediately apparent if done
incorrectly.
• After alignment is complete, torque jam nuts to
specification.
Tie Rod End Jam Nut:
12-14 ft-lbs (16-19 Nm)
SUSPENSION (STANDARD)
Spring Preload Adjustment
The front and rear shock absorber springs are adjustable
by rotating the adjustment cam to change spring tension
preload.
WARNING
Uneven adjustment may cause poor handling of the
vehicle, which could result in an accident and serious
injury or death. Always adjust both the left and right
spring preloads equally.
Suspension Spring Adjustment
1. Position the vehicle on a level surface and stop the
engine.
2. Raise and safely support front or rear of vehicle off
the ground to allow the suspension to fully extend.
NOTE: The tires should not be touching the
ground.
3. To adjust the suspension, rotate the adjustment cam
clockwise to increase spring tension or counterclockwise to decrease spring tension.
2.34
Shock Spanner Wrench:
4. Each notch of the adjustment will add 6% - 8% more
preload to the spring over the primary position.
The front and rear shocks have a spring preload
adjustment. Suspension spring preload may be adjusted
to suit different riding conditions or vehicle payloads.
WARNING
Uneven adjustment may cause poor handling of the
vehicle, which could result in an accident and serious
injury or death. Always adjust both the left and right
spring preloads equally.
RZR S
Factory Spring Preload Setting
FrontRear
4.34 in. (11 cm)5.15 in. (13 cm)
RZR 4 (Base)
Factory Spring Preload Setting
FrontRear
4.5 in. (11.4 cm)5.29 in. (13.4 cm)
3. Once you have obtained the correct preload, hold
the lower adjustment ring while tightening the upper
adjustment ring to lock them in place.
Shock Spanner Wrench
(PN 2870803)
2
RZR 4 (L.E.) Factory Spring Preload Setting
FrontRear
4.31 in. (10.9 cm)4.99 in. (12.7 cm)
NOTE: Refer to the shock illustration within this
procedure for spring preload measurement location.
1. Raise and safely support front or rear of vehicle off
the ground to allow the suspension to fully extend.
2. Loosen the upper jam nut adjustment ring (1). Turn
the lower adjustment ring (2) clockwise to increase
preload or counter-clockwise to decrease preload.
IMPORTANT:DO NOT increase the spring
preload by more than one inch (25.4 mm) over
the factory setting.
IMPORTANT: Always return the spring preload
to the factory setting after the load is removed
from the vehicle. The increased suspension
height will negatively impact vehicle stability
when operating without a load.
2.35
Page 60
MAINTENANCE
Shock Compression Adjustment
The compression damping adjustment is located on top
of the shock ‘Piggyback’ reservoir of each shock.
Turn the clicker adjuster knob to make damping
adjustments.
NOTE:When the clicker adjuster is turned
clockwise until it stops, the damping is in the fully
closed position.
Turn the clicker clockwise to increase compression
damping. Turn the clicker counter-clockwise to decrease
compression damping.
NOTE: The factory setting is 10 clicks from closed.
Refer to the “Compression Adjustment Table” below.
Compression Adjustment Table
SettingCompression Damping
Softest
Factory
Firmest2 clicks from closed
Full counter-clockwise position
10 clicks from closed
BRAKE SYSTEM
Brake Fluid Inspection
Always check the brake pedal travel and inspect the
brake fluid reservoir level before each operation. If the
fluid level is low, add DOT 4 brake fluid only.
Recommended Brake Fluid:
DOT 4 Brake Fluid
(PN 2872189)
Brake fluid should be changed every two years. The fluid
should also be changed anytime the fluid becomes
contaminated, the fluid level is below the minimum level,
or if the type and brand of the fluid in the reservoir is
unknown.
The brake fluid master cylinder reservoir can be
accessed through the left front wheel well.
1. Position the vehicle on a level surface.
2. Place the transmission in PARK (P).
3. View the brake fluid level in the reservoir. The level
should be between the MAX and MIN level lines.
4. If the fluid level is lower than the MIN level line, add
brake fluid until it reaches the MAX level line.
5. Install the reservoir cap and apply the brake pedal
forcefully for a few seconds and check for fluid
leakage around the master cylinder fittings and the
brake caliper fittings.
1. Check the brake pads for wear, damage, or
looseness.
2. Inspect the brake pad wear surface for excessive
wear.
3. Pads should be changed when the friction material is
worn to .040” (1 mm).
4. Check surface condition of the brake discs.
5. Measure the thickness of the front and rear brake
discs.
6. The disc (s) should be replaced if thickness is less
than .170” (4.32 mm).
MAINTENANCE
2
Brake Hose and Fitting Inspection
Check brake system hoses and fittings for cracks,
deterioration, abrasion, and leaks. Tighten any loose
fittings and replace any worn or damaged parts.
2. Remove pressure cap and pressure test the cooling
system using a commercially available tester.
3. The system must maintain 10 psi for five minutes. If
pressure loss is evident within five minutes, check
radiator, hoses, clamps and water pump seals.
Pressure Cap Test
1. Remove the front hood (see Warning under “Cooling
System Pressure Test”).
2. Remove pressure cap and test using a pressure cap
tester (commercially available).
3. The pressure cap relief pressure is 13 psi. Replace
cap if it does not meet this specification.
Recommended Coolant
Use only high quality antifreeze/coolant mixed with
distilled water in a 50/50 or 60/40 ratio, depending on
freeze protection required in your area.
CAUTION: Using tap water in the cooling system will
lead to a buildup of deposits which may restrict coolant
flow and reduce heat dissipation, resulting in possible
engine damage. Polaris Premium 60/40 Antifreeze/
Coolant is recommended for use in all cooling systems
and comes pre-mixed, ready to use.
Cooling System Pressure Test
1. Remove the hood from the front cab.
WARNING
Never remove pressure cap when engine is warm or
hot. The cooling system is under pressure and serious
Always wear safety glasses and proper shop clothing
when performing the procedures in this manual. Failing
to do so may lead to possible injury or death.
CAUTION
Use caution when performing these procedures.
Coolant may be hot and may cause severe injury or
burns.
NOTE: If the coolant level is LOW in the radiator, or
if there are leaks in the system, the coolant system
will not draw coolant from the reservoir tank.
NOTE: Use this procedure when a unit overheats
and no apparent leaks in the cooling system are
found.
1. Drive the vehicle onto a slight incline or use properly
weight rated ramps. If an incline is not available,
slightly elevate the front of the vehicle.
2. Place the vehicle in Park and block the rear wheels.
CAUTION
Be sure the engine has cooled and no pressure is built
up in the cooling system before removing the pressure
cap. The coolant may be hot and could cause severe
injury or burns.
3. Remove pressure cap and top off coolant.
4. Remove recovery bottle cap and fill bottle to the full
line.
5. Leave the cap off of the radiator to allow any
possible air to escape.
6. Start the engine and let it idle for 5-10 minutes or
until the thermostat opens and allows coolant to flow
through the system.
7. Squeeze the coolant lines by hand to help purge the
system of air.
8. Slightly loosen the bleed screw (C) on the cylinder
head to let air escape. If no air is present, a steady
stream of coolant will stream out. If air is present, the
screw will bubble and sputter as the air escapes.
9. Tighten the bleed screw to specification and properly
install the pressure cap.
Coolant Bleed Screw:
70 ± 10 in-lbs (8 ± 1.13 Nm)
NOTE: If there is air in the system you will see
air bubbles forming through the radiator filler
neck.
10. Add Polaris Premium Antifreeze to the radiator filler
neck if the level goes down. If no bubbles are seen at
the filler neck, the system should be purged of air.
WARNING
Be sure to install the pressure cap before shutting off
Coolant may spit out of the radiator.
11. Stop the engine and let cool, top off the radiator filler
neck with coolant. If you hear or see a “glug” at the
filler neck, or there is a dropping of the coolant level,
indicating that coolant has been pulled into the
system; Fill the recovery bottle only after you have
completely filled the cooling system at the radiator
filler neck.
12. Repeat this procedure, if overheating still occurs.
This chart describes the flow of oil through the 800 EFI engine. Beginning in the crankcase sump, the oil is drawn
through an oil galley to the feed side of the oil pump. The oil is then pumped through the oil filter. If the oil filter is
obstructed, a bypass valve contained in the filter allows oil to bypass the filter element. At this point, the oil is supplied
to the main oil galley through a crankcase passage. Oil is then diverted three ways from the main oil galley, with the
first path entering the camshaft bores, onto the rear balance shaft journal and then draining back into the crankcase
sump. The second oil path from the main oil galley feeds the lifter bores and then drains back to the crankcase sump.
The third oil path flows through a crankcase galley to the MAG side crankshaft journal and also to the front balance
shaft journal and onto the crankcase sump.
Because of its design configuration and fastener torque
requirements, Polaris recommends removing the engine,
transmission and rear gearcase as one assembly. Use
the following procedure when engine removal is
required.
IMPORTANT: Some engine repair procedures can be
performed without removing the engine assembly
from the vehicle. Refer to “Accessible Engine
Components” on Page 3.16 for further information.
NOTE: The use of an overhead or portable engine
hoist is the only recommended method for removing
and installing the engine / transmission / rear
gearcase assembly.
NOTE: Have an assistant help guide the engine in
and out of the vehicle while using an engine hoist to
prevent personal injury or damage to vehicle
components.
WARNING
Always wear safety glasses and proper shop clothing
when performing the procedures in this manual. Failing
to do so may lead to possible injury or death.
8. Remove the (2) screws (A) from the rear of the
center console (RZR / RZR S only).
3
9. Remove the rear seat base assembly from the
vehicle:
• RZR / RZR S: Remove the (2) fasteners (B) from
the rear seat base (as shown above).
• RZR 4: Remove the (2) fasteners and seat latch
plunger (C). Slide the rear seat base to the left and
remove it.
1. If vehicle was recently operated, allow it to cool down
before attempting to perform any work.
2. Clean work area.
3. Thoroughly clean the engine and chassis.
4. Drain appropriate lubricant(s):
• If servicing the engine, drain engine oil.
• If servicing the transmission, drain the lubricant
from the main gearcase and transfer case.
• If servicing the rear gearcase, drain the gearcase
lubricant.
5. Remove the driver’s seat (see Chapter 5).
6. Disconnect negative (-) battery cable.
7. Remove the passenger seat(s) and remove the rear
service panel (see Chapter 5).
10. Remove the rear bumper, rear cargo box and box
supports from the vehicle (see Chapter 5).
3.19
Page 82
ENGINE
11. Remove the (2) push rivets and remove the intake
box from the vehicle.
12. Elevate the rear of the vehicle off the ground using a
suitable ATV lift and remove both rear wheels.
13. Remove all exhaust components from vehicle and
engine.
14. Loosen the hose clamp attaching the outlet duct to
the PVT cover. Leave the duct attached to the upper
frame support.
16. Remove the high tension leads from the spark plugs
and disconnect the ignition coil harness.
IMPORTANT: Mark or note which ignition coil
wire goes to which cylinder and ignition coil
post. The engine will misfire if the spark plug
wires are installed incorrectly. The spark plug
wires are marked with PTO and MAG from the
factoryand shouldbe installedtothe
corresponding cylinder and ignition coil post.
17. Remove the vent lines from the upper bolt-in frame
brace and plug vent lines to prevent fluid leakage
during removal.
18. Remove the (6) fasteners retaining the upper bolt-in
frame brace and remove it from the vehicle with the
ignition coil and PVT duct attached.
15. Remove the (8) screws that retain the PVT cover and
remove cover.
24. Remove the remaining bolt attaching the airbox to
the frame (see photo).
3.21
Page 84
ENGINE
25. Remove the airbox and throttle body from the vehicle
as an assembly. Take care in not allowing the throttle
cable to bend excessively or kink. Carefully place the
assembly on the floor next to the vehicle. Insert a
shop towel into the engine intake adaptor to prevent
dirt from entering the engine.
NOTE:Ensure throttle cable is not being
excessively bent or kinked while removed from
the vehicle.
26. Mark the fuel injector harnesses to identify MAG and
PTO harness connections to aid during reassembly.
Disconnect the fuel injector harnesses.
NOTE: The fuel injector harness connector and
locking spring is bonded to the fuel injectors
with an epoxy mix. DO NOT attempt to
disconnect the connector from the fuel injectors.
Damage will occur to the injector and/or harness
if attempting to separate at that location.
Separate the fuel injector from the vehicle by
disconnecting at the end of the harness as
shown.
27. Disconnect the fuel line from the fuel injector rail by
slightly squeezing the lock tabs and gently pushing
the connector lock out. To separate the lines, pull the
fuel line from the tank strait down.
28. Disconnect the shift cable from the transmission bell
crank.
IMPORTANT: Take note of PTO and MAG fuel
injectorharnessconnectorsbefore
disconnecting them. The harnesses are different
and can not be connected incorrectly (PTO Gray; MAG - Black).
29. Mark the upper jam nut and loosen the lower jam
nut. Pull the shift cable out of the mount.
NOTE: If the upper jam nut is moved, shift cable
adjustment will be required during engine
installation(seeChapter2“Shift Cable
Inspection / Adjustment”).
30. Disconnect the transmission gear indicator switch
harness.
31. Disconnect the CPS harness.
3
32. Disconnect the stator / alternator harness.
33. Disconnect the transmission speed sensor harness.
NOTE: Clean area around drive shaft orifices on
both sides of rear gearcase and cover orifices
using duct tape. This will prevent the lubricant
from leaking out during removal.
Page 87
ENGINE
39. Disconnect the engine coolant temperature (ECT)
sensor harness and the bypass coolant hose.
40. Loosen the hose clamp and remove the lower
coolant hose from the water pump cover inlet and
drain coolant into a suitable container.
44. Remove RH engine mount fastener.
3
45. Remove the (2) lower bolts that retain the LH
transmission mount to the frame.
41. Remove the filler neck pressure cap to relieve the
cooling system vacuum.
NOTE: Use a portable wet-vac or syphon to
prevent any coolant from spilling.
42. Remove the upper coolant hose from the thermostat
housing outlet to relieve any coolant vacuum created
in the engine. Allow engine coolant to completely
drain. Properly dispose of the engine coolant /
antifreeze.
43. Remove the (+) positive battery cable from the
starter motor terminal and (-) negative battery cable
from the starter motor engine mount.
46. Remove the (2) rear gearcase mount bracket
fasteners and mount bolt and remove bracket from
vehicle.
NOTE: The use of an overhead or portable
engine hoist is the only recommended method
for removing and installing the engine /
transmission / rear gearcase assembly.
47. Using an engine hoist, hook a chain between the
engine / transmission mounting plate and the
transmission / rear gearcase mounting plate.
3.26
NOTE: Have an assistant help guide the engine
in and out of the vehicle while using an engine
hoist to prevent personal injury or damage to
vehicle components.
48. Lift the front portion of the assembly out first to allow
the engine valve cover to clear the vehicle frame.
49. Remove propshaft from the transmission output
shaft.
50. Then move assembly towards the front of the vehicle
while lifting it out to allow the rear gearcase to clear
the rear portion of the frame.
51. Then lift assembly high enough to clear vehicle
frame and completely remove it from the vehicle to a
work bench.
2. Remove the (6) fasteners retaining the inner clutch
cover to the engine and transmission.
3
3. Remove only the (4) outer fasteners retaining the
engine to the transmission bracket.
Engine / Transmission Separation
Once the engine / transmission / rear gearcase assembly
has been removed from the vehicle, the engine and
transmission will need to be separated to allow engine
servicing. Use the following procedure to separate the
engine from the assembly.
1. Remove the drive belt, drive clutch and driven clutch
(see Chapter 6).
2. Mark or tag rocker arms in order of disassembly to
keep them in order for reassembly.
3. Inspect the wear pad at the valve end of the rocker
arm for indications of scuffing or abnormal wear. If
the pad is grooved, replace the rocker arm.
NOTE: Do not attempt to true this surface by
grinding.
4. Check the rocker arm pad and fulcrum seat for
excessive wear, cracks, nicks or burrs.
Push Rods
1. Clean push rods (A) in a suitable solvent. Blow dry
push rods with compressed air.
2. Use compressed air to confirm the oil passage is
clear in the center of the push rod.
5. If the push rod (A) is visibly bent, it should be
replaced.
3
Cylinder Head Removal
NOTE: The cargo box assembly and the upper
frame bolt-in brace must be removed to allow
enough clearance to remove all the cylinder head
bolts. Refer to Chapter 5 for removal procedures.
1. Loosen the six cylinder head bolts (A) evenly 1/8 turn
each in a criss-cross pattern until loose.
2. Remove bolts (A) and tap cylinder head (B) lightly
with a soft face hammer until loose. CAUTION: Tap
only in reinforced areas or on thick parts of cylinder
head casting to avoid damaging the head or cylinder.
WARNING
Always wear safety glasses when working with
compressed air to prevent personal injury.
3. Check the ends of the push rods (A) for nicks,
grooves, roughness or excessive wear.
4. The push rods (A) can be visually checked for
straightness while they are installed in the engine by
rotating them with the valve closed. Push rods can
also be checked with a dial indicator or rolled across
a flat surface to check for straightness.
3. Remove cylinder head (B) and head gasket (C) from
the cylinder (D).
Cylinder Head Inspection
Thoroughly clean cylinder head surface to remove all
traces of gasket material and carbon.
CAUTION
Cylinder Head Warp
Lay a straight edge (A) across the surface of the cylinder
head (B) at several different points and measure warp by
inserting a feeler gauge between the straight edge and
the cylinder head surface. If warp exceeds the service
limit, replace the cylinder head.
Cylinder Head Warp Limit:
.004" (.1016 mm) max
Valve Seal / Spring Service (On Engine)
NOTE: The following procedure is only for servicing
the top end of the valve train when replacing valve
springs or replacing valve seals.
3.30
Use care not to damage sealing surface.
9924707 - 2013–2014 RZR 800 Service Manual
In some cases the valve train can be serviced while the
cylinder head is still on the engine. Keep all parts in order
with respect to their location in the cylinder head.
WARNING
Wear eye protection or a face shield during cylinder
head disassembly and reassembly.
1. Having already removed the valve cover, rocker
arms and pushrods, align the cylinder to be worked
on at top dead center (TDC). Install the Valve
Pressure Hose (PU-45652) into the spark plug hole.
Hook the hose to an air compressor and supply 50 to
100 psi to the hose. This will seat the valves during
valve spring removal. Do not remove air supply until
reassembly is completed.
IMPORTANT: It is recommended to replace seals
whenever the cylinder head is disassembled.
Hardened, cracked or worn valve seals will cause
excessive oil consumption and carbon buildup.
3.31
Page 94
ENGINE
5. Mark the valves with a white pen. Remove the valves
from the cylinder head. This will ensure that the
valvesareproperlyplacedduringengine
reassembly.
Valve Inspection
1. Remove all carbon from valves with a soft wire wheel
or brush.
2. Check valve face for runout, pitting, and burnt spots.
To check for bent valve stems, mount valve in a drill
or use “V” blocks and a dial indicator.
3. Check end of valve stem (A) for flaring, pitting, wear
or damage. Inspect split keeper groove (B) for wear
or flaring of the keeper seat area.
NOTE: The valves can be re-faced or end
ground, if necessary. They must be replaced if
extensively worn, burnt, bent, or damaged.
4. Measure diameter of valve stem with a micrometer in
three places, then rotate 90 degrees and measure
again (six measurements total). Compare to
specifications.
5. Measure valve guide (C) inside diameter at the top
middle and end of the guide using a small hole
gauge and a micrometer. Measure in two directions.
Valve Guide I.D.:
0.23672" ± 0.000295"
(6.0617 ± 0.0075 mm)
6. Subtract valve stem measurement from the valve
guide measurement to obtain stem to guide
clearance.
Combustion Chamber
1. Clean all accumulated carbon deposits from
combustion chamber and valve seat area with
carbon cleaner and a soft plastic scraper.
IMPORTANT: Do not use a wire brush, metal
scraper, or abrasive cleaners to clean the bottom
of the cylinder head. Extensive damage to the
cylinder head may result. Wear safety glasses
during cleaning.
3
Valve Seat Reconditioning
NOTE: Polaris recommends that the work be done
by a local machine shop that specializes in this area.
NOTE: The cylinder head valve guides cannot be
replaced.
Valve Stem Oil Clearance:
Intake: 0.00228" ± 0.00098"
(0.058 ± 0.025 mm)
Exhaust: 0.00275" ± 0.00098"
(0.087 ± 0.025 mm)
NOTE: The valve guides cannot be replaced. Be
sure to measureeach guide and valve
combination individually.
Wear eye protection or a face shield during cylinder
head disassembly and reassembly.
Valve Seat Inspection
Inspect valve seat in cylinder head for pitting, burnt
spots, roughness, and uneven surface. If any of the
above conditions exist, the valve seat must be
reconditioned. If the valve seat is cracked, the cylinder
head must be replaced.
Follow the manufacturers instructions provided with the
valve seat cutters in the commercially available cylinder
headreconditioningkit.Abrasivestoneseat
reconditioning equipment can also be used. Keep all
valves in order with their respective seat.
3.33
Page 96
ENGINE
NOTE: Valve seat width and point of contact on the
valve face is very important for proper sealing. The
valve must contact the valve seat over the entire
circumference of the seat, and the seat must be the
proper width all the way around. If the seat is
uneven, compression leakage will result. If the seat
is too wide, seat pressure is reduced, causing
carbon accumulation and possible compression
loss. If the seat is too narrow, heat transfer from
valve to seat is reduced. The valve may overheat and
warp, resulting in burnt valves.
1. Install pilot into valve guide.
2. Apply cutting oil to valve seat and cutter.
3. Place 46° cutter on the pilot and make a light cut.
4. Inspect the cut area of the seat:
* If the contact area is less than 75% of the
circumference of the seat, rotate the pilot 180° and
make another light cut.
* If the cutter now contacts the uncut portion of the
seat, check the pilot. Look for burrs, nicks, or runout.
If the pilot is bent it must be replaced.
* If the contact area of the cutter is in the same place,
the valve guide is distorted from improper
installation.
* If the contact area of the initial cut is greater than
75%, continue to cut the seat until all pits are
removed and a new seat surface is evident. NOTE:
Remove only the amount of material necessary
to repair the seat surface.
5. To check the contact area of the seat on the valve
face, apply a thin coating of Prussian Blue™ paste to
the valve seat. If using an interference angle (46°)
apply black permanent marker to the entire valve
face (A).
3.34
6. Insert valve into guide and tap valve lightly into place
a few times.
7. Remove valve and check where the Prussian Blue™
indicates seat contact on the valve face. The valve
seat should contact the middle of the valve face or
slightly above, and must be the proper width.
* If the indicated seat contact is at the top edge of the
valve face and contacts the margin area (B) it is too
high on the valve face. Use the 30° cutter to lower
the valve seat.
* If too low, use the 60° cutter to raise the seat. When
contact area is centered on the valve face, measure
seat width.
* If the seat is too wide or uneven, use both top and
bottom cutters to narrow the seat.
* If the seat is too narrow, widen using the 45° cutter
and re-check contact point on the valve face and
seat width after each cut.
NOTE: When using an interference angle, the
seat contact point on the valve will be very
narrow, and is a normal condition. Look for an
even and continuous contact point all the way
around the valve face (A).
ENGINE
3
Valve Seat Width:
Intake Std: 0.028" (0.7 mm)
Limit: 0.055" (1.4 mm)
Exhaust Std: 0.039” (1.0 mm)
Limit: 0.071" (1.8 mm)
8. Clean all filings from the area with hot soapy water.
Rinse and dry with compressed air.
9. Lubricate the valve guides with clean engine oil, and
apply oil or water based lapping compound to the
face of the valve.
NOTE:Lapping is not required with an
interference angle valve job.
10. Insert the valve into its respective guide and lap
using a lapping tool or a section of fuel line
connected to the valve stem.
11. Rotate the valve rapidly back and forth until the cut
sounds smooth. Lift the valve slightly off of the seat,
rotate 1/4 turn, and repeat the lapping process. Do
this four to five times until the valve is fully seated,
and repeat process for the other valve(s).
12. Thoroughly clean cylinder head and valves.
Cylinder Head Reassembly
NOTE: Assemble the valves one at a time to
maintain proper order.
1. Apply engine oil to valve guides and seats.
2. Coat valve stem with molybdenum disulfide grease
or synthetic engine oil.
3. Install valve carefully with a rotating motion to avoid
damaging valve seal.
4. Valve seals should be installed after the valves are in
the head to avoid valve seal damage. Install new
valve seals on valve guides.
5. Dip valve spring and retainer in clean engine oil and
install.
6. Place retainer on spring and install Valve Spring
Compressor (PU-45257). Install split keepers with
the gap even on both sides.
NOTE: A small magnet can be used to aid in the
installation of the keepers.
Valve Sealing Test
1. Clean and dry the combustion chamber area (A).
2. Pour a small amount of clean solvent onto the intake
port and check for leakage around each intake valve.
The valve seats should hold fluid with no seepage.
3. Repeat for exhaust valves by pouring fluid into
exhaust port.
Cylinder Removal
1. Follow engine disassembly procedures to remove
rocker cover and cylinder head.
2. Tap cylinder (A) lightly with a rubber mallet in the
reinforced areas only until loose.
3. Rock cylinder forward and backward while lifting it
from the crankcase, supporting pistons and
connecting rods. Support pistons with Piston Support
Block (PN 2870390).
7. Repeat procedure for remaining valves. When all
valves are installed, tap lightly with soft faced
hammer on the end of the valves to seat the split
keepers.
NOTE: To prevent damage to the valve seals, do
not compress the valve spring more than
necessary to install the keepers.
1. Remove the valve lifters by reaching into the
crankcase and pushing the lifter up through the lifter
bore by hand.
2. Thoroughly clean the lifters in cleaning solvent and
wipe them with a clean, lint-free cloth.
3. Mark the lifters with a white pen if using the lifters for
reassembly. This will ensure that the lifters are
properly placed during engine reassembly.
4. Check the lifters for wear or scores.
5. Check the bottom end of lifter to make sure that it
has a slight convex.
6. If the bottom surface has worn flat, it may be used
with the original camshaft only.
Piston Removal
1. Remove the circlip. Mark the piston with a white pen
to ensure proper orientation (if reused) during
assembly.
3
NOTE:If the pistons are to be reused,
reassemble the pistons in the same cylinder and
direction from which they were removed.
NOTE: New pistons are non-directional and can
be placed in either cylinder.
2. Remove piston circlip and push piston pin out of
piston. If necessary, heat the crown of the piston
slightly with a propane torch. CAUTION: Do not
apply heat to the piston rings. The ring may lose
radial tension.
3. Remove top compression ring:
*Using a piston ring pliers: Carefully expand ring
and lift it off the piston. CAUTION: Do not expand
the ring more than the amount necessary to remove
it from the piston, or the ring may break.
*By hand: Placing both thumbs as shown, spread
the ring open and push up on the opposite side. Do
not scratch the ring lands.
NOTE: Lifters that are scored, worn, or if the
bottom is not smooth should be replaced with
new lifters and cam as an assembly. If replacing
the lifters, the camshaft should also be replaced.
The oil control ring is a three piece design consisting
of a top and bottom steel rail and a center expander
section. The top rail has a locating tab on the end
which fits into a notch (B) in the upper oil ring land of
the piston.
To Remove:
A) Remove the top rail first followed by the bottom
rail.
B) Remove the expander.
Cylinder Inspection
1. Remove gasket material from cylinder sealing
surfaces.
2. Inspect top of the cylinder (B) for warp using a
straight edge (A) and feeler gauge (C). Refer to Ill. 1
and Ill. 2.