Polaris RZR 800 (2013) User guide

Page 1

2013–2014 RZR 800

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 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

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.

Page 4

Page 5

GENERAL INFORMATION

MAINTENANCE

ENGINE

ELECTRONIC FUEL INJECTION

BODY / STEERING / SUSPENSION

CLUTCHING

FINAL DRIVE

TRANSMISSION

BRAKES

ELECTRICAL

Page 6

Page 7

GENERAL INFORMATION

CHAPTER 1

GENERAL INFORMATION

VEHICLE IDENTIFICATION .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . . 1.2

MODEL NUMBER DESIGNATION. . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . . 1.2

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

VEHICLE IDENTIFICATION NUMBER (VIN) DESIGNATION . .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . 1.2

VEHICLE AND ENGINE SERIAL NUMBER LOCATIONS. . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . .. .. . . . .. 1.3

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

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

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

SPECIAL TOOLS . . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . . 1.5

GENERAL SPECIFICATIONS. . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. 1.6

MODEL: 2013–2014 RZR 800 . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. . . . . . .. .. . . . .. .. . . . .. .. . 1.6

MODEL: 2013–2014 RZR EPS 800 . . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . 1.6

MODEL: 2014 RZR 800 XC. . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . .. 1.7

MODEL: 2013–2014 RZR / EPS 800. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. . . . . . .. . . . . . .. . . . . . .. 1.7

MODEL: 2013–2014 RZR S 800 . . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . . 1.9

MODEL: 2013–2014 RZR S INT’L 800 . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . 1.9

MODEL: 2013 RZR S / INT’L 800 . . . . .. .. . . . .. .. . . . . . .. . . . . . .. . . . . . .. . . . .. .. . . . .. .. . . . . . .. . . . .. .. . .1.10

MODEL: 2013 RZR 4 800 .. . . . . . .. . . . . . .. . . . . . .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . 1.12

MODEL: 2013–2014 RZR 4 EPS 800 . . .. .. . . . .. .. . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. .. . . . .. .. . . . .. ..1.12

MODEL: 2013 RZR 4 / EPS 800 .. . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . .1.13

MISC. SPECIFICATIONS AND CHARTS .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . ..1.15

CONVERSION TABLE .. . . . .. .. . . . .. .. . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .1.15

STANDARD BOLT TORQUE SPECIFICATION. . . .. .. . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .1.16

METRIC BOLT TORQUE SPECIFICATION .. . .. .. . . . .. .. . . . .. .. . . . .. . . . . . .. . . . . . .. .. . . . .. .. . . . .. ..1.16

SAE TAP / DRILL SIZES . .. . . . . . .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . 1.17

METRIC TAP / DRILL SIZES .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . .1.17

DECIMAL EQUIVALENTS. . . . .. .. . . . .. .. . . . .. .. . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . .1.18

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GENERAL INFORMATION

VEHICLE IDENTIFICATION

Model Number Designation

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

1st 2nd 3rd 4th* 5th* 6th* 7th* 8th* 9th** 10th

R 1 3 X T 9 E A K

* = 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

1st 2nd 3rd

Z 1 4 V H 7 6 A D

MODEL

YEAR

MODEL

YEAR

CHASSIS

4th* 5th* 6th* 7th* 8th* 9th** 10th

DRIVE-

LINE

DRIVE-

LINE

ENGINE /

MOTOR CODE

ENGINE /

MOTOR CODE

CATEGORY OPTION REGION

Engine Designation Number

1204620 RZR800-13: Twin Cylinder, Liquid Cooled, OHV 4 Stroke, Electric Start

Vehicle Identification Number (VIN) Designation

Example: 4XAVH76A4E3000000

Vehicle Descriptors

World Mfg. ID

Chassis

Driveline

Engine Size

1 2

4 X A V H 7 6 A 4 E 3 0 0 0 0 0 0

* Model Year: A = 2010; B = 2011; C = 2012; D = 2013; E = 2014

3 4

6 7 8 9 10 11 12

Category

Check Digit

Engine Modifier

Model Year *

Vehicle Identifiers

Mfg. Location

Individual Serial No.

14 15 16 17

1.2

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GENERAL INFORMATION

Vehicle and Engine Serial Number Locations

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

The VIN can be found stamped on the rear upper frame rail, behind the left rear fender, near the air box (Figure 1-1).

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

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Page 10

GENERAL INFORMATION

VEHICLE INFORMATION

Publication Numbers

Model Model No. Owner’s Manual Parts Manual

2013 RZR 800

2013 RZR EPS 800 R13VH7EAI 9924099 9924104

2013 RZR S 800

2013 RZR S INT’L 800

2013 RZR 4 800 R13XE76AD 9924099 9924106

2013 RZR 4 EPS 800 R13XE7EAI 9924099 9924106

2014 RZR 800

2014 RZR EPS 800

2014 RZR S 800

2014 RZR S INT’L 800

2014 RZR 4 EPS 800 Z14XE7EAL 9924707 9924729

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

9924099 9924104

9924099 9924100

9924099 9924101

9924707 9924712

9924707 9924709

9924707 9924708

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.

Series# Part Number

20 4010278

21 4010278

23 4010321

27 4010321

28 4010321

31 4110141

32 4110148

67 4010278

68 4010278

4010321

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GENERAL INFORMATION

SPECIAL TOOLS

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/.

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Page 12

GENERAL INFORMATION

GENERAL SPECIFICATIONS

MODEL: 2013–2014 RZR 800

MODEL NUMBER: R13VH76AC, AD, AN, AS; Z14VH76AC, AD

Category Dimension / Capacity

Length

Width 50 in. / 127 cm

Height

Wheel Base 77 in. / 196 cm

Ground Clearance 10 in. / 25.4 cm

Dry Weight 978 lbs. / 444 kg

Gross Vehicle Weight 1727 lbs. / 783 kg

Front Storage Capacity 25 lbs. / 11.3 kg

Cargo Box Dimension

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

103 in. / 261.6 cm

69 in. / 175.3 cm

42 in. x 22 in. / 107 cm x 56 cm

740 lbs. / 335.6 kg

(Includes rider(s), cargo, accessories

and trailer tongue weight)

MODEL: 2013–2014 RZR EPS 800

MODEL NUMBER: R13VH7EAI; Z14VH7EAI, AK, AL, AW

Category Dimension / Capacity

Length

Width 50 in. / 127 cm

Height

Wheel Base 77 in. / 196 cm

Ground Clearance 10 in. / 25.4 cm

Dry Weight 994 lbs. / 451 kg

Gross Vehicle Weight 1727 lbs. / 783 kg

Front Storage Capacity 25 lbs. / 11.3 kg

Cargo Box Dimension

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

103 in. / 261.6 cm

69 in. / 175.3 cm

42 in. x 22 in. / 107 cm x 56 cm

740 lbs. / 335.6 kg

(Includes rider(s), cargo, accessories

and trailer tongue weight)

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GENERAL INFORMATION

MODEL: 2014 RZR 800 XC

MODEL NUMBER: Z14VH7EAJ

Category Dimension / Capacity

Length

Width 55 in. / 139.7 cm

Height

Wheel Base 77 in. / 196 cm

Ground Clearance 11.3 in. / 28.7 cm

Dry Weight 1100 lbs. / 499 kg

Gross Vehicle Weight 1727 lbs. / 783 kg

Front Storage Capacity 25 lbs. / 11.3 kg

Cargo Box Dimension

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

Front Wheel Type / Size

Rear Wheel Type / Size

Front Tire Type / Size Maxxis Bighorn / 26 x 9 R12

Rear Tire Type / Size Maxxis Bighorn / 26 x 11 R12

Walker Evans Preload Front / Rear

Walker Evans Clicker Setting (Stock)

1.25 in. (3.175 cm) / 1.875 in. (4.76 cm)

103 in. / 261.6 cm

69 in. / 175.3 cm

42 in. x 22 in. / 107 cm x 56 cm

740 lbs. / 335.6 kg

(Includes rider(s), cargo, accessories

and trailer tongue weight)

Aluminum / 14 x 7

Aluminum / 14 x 9

6 Turns from full soft

MODEL: 2013–2014 RZR / EPS 800

MODEL NUMBER: R13VH76AC, AD, AN, AS; Z14VH76AC, AD

MODEL NUMBER: R13VH7EAI; Z14VH7EAI, AJ, AK, AL, AW

Engine

Platform

Engine Number

Engine Displacement

Number of Cylinders

Bore & Stroke (mm)

Compression Ratio

Compression Pressure 165 - 185 psi

Engine Idle Speed

Engine Max Operating RPM

Lubrication

Oil Requirements PS-4 Synthetic

Oil Capacity 2 qts. / 1.9 liters

Coolant Capacity 4.8 qts. / 4.5 liters

Overheat Warning

Exhaust System Dual Headpipe / Single Silencer

Fuel System Type

Fuel Delivery Electronic Fuel Pump (in tank)

Fuel Pressure

Fuel Filters

Fuel Capacity / Requirement

Alternator Rated Output 500 Watts @ 3000 RPM

Headlights (Halogen)

Headlights (LED)

Tail / Brake 2 - 6 Watts / 2 - 27 Watts

Starting System

Ignition System Bosch M17 (ECU Controlled)

Ignition Timing (Variable) 3° - 10° BTDC @ 1200 RPM

Spark plug / Gap RC7YC3 / 0.035 in. (0.9 mm)

Battery (RZR)

Battery (RZR EPS)

Instrument Type

H.O. Domestic Twin Cylinder,

Liquid Cooled, 4-Stroke

1204670 RZR800-13

760cc H.O.

80 x 76.5 mm

11:1

1250 ± 100 RPM

6600 RPM

Pressurized Wet Sump

Instrument Cluster Indicator

Fuel System

Bosch M17 EFI

2013: 45 +/- 2 psi (310 +/- 14 kPa) 2014: 58 +/- 2 psi (400 +/- 14 kPa)

See Chapter 4

7.25 gal. (27.4 liters)

87 Octane (minimum)

Electrical

2 - Halogen: Low 55 W / High 60

Low 27 Watts; High 40 Watts

18 Amp Hr. / 310 CCA / 12 Volt

Multifunction Instrument Cluster

2 - Dual Beam LED:

Electric Start

Yuasa YTX20HL /

Deka ETX30L / 30 AH

365 CCA / 12 Volt

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GENERAL INFORMATION

Engine

DC Outlet Standard 12 Volt

Relays

Circuit Breaker

Fuses (Fuse/Relay Box)

Fuses (Power Fuse Holder)

Chassis / EFI / Fan

Fuel Pump / EPS

Fan Motor: 20 Amp

Drive / Fuel Pump: 10 Amp

Lights / EFI / Accessory: 20 Amp

EFI: 20 Amp

Chassis / EPS: 30 Amp

Drivetrain

Transmission Type

Drive Ratio - Front 3.82:1

Drive Ratio - Final 3.70:1

Shift Type

Front Gearcase Fluid Type / Capacity

Transmission: Main Gearcase Fluid Type / Capacity

Transmission: Transfer Case Fluid Type / Capacity

Rear Gearcase Fluid Type / Capacity

Clutch Type (Standard Model)

Clutch Type (EPS Model)

Drive Belt 3211113

Steering / Suspension

Front Suspension

Front Travel 9 in. / 23 cm

Rear Suspension Rolled IRS w/Anti-Sway Bar

Rear Travel 9.5 in. / 24 cm

Shock Preload Adjustment Front / Rear

Toe Out

Wheels / Brakes

Front Wheel Type / Size

Rear Wheel Type / Size

Front Tire Type / Size

Rear Tire Type / Size

Tire Air Pressure - Front / Rear

Brake - Front / Rear

Brake Fluid DOT 4

Polaris Automatic PVT

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

Polaris Demand Drive

6.75 oz. (200 ml)

Polaris AGL

24 oz. (710 ml)

Polaris AGL

14 oz. (414 ml)

Polaris Premium ADF

26 oz. (769 ml)

Standard PVT

PVT with EBS

Independent Dual A-arm

w/Anti-Sway Bar

Cam Adjustment

1/8 - 1/4 in. (3 - 6.4 mm)

Steel / 12 x 6

Aluminum / 12 x 6

Steel / 12 x 8

Aluminum / 12 x 8

Ancla / 25 x 8 R12

Maxxis / 25 x 8 R12

Ancla / 25 x 10 R12

Maxxis / 25 x 10 R12

8 psi (55 kPa)

Foot Actuated - 4 Wheel

Hydraulic Disc

CLUTCH CHART (All Non-EPS Models)

Meters

(Feet)

Altitude

0-1500

(0-5000)

1500-3700

(5000 - 12000)

Shift

Weight

23-62

(5632337)

23-58 (B)

(1322911)

Drive

Spring

Green

(7043789)

Green

(7043789)

CLUTCH CHART (EPS Model with EBS)

Meters

(Feet)

Altitude

0-1500

(0-5000)

1500-3700

(5000 - 12000)

Shift

Weight

23-66

(5632763)

23-62

(5632337)

Drive

Spring

Green

(7043789)

Green

(7043789)

Driven Spring

Blk / Almond

(7043167)

Blk / Almond

(7043167)

Driven Spring

Red

(3234452)

Red

(3234452)

1.8

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GENERAL INFORMATION

MODEL: 2013–2014 RZR S 800

MODEL NUMBER: R13VE76AD, AI, AS, AW; Z14VE76AD, AL, AS, AV, AW

Category Dimension / Capacity

Length

Width 60.5 in. / 154 cm

Height

Wheel Base 77 in. / 196 cm

Ground Clearance 12.5 in. / 32 cm

Dry Weight 1022 lbs. / 464 kg

Gross Vehicle Weight

Front Storage Capacity

Cargo Box Dimension

Cargo Box Capacity

Maximum Weight Capacity (Payload)

Hitch Towing Capacity

Hitch Tongue Capacity

104 in. / 264.2 cm

70.5 in. / 179 cm

1782 lbs. / 808 kg

25 lbs. / 11.3 kg

42 in. x 22 in. / 107 cm x 56 cm

300 lbs. / 136 kg

740 lbs. / 335.6 kg

(Includes rider(s), cargo,

accessories and trailer tongue

weight)

1500 lbs. / 680 kg

150 lbs. / 68 kg

MODEL: 2013–2014 RZR S INT’L 800

MODEL NUMBER: R13VE76FI, FX; Z14VE76FI, FX

Category Dimension / Capacity

Length

Width 60.5 in. / 154 cm

Height

Wheel Base 77 in. / 196 cm

Ground Clearance 12.5 in. / 32 cm

Dry Weight 1038 lbs. / 471 kg

Gross Vehicle Weight

Front Storage Capacity

Cargo Box Dimension

Cargo Box Capacity

Maximum Weight Capacity (Payload)

Hitch Towing Capacity

Hitch Tongue Capacity

104 in. / 264.2 cm

70.5 in. / 179 cm

1782 lbs. / 808 kg

25 lbs. / 11.3 kg

42 in. x 22 in. / 107 cm x 56 cm

300 lbs. / 136 kg

740 lbs. / 335.6 kg

(Includes rider(s), cargo,

accessories and trailer tongue

weight)

1500 lbs. / 680 kg

150 lbs. / 68 kg

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GENERAL INFORMATION

MODEL: 2013 RZR S / INT’L 800

MODEL NUMBER: R13VE76AD, AI, AS, AW; Z14VE76AD, AL, AS, AV, AW

MODEL NUMBER: R13VE76FI, FX; Z14VE76FI, FX

Engine

Platform

Engine Number

Engine Displacement

Number of Cylinders

Bore & Stroke (mm)

Compression Ratio

Compression Pressure 165 - 185 psi

Engine Idle Speed

Engine Max Operating RPM

Lubrication

Oil Requirements PS-4 Synthetic

Oil Capacity 2 qts. / 1.9 liters

Coolant Capacity 4.8 qts. / 4.5 liters

Overheat Warning

Exhaust System

Fuel System

Fuel System Type

Fuel Delivery

Fuel Pressure

Fuel Filters

Fuel Capacity / Requirement

Electrical

Alternator Rated Output 500 Watts @ 3000 RPM

Headlights (Halogen)

H.O. Domestic Twin

Cylinder, Liquid Cooled, 4-

Stroke

1204670 RZR800-13

760cc H.O.

80 x 76.5 mm

11:1

1250 ± 100 RPM

6750 RPM

Pressurized Wet Sump

Instrument Cluster

Indicator

Dual Headpipe / Single

Silencer

Bosch M17 EFI

Electronic Fuel Pump (in

tank)

2013: 45 +/- 2 psi (310 +/-

14 kPa)

2014: 58 +/- 2 psi (400 +/-

14 kPa)

See Chapter 4

7.25 gal. (27.4 liters)

87 Octane (minimum)

2 - Halogen: Low 55 W /

High 60 W

Engine

Headlights (LED)

Tail / Brake 2 - 6 Watts / 2 - 27 Watts

Starting System

Ignition System

Ignition Timing (Variable)

Spark plug / Gap

Battery

Instrument Type

DC Outlet Standard 12 Volt

Relays

Circuit Breaker

Fuses (Fuse/Relay Box)

Fuses (Power Fuse Holder)

Drivetrain

Transmission Type

Drive Ratio - Front 3.82:1

Drive Ratio - Final 3.70:1

Shift Type

Front Gearcase Fluid Type / Capacity

Transmission: Main Gearcase Fluid Type / Capacity

Transmission: Transfer Case Fluid Type / Capacity

Rear Gearcase Fluid Type / Capacity

Rear Gearcase (INT’L)

2 - Dual Beam LED:

Low 27 Watts; High 40

Watts

Electric Start

Bosch M17 (ECU

Controlled)

3° - 10° BTDC @ 1200

RPM

RC7YC3 / 0.035 in. (0.9

mm)

Yuasa YTX20HL /

18 Amp Hr. / 310 CCA / 12

Volt

Multifunction Instrument

Cluster

Chassis / EFI / Fan

Fuel Pump

Fan Motor: 20 Amp

Drive / Fuel Pump: 10 Amp Lights / EFI / Accessory: 20

Amp

EFI: 20 Amp

Chassis: 30 Amp

Polaris Automatic PVT

In Line Shift - H / L / N / R

/ P

Polaris Demand Drive

6.75 oz. (200 ml)

Polaris AGL

24 oz. (710 ml)

Polaris AGL

14 oz. (414 ml)

Polaris Premium ADF

26 oz. (769 ml)

Polaris Premium ADF

1.10

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GENERAL INFORMATION

Drivetrain

Fluid Type / Capacity 22 oz. (650 ml)

Clutch Type

Drive Belt 3211133

Steering / Suspension

Front Suspension / Shock

Front Travel 12 in. / 30.5 cm

Rear Suspension / Shock

Rear Travel 12 in. / 30.5 cm

Shock Preload Adjustment Front / Rear

Toe Out

Wheels / Brakes

Front Wheel Type / Size

Rear Wheel Type / Size

Front Tire Type / Size

Rear Tire Type / Size

Tire Air Pressure - Front / Rear

Brake - Front / Rear

Brake Fluid DOT 4

Standard PVT

Independent Dual A-arm

Standard: Monotube

FOX™: PODIUM

Rolled IRS w/Anti-Sway

Bar Standard: Monotube

FOX™: PODIUM

Standard: Cam

Adjustment

FOX™: Threaded

Spanner Wrench

Adjustment

1/8 - 1/4 in. (3 - 6.4 mm)

Aluminum / 12 x 6

Aluminum / 12 x 8

ITP “900XCT” / 27 x 9

R12

Maxxis Bighorn / 26 x 9

R12

ITP “900XCT” / 27 x 11

R12

Maxxis Bighorn / 26 x 12

R12

8 psi (55 kPa)

Foot Actuated - 4 Wheel

Hydraulic Disc

CLUTCH CHART

Altitude

0-1500

Meters

(Fee-

(0-5000)

1500-3700

(5000 -

12000)

Shift

Weight

23-62

(56323-

37)

23-58

(B)

(13229-

11)

Drive

Spring

Green

(70437-

89)

Green

(70437-

89)

Driven Spring

Blk /

Almond

(704316-

Blk /

Almond

(704316-

9924882 - 2013–2014 RZR 800

1.11

Page 18

GENERAL INFORMATION

MODEL: 2013 RZR 4 800

MODEL NUMBER: R13XE76AD

Category Dimension / Capacity

Length

Width 60.5 in. / 154 cm

Height

Wheel Base 103 in. / 262 cm

Ground Clearance 11.5 in. / 29 cm

Dry Weight 1255 lbs. / 569 kg

Gross Vehicle Weight

Front Storage Capacity

Cargo Box Dimension

Cargo Box Capacity

Maximum Weight Capacity (Payload)

Hitch Towing Capacity

Hitch Tongue Capacity

130 in. / 330 cm

75 in. / 190.5 cm

2206 lbs. / 1000 kg

25 lbs. / 11.3 kg

42 in. x 22 in. / 107 cm x 56 cm

300 lbs. / 136 kg

900 lbs. / 408 kg

(Includes rider(s), cargo,

accessories and trailer tongue

weight)

1500 lbs. / 680 kg

150 lbs. / 68 kg

MODEL: 2013–2014 RZR 4 EPS 800

MODEL NUMBER: R13XE7EAI; Z14XE7EAL

Category Dimension / Capacity

Length

Width 60.5 in. / 154 cm

Height

Wheel Base 103 in. / 262 cm

Ground Clearance 11.5 in. / 29 cm

Dry Weight 1271 lbs. / 577 kg

Gross Vehicle Weight

Front Storage Capacity

Cargo Box Dimension

Cargo Box Capacity

Maximum Weight Capacity (Payload)

Hitch Towing Capacity

Hitch Tongue Capacity

130 in. / 330 cm

75 in. / 190.5 cm

2206 lbs. / 1000 kg

25 lbs. / 11.3 kg

42 in. x 22 in. / 107 cm x 56 cm

300 lbs. / 136 kg

900 lbs. / 408 kg

(Includes rider(s), cargo,

accessories and trailer tongue

weight)

1500 lbs. / 680 kg

150 lbs. / 68 kg

1.12

9924882 - 2013–2014 RZR 800

Page 19

GENERAL INFORMATION

MODEL: 2013 RZR 4 / EPS 800

MODEL NUMBER: R13XE76AD

MODEL NUMBER: R13XE7EAI; Z14XE7EAL

Engine

Platform

Engine Number

Engine Displacement

Number of Cylinders

Bore & Stroke (mm)

Compression Ratio

Compression Pressure 165 - 185 psi

Engine Idle Speed

Engine Max Operating RPM

Lubrication

Oil Requirements PS-4 Synthetic

Oil Capacity 2 qts. / 1.9 liters

Coolant Capacity 5.5 qts. / 5.2 liters

Overheat Warning

Exhaust System

Fuel System

Fuel System Type

Fuel Delivery

Fuel Pressure

Fuel Filters

Fuel Capacity / Requirement

Electrical

Alternator Rated Output 500 Watts @ 3000 RPM

Headlights (Halogen)

Headlights (LED)

H.O. Domestic Twin

Cylinder, Liquid Cooled, 4-

Stroke

1204671 RZR800-13

760cc H.O.

80 x 76.5 mm

11:1

1250 ± 100 RPM

6750 RPM

Pressurized Wet Sump

Instrument Cluster

Indicator

Dual Headpipe / Single

Silencer

Bosch M17 EFI

Electronic Fuel Pump (in

tank)

2013: 45 +/- 2 psi (310 +/-

14 kPa)

2014: 58 +/- 2 psi (400 +/-

14 kPa)

See Chapter 4

7.25 gal. (27.4 liters)

87 Octane (minimum)

2 - Halogen: Low 55 W /

High 60 W

2 - Dual Beam LED:

Engine

Low 27 Watts; High 40

Tail / Brake 2 - 6 Watts / 2 - 27 Watts

Starting System

Ignition System

Ignition Timing (Variable)

Spark plug / Gap

Battery

Instrument Type

DC Outlets

Relays

Circuit Breaker

Fuses (Fuse/Relay Box)

Fuses (Power Fuse Holder)

Transmission Type

Drive Ratio - Front 3.82:1

Drive Ratio - Final 3.70:1

Shift Type

Front Gearcase Fluid Type / Capacity

Transmission: Main Gearcase Fluid Type / Capacity

Transmission: Transfer Case Fluid Type / Capacity

Rear Gearcase Fluid Type / Capacity

Clutch Type

Drive Belt 3211133

3° - 10° BTDC @ 1200

RC7YC3 / 0.035 in. (0.9

Deka ETX30L / 30 AH

Multifunction Instrument

Drive / Fuel Pump: 10 Amp

Lights / EFI / Accessory: 20

Chassis / EPS: 30 Amp

Drivetrain

In Line Shift - H / L / N / R

Watts

Electric Start

Bosch M17 (ECU

Controlled)

RPM

mm)

365 CCA / 12 Volt

Cluster

(2) Standard 12 Volt

Chassis / EFI / Fan

Fuel Pump / EPS

Fan Motor: 20 Amp

Amp

EFI: 20 Amp

Polaris Automatic PVT

/ P

Polaris Demand Drive

6.75 oz. (200 ml)

Polaris AGL

24 oz. (710 ml)

Polaris AGL

14 oz. (414 ml)

Polaris Premium ADF

26 oz. (769 ml)

Standard PVT

9924882 - 2013–2014 RZR 800

1.13

Page 20

GENERAL INFORMATION

Drivetrain

Steering / Suspension

Independent Dual A-arm

Front Suspension / Shock

Front Travel 12 in. / 30.5 cm

Rear Suspension / Shock

Rear Travel 12 in. / 30.5 cm

Shock Preload Adjustment Front / Rear

Toe Out

Wheels / Brakes

Front Wheel Type / Size

Rear Wheel Type / Size

Front Tire Type / Size

Rear Tire Type / Size

Tire Air Pressure

Brake - Front / Rear

Brake Fluid DOT 4

FOX™ 2.0 PODIUM Top

FOX™ 2.0 PODIUM

Rolled IRS w/Anti-Sway

FOX™ 2.0 PODIUM Top

FOX™ 2.0 PODIUM

Threaded Spanner

Wrench Adjustment

1/8 - 1/4 in. (3 - 6.4 mm)

ITP “900XCT” / 27 x 9

Maxxis Bighorn / 26 x 9

ITP “900XCT” / 27 x 11

Maxxis Bighorn / 26 x 12

Front: 10 psi (69 kPa)

Rear: 12 psi (83 kPa)

Foot Actuated - 4 Wheel

Fill

Piggyback

Bar

Fill

Piggyback

Aluminum / 12 x 6

Aluminum / 12 x 8

R12

Hydraulic Disc

CLUTCH CHART

Altitude

0-1500

(0-5000)

1500-3700

(5000 -

12000)

Me-

ters

(Fee-

1.14

Shift

Weight

23-62

(56323-

37)

23-58

(B)

(13229-

11)

Drive

Spring

Green

(70437-

89)

Green

(70437-

89)

Driven

Spring

Blk /

Almond

(704316-

Blk /

Almond

(704316-

9924882 - 2013–2014 RZR 800

Page 21

MISC. SPECIFICATIONS AND CHARTS

Conversion Table

GENERAL INFORMATION

Unit of Measure

ft-lbs

in-lbs x 0.0833

ft-lbs x 1.356 = Nm

in-lbs x 0.0115 = kg-m

Nm x 0.7376

kg-m x 7.233 = ft-lbs

kg-m x 86.796 = in-lbs

kg-m x 10 = Nm

inch x 25.4

inch x 2.54

mile (mi) x 1.6 = km

km x 0.6214 = mile

ounces (oz) x 28.35 = grams (g)

fluid ounces (fl oz)

cubic centimeters (cc)

grams (g) x 0.035

pounds (lb)

kilogram (kg) x 2.2046 = lbs

cubic inches (cu in) x 16.387

cubic centimeters (cc)

US quarts x 0.946 = liters (L)

liters (L)

US gallons

liters (L) x 0.264 = US gallons

PSI

kilopascals (kPa)

π (3.14) x Radius² x Height =

°C to °F: 9/5 (°C + 32) = °F

°F to °C: 5/9 (°F − 32) = °C

Multiplied by

x 12 = in-lbs

x 0.03937 = inch

x 29.57

x .03381

x 0.454 = kg

x 0.061 = cubic inches

x 1.057

x 3.785

x 6.895

x 0.145

Converts to

= ft-lbs

= mm

= cm

= cubic centimeters (cc)

= fluid ounces

= ounces

= cc

= US quarts

= liters (L)

= kilopascals (kPa)

PSI

= cylinder volume

9924882 - 2013–2014 RZR 800

1.15

Page 22

GENERAL INFORMATION

Standard Bolt Torque Specification

Bolt Size

1/4-20

1/4-28

5/16-18

5/16-24

3/8-16

3/8-24

7/16-14

7/16-20

1/2-13

1/2-20

Grade 2

Ft. Lbs. (Nm)

5 (7) 8 (11) 12 (16)

6 (8) 10 (14) 14 (19)

11 (15) 17 (23) 25 (35)

12 (16) 19 (26) 29 (40)

20 (27) 30 (40) 45 (62)

23 (32) 35 (48) 50 (69)

30 (40) 50 (69) 70 (97)

35 (48) 55 (76) 80 (110)

50 (69) 75 (104) 110 (152)

55 (76) 90 (124) 120 (166)

Metric Bolt Torque Specification

Bolt Size

M10

M12

M14

M16

M18

4.6 4.8 8.8 / 8.9 10.9 12.9

.3 (.5) .5 (.7) 1 (1.3) 1.5 (2) 1.5 (2)

.8 (1.1) 1 (1.5) 2 (3) 3 (4.5) 4 (5)

1.5 (2.5) 2 (3) 4.5 (6) 6.5 (9) 7.5 (10)

3 (4) 4 (5.5) 7.5 (10) 11 (15) 13 (18)

7 (9.5) 10 (13) 18 (25) 26 (35) 33 (45)

14 (19) 18 (25) 37 (50) 55 (75) 63 (85)

26 (35) 33 (45) 63 (85) 97 (130) 11 (150)

37 (50) 55 (75) 103 (140) 151 (205) 177 (240)

59 (80) 85 (115) 159 (215) 232 (315) 273 (370)

81 (110) 118 (160) 225 (305) 321 (435) 376 (510)

Grade 5

Ft. Lbs. (Nm)

Grade

Ft.— Lbs. (Nm) Dry Threads

Grade 8

Ft. Lbs. (Nm)

1.16

9924882 - 2013–2014 RZR 800

Page 23

GENERAL INFORMATION

SAE Tap / Drill Sizes

Thread Size Drill Size Thread Size Drill Size

#0–80 3/64 1/2–13 27/64

#1–64 53 1/2–20 29/64

#1–72 53 9/16–12 31/64

#2–56

#2–64

#3–48 5/64 5/8–18 37/64

#3–56

#4–40

#4–48

#5–40 38 7/8–14 13/16

#5–44 37 1–8 7/8

#6–32

#6–40

#8–32

#8–36

#10–24

#10–32 21 1 1/2–6 1 11/32

#12–24 17 1 1/2–12 1 27/64

#12–28

1/4–20

1/4–28

5/16–18

5/16–24

3/8–16 O 2 1/2–4 2 1/4

3/8–24 Q 2 3/4–4 2 1/2

7/16–14

7/16–20 25/64

36 1–12

4.6 mm

F 2–12

U 3–4

2 1/4–4 1/2 2 1/32

9/16–18 33/64

5/8–11 17/32

3/4–10 21/32

3/4–16 11/16

7/8–9 49/64

59/64

1 1/8–7 63/64

1 1/8–12 1 3/64

1 1/4–7 1 7/64

1 1/4–12 1 11/64

1 3/4–5 1 9/16

1 3/4–12 1 43/64

2–4 1/2 1 25/32

1 59/64

2 3/4

Metric Tap / Drill Sizes

Tap Size

3 x .50 #39 0.0995 3/32

3 x .60 3/32 0.0937 3/32

4 x .70 #30 0.1285 1/8

4 x .75

5 x .80

5 x .90

6 x 1.00

7 x 1.00

8 x 1.00 J 0.277 9/32

8 x 1.25 17/64 0.265 17/64

9 x 1.00

9 x 1.25

10 x 1.25

10 x 1.50 R 0.339

11 x 1.50 3/8 0.375 3/8

12 x 1.50 13/32 0.406 13/32

12 x 1.75 13/32 0.406 13/32

Drill Size Decimal

1/8

#19

#20

16/64

5/16

11/32

0.125

0.166

0.161

0.196

0.234

0.3125

0.3437

Fraction

Nearest

1/8

11/64

5/32

13/64

15/64

5/16

11/32

9924882 - 2013–2014 RZR 800

1.17

Page 24

GENERAL INFORMATION

Decimal Equivalents

Fraction Decimal mm to inches

1/64 0.0156″

1/32

3/64

1/16

5/64 0.0781″ 2 mm = 0.0787″

3/32

7/64

1/8 0.1250″

9/64

5/32

11/64 0.1719″

3/16

13/64

7/32 0.2188″

15/64 0.2344″ 6 mm = 0.2362″

1/4

17/64

9/32 0.2813″

19/64

5/16

21/64 0.3281″

11/32

23/64

3/8 0.375″

25/64

13/32

27/64 0.4219″ 11 mm = 0.4331″

7/16 0.4375″

29/64

15/32 0.4688″ 12 mm = 0.4724″

31/64 0.4844″

1/2

33/64

17/32 0.5313″

35/64

9/16

37/64 0.5781″ 15 mm = 0.5906″

19/32 0.5938″

39/64

5/8

0.0312″ 1 mm = 0.0394″

0.0469″

0.0625″

0.0938″

0.1094″ 3 mm = 0.1181″

0.1406″

0.1563″ 4 mm = 0.1575″

0.1875″ 5 mm = 0.1969″

0.2031″

0.25″

0.2656″ 7 mm = 0.2756″

0.2969″

0.3125″ 8 mm = 0.3150″

0.3438″ 9 mm = 0.3543″

0.3594″

0.3906″ 10 mm = 0.3937″

0.4063″

0.4531″

0.500″ 13 mm = 0.5118″

0.5156″

0.5469″ 14 mm = 0.5512″

0.5625″

0.6094″

0.625″ 16 mm = 0.6299″

Fraction Decimal mm to inches

41/64 0.6406″

21/32

43/64

11/16

45/64 0.7031″ 18 mm = 0.7087″

23/32

47/64

3/4 0.750″

49/64

25/32

51/64 0.7969″

13/16

53/64

27/32 0.8438″

55/64 0.8594″ 22 mm = 0.8661″

7/8

57/64

29/32 0.9063″

59/64

15/16

61/64 0.9531″

31/32

63/64

1 1.000″

0.6563″ 17 mm = 0.6693″

0.6719″

0.6875″

0.7188″

0.7344″ 19 mm = 0.7480″

0.7656″

0.7813″ 20 mm = 0.7874″

0.8125″ 21 mm = 0.8268″

0.8281″

0.875″

0.8906″ 23 mm = 0.9055″

0.9219″

0.9375″ 24 mm = 0.9449″

0.9688″ 25 mm = 0.9843″

0.9844″

1.18

9924882 - 2013–2014 RZR 800

Page 25

MAINTENANCE

CHAPTER 2

MAINTENANCE

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

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

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

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

PRE-RIDE - 50 HOUR MAINTENANCE INTERVAL .. . . . . . .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. 2.4

100 - 300 HOUR MAINTENANCE INTERVAL . . . . .. .. . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. 2.5

MAINTENANCE QUICK REFERENCE . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. . . . . . .. . . . . . .. .. . . . .. . 2.6

MAINTENANCE QUICK REFERENCE, CONTINUED...... . . . .. . . . . . .. . . . . . .. . . . . . .. .. . . . .. . . . . . .. . . . 2.7

GREASE LUBRICATION POINTS .. . . .. .. . . . .. .. . . . .. .. . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . 2.8

LUBRICANTS / SERVICE PRODUCTS. . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . . 2.9

POLARIS LUBRICANTS, MAINTENANCE AND SERVICE PRODUCTS . .. .. . . . .. . . . . . .. . . . . . .. . . . . . 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 . . . . .. . . . . . .. . . . . . .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . .2.12

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

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

AIR FILTER SERVICE. . . .. .. . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. .. . . . .. .. . . . .. ..2.13

ENGINE . . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .2.15

ENGINE OIL LEVEL.. . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. .. . . . .. .. . . . .. . .2.15

ENGINE OIL AND FILTER SERVICE . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . .2.16

ENGINE BREATHER HOSE INSPECTION . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . .. .. . . .2.17

ENGINE AND TRANSMISSION MOUNTS . . .. .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . .. .. . . . . . .. . .2.17

COMPRESSION AND LEAKDOWN TEST . . .. .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . .. .. . . . .. .. . . . .. .. . .2.17

EXHAUST - SPARK ARRESTOR . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. . . . . . .. . . . . . .. .. . . . .. . . . . . ..2.17

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. . . . . .. . . . . . .. . . . . . .. . . . .. .. . . . .. .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . .2.24

COOLING SYSTEM OVERVIEW .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .2.24

COOLANT LEVEL INSPECTION . .. . . . . . .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. ..2.24

COOLANT STRENGTH / TYPE.. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. .2.24

COOLING SYSTEM PRESSURE TEST.. .. . . . .. .. . . . .. .. . . . .. .. . . . .. . . . . . .. . . . . . .. .. . . . .. .. . . . .. ..2.25

COOLING SYSTEM HOSES .. . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . .. .. . . . .. .. . . . .. .. . . . . . .. . . . . . .. . . . . . .2.25

RADIATOR.. .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. . . . . . .. . . . . . .. .. . . . .. .. . . . .. . . . . . .. . . . . . .. . . . . . ..2.25

9924707 - 2013–2014 RZR 800 Service Manual

2.1

Page 26

MAINTENANCE

COOLANT DRAIN. .. . . . . . .. . . . . . .. . . . .. .. . . . .. .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .2.25

FINAL DRIVE / WHEEL AND TIRE. . .. .. . . . .. .. . . . .. .. . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . 2.26

WHEEL AND HUB TORQUE TABLE. . .. .. . . . .. .. . . . . . .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .2.26

WHEEL REMOVAL.. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .2.26

WHEEL INSTALLATION. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . .2.26

TIRE INSPECTION. .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . .. .. . . . . . .. . . . . . .. . . . .. .. . . . .. .. . . . ..2.27

TIRE PRESSURE . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . . . .. . . . . . .. . . . .. .. . . .2.27

DRIVE SHAFT BOOT INSPECTION . . . .. .. . . . .. .. . . . .. .. . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . ..2.28

ELECTRICAL AND IGNITION SYSTEM .. . . .. .. . . . .. .. . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . .. .. . . . .. ..2.28

BATTERY MAINTENANCE . . . . .. .. . . . .. .. . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . 2.28

BATTERY REMOVAL . . . . . . .. . . . . . .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .2.29

BATTERY INSTALLATION.. . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. ..2.29

BATTERY OFF SEASON STORAGE .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . .2.29

BATTERY CHARGING (MAINTENANCE FREE) . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. ..2.29

SPARK PLUG SERVICE . .. . . . .. .. . . . .. .. . . . .. .. . . . . . .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .2.29

ENGINE TO FRAME GROUND. .. . . . . . .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. ..2.31

STEERING .. . . . . .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. . . . . . .. . . .2.31

STEERING INSPECTION .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . 2.31

STEERING WHEEL FREEPLAY. . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . .2.31

TIE ROD END / WHEEL HUB INSPECTION .. . . .. .. . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . .2.32

WHEEL TOE ALIGNMENT INSPECTION . .. .. . . . .. .. . . . .. .. . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . .2.33

WHEEL TOE ADJUSTMENT .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. . . . . . .. . . .2.33

SUSPENSION (STANDARD). . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .2.34

SPRING PRELOAD ADJUSTMENT .. . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . .. .. . . . .. .. . . . . . .. . . . .. .. . . . .2.34

SUSPENSION (FOX™) . .. . . . . . .. . . . . . .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. ..2.35

SPRING PRELOAD ADJUSTMENT .. . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . .. .. . . . .. .. . . . . . .. . . . .. .. . . . .2.35

SHOCK COMPRESSION ADJUSTMENT. . . . . .. . . . . . .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. ..2.36

BRAKE SYSTEM. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . .2.36

BRAKE FLUID INSPECTION . .. . . . . . .. . . . . . .. . . . . . .. .. . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . .2.36

BRAKE PAD / DISC INSPECTION . . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. .. . . . .. . . . . . .2.37

BRAKE HOSE AND FITTING INSPECTION .. . . . . . .. . . . . . .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . .2.37

2.2

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MAINTENANCE

PERIODIC MAINTENANCE CHART

Periodic Maintenance Overview

Inspection, adjustment and lubrication of important components are explained in the periodic maintenance chart.

Inspect, clean, lubricate, adjust and replace parts as necessary. When inspection reveals the need for replacement parts, use genuine Pure Polaris parts available from your Polaris dealer.

NOTE: Service and adjustments are critical. If you’re not familiar with safe service and adjustment procedures, have a qualified dealer perform these operations.

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

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MAINTENANCE

Pre-Ride - 50 Hour Maintenance Interval

Maintenance Interval

Item

Steering

■

Front / Rear Suspension

▶

Tires

▶

Brake Fluid Level

▶

Brake Pedal Travel

Brake Systems

Wheels / Fasteners

Frame Fasteners

▶

Engine Oil Level

▶

Air Filter

Coolant Level

Head Lamp / Tail Lamp

▶

Air Filter

▶

Brake Pad Wear 10 H

■

Battery

Engine Breather Filter

▶

(if equipped)

Engine Oil Change

▶

(Break-In Period)

Front Gearcase Oil

▶

(Demand Drive )

Rear Gearcase Oil

▶

(ATVAngle Drive Fluid)

Transmission - Main

▶

(AGL Gearcase Lubricant)

Transmission - Transfer

▶

(AGL Gearcase Lubricant)

▶

General Lubrication 50 H 3 M

Shift Linkage

Steering

■

Front / Rear Suspension

▶

■ Throttle Cable / Throttle Pedal 50 H 6 M

Throttle Body Air Intake Ducts /

Flange

Cooling System

▶ 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.

(whichever comes first)

Hou-

25 H

25 H 1 M

50 H 6 M

Calendar

Pre-Ride

Daily

Weekly

Monthly 100 (160) Inspect periodically

Monthly 250 (400)

Monthly 250 (400) Inspect; replace if necessary

Miles

Remarks

(KM)

250 (400)

250 (400) Initial fluid level inspection; add lubricant if needed

500 (800) Lubricate all fittings, pivots, cables, etc.

500 (800) Inspect, lubricate, adjust

500 (800)

500 (800) Inspect; adjust; lubricate; replace if necessary

500 (800) Inspect ducts for proper sealing / air leaks

500 (800)

Make adjustments as needed. See Pre-Ride Checklist on Page 2.10.

Inspect; replace as needed

Check level daily, change coolant every 2 years

Check operation; apply dielectric grease if replacing

Inspect; replace as needed

Check terminals; clean; test

Perform a break-in oil change after the first 25 hours or one month of operation

Lubricate

Inspect coolant strength seasonally; pressure test system yearly

2.4

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100 - 300 Hour Maintenance Interval

Maintenance Interval

Item

Engine Oil and

▶

Oil Filter Change

Front Gearcase Oil

▶

(Demand Drive )

Rear Gearcase Oil

▶

(ATVAngle Drive Fluid)

Transmission - Main

▶

(AGL Gearcase Lubricant)

Transmission - Transfer

▶

(AGL Gearcase Lubricant)

■ Fuel System

■ Spark Plug

Drive Belt 100 H 12 M

▶

Radiator 100 H 12 M

Cooling Hoses

▶

Engine Assembly Mounts

▶

Exhaust Muffler / Pipe

Wiring

▶

Clutches (Drive and Driven)

■

Front Wheel Bearings

■

▶

Shocks 100 H

▶

Shocks

■

Brake Fluid 200 H 24 M

Spark Arrestor

Toe Adjustment

■

Headlight Aim

▶ 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.

(whichever comes first)

Hours Calendar

100 H 6 M

100 H 12 M

- -

300 H 36 M

12 M

MAINTENANCE

Miles

(KM)

1000 (1600)

1000 (1600) Change lubricant

1000 (1600)

1000 (1600) Inspect; replace as needed

1000 (1600) Inspect; clean external surfaces

1000 (1600) Inspect for leaks

1000 (1600) Inspect, torque to specification

1000 (1600) Inspect

1000 (1600)

1000 (1600) Inspect; clean; replace worn parts

1000 (1600) Inspect; replace as needed

1500 (2400) Change shock oil and inspect seals

2000 (3200) Change every two years (DOT 4)

3000 (4800)

Perform a break-in oil change at 25 hours or one month / always replace oil filter when changing engine oil

Check for leaks at fill cap, fuel line / rail, and fuel pump: Replace lines every two years

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

Visually inspect shock seals

Clean out

Inspect periodically; adjust when parts are replaced

Adjust as needed

Remarks

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MAINTENANCE

Maintenance Quick Reference

III.

# Item Lube Rec. Method

Engine Oil

Engine Coolant

3 Brake Fluid Polaris DOT 4 Brake Fluid

* More often under severe use, such as operated in water or under severe loads.

Polaris PS-4 Performance Synthetic 4-Cycle Engine Oil

Polaris 60/40 Coolant

Add oil to proper level on dipstick

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

2.6

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Page 31

Maintenance Quick Reference,

Continued.....

MAINTENANCE

III.

# Item Lube Rec. Method

4 Front Gearcase Polaris Demand Drive

Rear Gearcase

6 Transmission

* More often under severe use, such as operated in water or under severe loads.

Polaris ATV Angle Drive Fluid (ADF)

Polaris AGL Gearcase Lubricant

Add lubricant until it is visible at the fill hole threads

Frequency*

Initial level check at 25 hours; change according to intervals

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MAINTENANCE

Grease Lubrication Points

There are grease fittings at each A-arms pivot point, each front or rear stabilizer bushing, and on the front

Item Recommended Lube Method

Front Propshaft Yoke(s)

A-arm Pivot Bushings

Stabilizer Bar Bushings

Polaris Premium U-Joint Grease

propshaft yoke. Apply grease until all traces of water have been purged out at each of these areas.

Frequency

Grease before long periods Grease fittings every 500 miles (800 km).

of storage, and after

thoroughly washing or

submerging the vehicle.

2.8

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MAINTENANCE

LUBRICANTS / SERVICE PRODUCTS

Polaris Lubricants, Maintenance and Service Products

Part No.

Engine Lubricant

2870791

2876244

2876245

2540086

2202166

2878068

2878069

2878070

2876160

2872276

2877922

2877923

2870465

2871312 Grease Gun Kit

2871322

2871423

2871460

2871515

2871551

2871329

2871323

2871534

Fogging Oil (12 oz. Aerosol)

PS-4 Performance Synthetic 4-Cycle Engine Oil (Quart)

PS-4 Performance Synthetic 4-Cycle Engine Oil (Gallon)

Engine Oil Filter

Engine Oil Change Kit (Twin Cylinder)

Gearcase / Transmission Lubricants

AGL Gearcase Lubricant (1 Qt.) (12 Count)

AGL Gearcase Lubricant (1 Gal.) (4 Count)

AGL Gearcase Lubricant (2.5 Gal.) (2 Count)

ATVAngle Drive Fluid

(8 oz.) (12 Count)

ATVAngle Drive Fluid (2.5 Gal) (2 Count)

Demand Drive (Quart)

Demand Drive (2.5 Gallon)

Oil Pump for 1 Gallon Jug

Grease / Specialized Lubricants

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

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

Starter Drive Grease (12 Count)

Premium U-Joint Lube (3 oz.) (24 Count)

Premium U-Joint Lube (14 oz.) (10 Count)

Dielectric Grease (Nyogel™)

60/40 Coolant (Gallon) (6 Count)

60/40 Coolant (Quart) (12 Count)

Description

Coolant

Part No.

Additives / Sealants / Thread Locking Agents /

2871950

2871326

2870652

2872189

2871557

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

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

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

Fuel Stabilizer (16 oz.) (12 Count)

DOT 4 Brake Fluid (12 Count)

Crankcase Sealant, 3-Bond 1215 (5 oz.)

Description

Misc.

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

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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.

• 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

• Ratcheting noise on deceleration

• Inability to engage into a gear

• Excessive gear lash (noise)

2.10

9924707 - 2013–2014 RZR 800 Service Manual

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.

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.

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NOTE: Refer to Chapter 4 for fuel pump replacement and all other information related to the EFI System.

2.11

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MAINTENANCE

Vent Lines

1. Check fuel tank, front gearcase, rear gearcase 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.

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.

Always check that the throttle pedal moves 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”).

2.12

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MAINTENANCE

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.

5. Slide back the cable adjuster boot.

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3. Remove the air filter assembly.

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MAINTENANCE

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

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

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

Installation

1. Clean the air box thoroughly.

2. Place the filter ring over the end of the filter.

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

3. Install the filter into the air box and be sure it fits tightly.

4. Install air box cap and secure with clips.

Air Box / Air Filter Exploded View

2.14

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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:

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).

• 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.

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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

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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

with skin, as serious burns may result.

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Oil Filter Wrench:

PU-50105: 2.5” (64 mm)

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.

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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.

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.

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Periodically clean spark arrestor to remove accumulated carbon (see “Periodic Maintenance Chart”).

1. Remove the retaining screw, nut and spark 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.

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4. Reinstall the arrestor and torque the screw to specification.

Spark Arrestor Screw:

40 in-lbs (4.5 Nm)

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TRANSMISSION AND GEARCASES

Transmission / Gearcase Specification Chart

MAINTENANCE

Gearcase Lubricant

Transmission

(Main Gearcase)

Transmission

(Transfer Case)

Front Gearcase Demand Drive

Rear Gearcase

Differential (INT’L)

AGL Gearcase

Lubricant

AGL Gearcase

Lubricant

ATVAngle Drive

Transmission Lubrication

Transmission Specifications

AGL Gearcase Lubricant (PN 2878068)

Specified Lubricant:

Approximate Capacity at Change:

Main Gearcase - 24 oz. (710 ml)

Transfer Case - 14 oz. (414 ml)

Drain / Level Plug Torque:

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

Fill Plug Torque:

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

Fluid

Capacity Fill Plug Torque

24 oz. (710 ml)

14 oz. (414 ml)

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

26 oz. (769 ml)

22 oz. (650 ml)

4. Add the recommended fluid through the fill plug hole

40-50 ft-lbs (54-68

Nm)

40-50 ft-lbs (54-68

Nm)

40-50 ft-lbs (54-68

Nm)

40-50 ft-lbs (54-68

Nm)

until it begins to flow out the level check plug hole.

Drain / Level Check

Plug Torque

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

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

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

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

Transfer Case - Lubricant Level Check:

1. Position vehicle on a level surface.

2. Remove the fill plug.

3. Remove the level check plug.

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5. Reinstall level check plug and torque to specification.

Level Check Plug:

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

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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.

Fill / Level Plug:

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

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Level Check Plug:

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

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.

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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.

1. Position vehicle on a level surface.

2. Remove the fill plug and check the fluid level.

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MAINTENANCE

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

4. Reinstall the fill plug and torque to specification.

Fill Plug:

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

Lubricant Change:

The drain plug is located on the bottom of the gearcase.

7. Reinstall the fill plug and torque to specification.

Fill / Drain Plug:

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

8. Check for leaks. Dispose of used lubricant properly.

Rear Gearcase Lubrication

The rear 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.

Rear Gearcase Specifications

Specified Lubricant:

ATVAngle Drive Fluid (PN 2876160)

Capacity: 26 oz. (769 ml)

RZR S INT’L Capacity: 22 oz. (650 ml)

Fill Plug Torque: 40-50 ft-lbs (54-68 Nm) Drain Plug Torque: 30-45 in-lbs (3-5 Nm)

1. Remove the fill plug.

2. Place a drain pan under the drain plug.

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

4. Clean the drain plug.

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

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

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MAINTENANCE

Lubricant Level Check:

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

1. Position the vehicle on a level surface.

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

3. Add the recommended lubricant as needed.

4. Reinstall the fill plug and torque to specification.

Lubricant Change:

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

1. Remove the fill plug.

2. Place a drain pan under the drain plug.

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

4. Clean the drain plug.

5. Reinstall the drain plug with new O-ring and torque to specification.

Fill Plug:

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

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Drain Plug:

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

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

7. Reinstall the fill plug and torque to specification.

Fill Plug:

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

8. Check for leaks. Dispose of used lubricant properly.

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MAINTENANCE

COOLING SYSTEM

Cooling System Overview

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

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

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

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:

1. Position the vehicle on a level surface.

2. Remove the hood from the front cab.

3. View the coolant level in the recovery bottle.

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Coolant Strength / Type

Test the strength of the coolant using an antifreeze hydrometer.

• A 50/50 or 60/40 mixture of antifreeze and distilled

water will provide the optimum cooling, corrosion protection, and antifreeze protection.

• Do not use tap water, straight antifreeze, or

straight water in the system. Tap water contains minerals and impurities which build up in the system.

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MAINTENANCE

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

Polaris 60/40 Anti-Freeze / Coolant

(PN 2871323)

Cooling System Pressure Test

Refer to Chapter 3 for cooling system pressure test procedure.

Cooling System Hoses

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

Radiator

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

2. Carefully straighten any bent radiator fins.

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

CAUTION

2. Check tightness of all hose clamps.

CAUTION

Do not over-tighten hose clamps at radiator or radiator

Radiator hose clamp torque is 36 in-lbs (4 Nm).

fitting may distort.

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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.

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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

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.

4. Attach the wheel nuts and finger tighten them.

5. Carefully lower the vehicle to the ground.

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MAINTENANCE

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

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

CAUTION

If wheels are improperly installed it could affect vehicle

handling and tire wear. On vehicles with tapered rear

wheel nuts, make sure tapered end of nut goes into

taper on wheel.

Tire Inspection

• Improper tire inflation may affect vehicle

maneuverability.

• When replacing a tire always use original

equipment size and type.

• The use of non-standard size or type tires may

affect vehicle handling.

WARNING

Operating with worn tires will increase the possibility of

the vehicle skidding easily with possible loss of control.

Worn tires can cause an accident.

Always replace tires when the tread depth measures 1/

8", (3 mm) or less.

Tire Tread Depth

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

Tire Pressure

Remove the valve stem cap and check tire pressure using the tire pressure gauge included in the vehicle’s tool kit.

CAUTION

Maintain proper tire pressure.

Refer to the warning tire pressure decal applied to the

vehicle.

RZR / RZR S

Tire Pressure Inspection (Cold)

Front Rear

8 psi (55 kPa) 8 psi (55 kPa)

10 psi (69 kPa) 12 psi (83 kPa)

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RZR 4

Tire Pressure Inspection (Cold)

Front Rear

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MAINTENANCE

Drive Shaft Boot Inspection

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.

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MAINTENANCE

Battery Removal

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. 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)

cable last.

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

Battery Off Season Storage

Refer to Chapter 10 “Electrical” for off season storage procedures.

Battery Charging (Maintenance Free)

Refer to Chapter 10 “Electrical” for charging procedure.

Spark Plug Service

1. Remove the rear service panel:

• RZR / RZR S: Remove the driver and passenger

seats.

• RZR 4: Remove both rear passenger seats.

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MAINTENANCE

WARNING

A hot exhaust system and engine can cause serious

burns. Allow engine to cool or wear protective gloves

when removing the spark plugs.

2. Remove the cargo box assembly to access the spark plugs (see Chapter 5).

3. Remove both spark plug caps and clean plug area so no dirt or debris can fall into engine when plugs are removed.

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

5. Remove spark plugs.

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

8. Measure gap with a wire gauge. Adjust gap if necessary by carefully bending the side electrode.

9. If necessary, replace spark plug with proper type.

CAUTION: Severe engine damage may occur if the incorrect spark plug is used.

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

11. Install spark plugs and torque to specification.

Spark Plug:

18 ft-lbs (24 Nm)

Recommended Spark Plug:

Champion RC7YC3

12. Install the plug caps to the appropriate cylinder by referencing the MAG and PTO spark plug cap decals.

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

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MAINTENANCE

Engine To Frame Ground

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: Whenever steering components are replaced, check front end alignment.

WARNING

Due to the critical nature of the procedures outlined in this chapter, Polaris recommends steering component

repair and adjustment be performed by an authorized

Polaris

MSD certified technician.

Use only genuine Polaris replacement parts.

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.

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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.

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MAINTENANCE

Wheel Toe Alignment Inspection

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.

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).

(A) - (B) = 1/8 to 1/4" (0.3 to 0.6 cm)

Wheel Toe-Out:

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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”.

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• 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.

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PN 2871095

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MAINTENANCE

SUSPENSION (FOX™)

Spring Preload Adjustment

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

Front Rear

4.34 in. (11 cm) 5.15 in. (13 cm)

RZR 4 (Base)

Factory Spring Preload Setting

Front Rear

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)

RZR 4 (L.E.) Factory Spring Preload Setting

Front Rear

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.

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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.

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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

Setting Compression Damping

Softest

Factory

Firmest 2 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.

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Brake Pad / Disc Inspection

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

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

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

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

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.

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MAINTENANCE

NOTES

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ENGINE

CHAPTER 3

ENGINE

ENGINE SPECIFICATIONS . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . 3.3

CRANKCASE EXPLODED VIEWS .. . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . .. .. . . . .. .. . . . . . .. . . . . . .. . 3.3

OIL PUMP / GEARS / ENGINE COVER EXPLODED VIEW. . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . 3.4

STATOR COVER / STARTER / WATER PUMP / LUBRICATION SYSTEM EXPLODED VIEW .. . . .. .. 3.5

CYLINDER / CYLINDER HEAD / PISTON EXPLODED VIEW . . . .. . . . . . .. . . . . . .. . . . .. .. . . . .. .. . . . .. . 3.6

ENGINE EFI SENSORS / VALVE COVER / GENERAL COMPONENTS EXPLODED VIEW . . . .. .. . . . 3.7

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

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

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

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

COOLING SYSTEM PRESSURE TEST.. .. . . . .. .. . . . .. .. . . . .. .. . . . .. . . . . . .. . . . . . .. .. . . . .. .. . . . .. ..3.12

PRESSURE CAP TEST .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. .3.12

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

RADIATOR REMOVAL . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .3.14

COOLING SYSTEM BLEEDING PROCEDURE . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . .3.15

GENERAL ENGINE SERVICE .. . .. . . . . . .. . . . . . .. . . . . . .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . . . .. . . . . . .. . . . . . .3.17

ENGINE LUBRICATION SPECIFICATIONS. . . . .. . . . . . .. . . . . . .. . . . . . .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . 3.17

OIL PRESSURE TEST .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . .3.17

ACCESSIBLE ENGINE COMPONENTS . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . .. .. . . . . . ..3.17

OIL FLOW CHART . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. . . . . . .. . . . . . .. .. . . . .. . . . . . .. . . . . . .. . . . . . ..3.18

ENGINE REMOVAL . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . .3.19

ENGINE / TRANSMISSION SEPARATION. .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . .3.27

ENGINE DISASSEMBLY AND INSPECTION . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . .. .. . . . .. .. . . . .. .. . . . .. ..3.28

CYLINDER HEAD ASSEMBLY EXPLODED VIEW . . .. . . . . . .. . . . . . .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . .3.28

ROCKER ARMS . . . . . . .. . . . . . .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .3.29

PUSH RODS. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . .3.29

CYLINDER HEAD REMOVAL . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . .. .. . . . .. .. . . . . . .. . . . .. .. . . . .. ..3.29

CYLINDER HEAD INSPECTION . . .. .. . . . .. .. . . . .. .. . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .3.30

CYLINDER HEAD WARP. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. . . . . . .. . . . . . .. .. . . . .. . . . . . .. . . .3.30

VALVE SEAL / SPRING SERVICE (ON ENGINE) .. . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. ..3.30

CYLINDER HEAD DISASSEMBLY . . . .. .. . . . .. .. . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . .3.31

VALVE INSPECTION . . . . . . .. . . . . . .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. ..3.32

COMBUSTION CHAMBER . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . .3.33

VALVE SEAT RECONDITIONING . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. . . . . . .. .. . . . .. .. . . . .3.33

CYLINDER HEAD REASSEMBLY . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. . . . . . .. .. . . . .. .. . . . .3.36

VALVE SEALING TEST .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. .3.36

CYLINDER REMOVAL . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. . . . . . .. .. . . . .. .. . . . .. . . . . . .. . 3.36

VALVE LIFTER REMOVAL / INSPECTION. . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . 3.37

PISTON REMOVAL . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. . . . . . .. . . . . . .. .. . . . .. . . . . . .. . . . . . .. . . . .3.37

CYLINDER INSPECTION . . . . .. .. . . . .. .. . . . .. .. . . . . . .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . .3.38

CYLINDER HONE SELECTION AND HONING PROCEDURE .. . . . .. . . . . . .. . . . . . .. .. . . . .. . . . . . .. . .3.40

HONING TO DEGLAZE . .. . . . . . .. . . . .. .. . . . .. .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . .3.40

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ENGINE

ENGINE REASSEMBLY . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . .3.55

ENGINE INSTALLATION . .. . . . . . .. . . . . . .. . . . . . .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . ..3.70

TROUBLESHOOTING . .. .. . . . .. .. . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . 3.72

CLEANING THE CYLINDER AFTER HONING . . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . 3.40

PISTON-TO-CYLINDER CLEARANCE . . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. .3.40

PISTON / ROD INSPECTION.. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. . . . . . .. . . . . . .. .. . . . .. . . . . . .. . . . . . .. . . .3.41

PISTON RING INSTALLED GAP . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . .. .. . . . .. .. . . . . . .. . . . .. .. . . . .3.42

STARTER DRIVE BENDIX REMOVAL / INSPECTION . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . .3.42

FLYWHEEL / STATOR REMOVAL / INSPECTION. . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .3.43

ENGINE CRANKCASE DISASSEMBLY / INSPECTION . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . .3.44

CAMSHAFT INSPECTION . . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .3.53

CRANKCASE REASSEMBLY .. . . . .. .. . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . .3.55

FLYWHEEL / STATOR INSTALLATION .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. ..3.65

CYLINDER HEAD REASSEMBLY . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . .3.66

OIL PUMP PRIMING .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . .3.69

ENGINE ASSEMBLY AND INSTALLATION .. . . . . . .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . . . .. . . . . . .. . . . . . .. . . .3.70

ENGINE BREAK-IN PERIOD . .. . . . . . .. . . . . . .. . . . . . .. .. . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . .3.71

ENGINE . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. . . . . . .. .. . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . ..3.72

COOLING SYSTEM . . . .. .. . . . .. .. . . . .. .. . . . .. . . . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. .. . . . .. ..3.73

3.2

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ENGINE SPECIFICATIONS

Crankcase Exploded Views

ENGINE

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ENGINE

Oil Pump / Gears / Engine Cover Exploded View

3.4

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Stator Cover / Starter / Water Pump / Lubrication System Exploded View

ENGINE

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ENGINE

Cylinder / Cylinder Head / Piston Exploded View

3.6

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Engine EFI Sensors / Valve Cover / General Components Exploded View

ENGINE

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ENGINE

Engine Torque Specifications

Fastener Size

Camshaft Gear 8 mm

Camshaft Phase Sensor Bolt 6 mm

Camshaft Thrust Plate 6 mm

Coolant Bleed Screw 6 mm

Coolant Bypass Hose Fitting

Counterbalance Gear 8 mm

Crankcase Bolts 8 mm

Crankcase Breather 5 mm

Cylinder Head Bolts

Exhaust Manifold 8 mm

Flywheel

Injector Rail

Magneto Cover

Oil Baffle Weldment 5 mm

Oil Drain Bolt (Crankcase)

Oil Fill Tube Bolt 5 mm

Oil Filter Pipe Fitting

Oil Pick Up

Oil Pressure Relief Plug

Oil Pump Housing Screw

Rocker Arm 8 mm

Rocker Cover 6 mm

Spark Plug

Starter Motor 6 mm

Stator Assembly

Stator Housing

Stator Wire Retainer Plate 5 mm

Thermistor Sensor 3/8 NPT

Thermostat Housing

Throttle Body Adaptor Bolts

T-MAP Sensor Bolt 5 mm

Water Pump Housing Cover

Water Pump Impeller Nut

3/8 NPT

11 mm

14 mm

8 mm

6 mm

12 mm

20 mm

5 mm

10 mm

6 mm

14 mm

6 mm

8 mm

6 mm

8 mm

in-lbs (Nm) ft-lbs (Nm)

50 ± 5 (5.65 ± 0.55)

115 ± 12 (13 ± 1.35) 9.5 ± 1 (13 ± 1.35)

70 ± 10 (7.9 ± 1.15)

120 (13.5)

84 ± 8 (9.5 ± 0.9)

216 ± 24 (24.5 ± 2.70) 18 ± 2 (24.5 ± 2.7)

* 96 ± 12 (10.85 ± 1.35)

60 ± 6 (6.8 ± 0.68)

192 ± 24 (21.7 ± 2.7) 16 ± (21.7)

50 ± 5 (5.64 ± 0.56)

60 ± 6 (6.8 ± 0.68)

* 84 ± 8 (9.5 ± 0.9)

216 ± 24 (24.5 ± 2.7) 18 ± 2 (24.5 ± 2.7)

* 84 ± 8 (9.5 ± 0.9)

84 ± 8 (9.5 ± 0.9)

* 96 ± 12 (10.85 ± 1.35)

84 ± 8 (9.5 ± 0.9)

216 ± 24 (24.5-± 2.7) 18 ± 2 (24.5 ± 2.7)

25 ± 3 (2.8 ± 0.3)

* 96 ± 12 (10.85 ± 1.35)

108 ± 3 (12 ± 0.35)

22 ± 2 (30 ± 3)

* 22 ± 2 (30 ± 3)

* 35 ± 4 (47.5 ± 5.4)

65 ± 7 (88 ± 9.50)

35 ± 4 (47.5 ± 5.4)

17 ± 2 (23 ± 2.7)

* 22 ± 2 (30 ± 3)

17 ± 2 (23 ± 2.7)

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

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800 EFI Engine Service Specifications

Cylinder Head - Engine Specifications

Main Component: Cylinder Head RZR800-13 (1204620)

Cam Lobe Height - Intake 1.357” (34.477 mm)

Cam Lobe Height - Exhaust 1.342” (34.096 mm)

Camshaft Journal Outer Diameter - Mag 1.654" ± 0.00039" (42 ± 0.01 mm)

Camshaft Journal Outer Diameter - Center

Camshaft Journal Outer Diameter - PTO

Camshaft

Counter Balance

Cylinder Head

Valve Seat

Valve Guide

Valve

Valve Spring

Camshaft Journal Bore Inner Diameter Mag

Camshaft Journal Bore Inner Diameter Center

Camshaft Journal Bore Inner Diameter PTO

Camshaft Oil Clearance

Camshaft End Play 0.0167" ± 0.0098" (0.425 ± 0.25 mm)

Counter Balance End Play 0.005" (0.127 mm)

Cylinder Head - Surface warp limit 0.00394" (0.10 mm)

Cylinder Head - Standard height 3.478" (88.35 mm)

Valve Seat - Contacting Width - Intake

Valve Seat - Contacting Width - Exhaust

Valve Seat Angle

Valve Guide Inner diameter

Valve Guide Protrusion Above Head

Valve Stem Diameter - Intake

Valve Stem Diameter - Exhaust

Valve Stem Oil Clearance - Intake

Valve Stem Oil Clearance - Exhaust

Valve Stem Overall Length - Intake 4.51" ± 0.01476" (114.555 ± 0.375 mm)

Valve Stem Overall Length - Exhaust 4.5453" ± 0.01496" (115.45 ± 0.38 mm)

Valve Spring Overall Length - Free Length 1.735" (46.069 mm)

Valve Spring Overall Length - Installed Height

ENGINE

1.634" ± 0.00039" (41.50 ± 0.01 mm)

1.614" ± 0.00039" (41 ± 0.01 mm)

1.656" ± 0.00039" (42.07 ± 0.01 mm)

1.637" ± 0.00039" (41.58 ± 0.01 mm)

1.617" ± 0.00039" (41.07 ± 0.01 mm)

0.00276" ± 0.00079" (0.07 ± 0.02 mm)

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

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

45.5° ± 0.255°

0.2367" ± 0.00029" (6.012 ± 0.007 mm)

0.807" ± 0.0039" (20.50 ± 0.01 mm)

0.2356" ± 0.00039" (5.985 ± 0.01 mm)

0.2351" ± 0.00039" (5.972 ± 0.01 mm)

0.00228" ± 0.00098" (0.058 ± 0.025 mm)

0.00275" ± 0.00098" (0.087 ± 0.025 mm)

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

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ENGINE

Cylinder / Piston - Engine Specifications

Main Components: Cylinder / Piston / Connecting Rod RZR800-13 (1204620)

Cylinder - Surface warp limit (mating with cylinder head)

Cylinder Bore - Standard 3.1495" (80 mm)

Cylinder

Lifter

Piston

Piston Pin

Cylinder Taper Limit 0.00031" (0.008 mm)

Cylinder Out of Round Limit 0.00030" (0.0075 mm)

Cylinder to Piston Clearance 0.0015" ± 0.00059" (0.04 ± 0.015 mm)

Lifter Outer Diameter Standard

Lifter Block Bore

Piston - Standard

Piston Standard Inner Diameter of Piston Pin Bore

Piston Pin Outer Diameter

Piston Pin - Standard Clearance - Piston Pin to Pin Bore

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

Piston / Connecting Rod / Crankshaft - Engine Specifications

Main Components: Piston / Connecting Rod RZR800-13 (1204620)

Top Ring - Standard 0.0059 - 0.0138" (0.15 - 0.35 mm)

Top Ring - Limit

Installed Gap

Piston Ring

Ring to Groove Clearance

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

Connecting Rod Small End

Connecting Rod

Crankshaft Crankshaft Runout Limit

Radial Clearance

Connecting Rod Big End Side Clearance

Connecting Rod Big End Radial Clearance

Second Ring - Standard 0.0098 - 0.0197" (0.25 - 0.50 mm)

Second Ring - Limit

Oil Ring - Standard 0.0197 ± 0.0098" (0.50 ± 0.25 mm)

Oil Ring - Limit

Top Ring - Standard 0.0024" ± 0.0008" (0.060 ± 0.02 mm)

Top Ring - Limit

Second Ring - Standard 0.0028" ± 0.0008" (0.070 ± 0.02 mm)

Second Ring - Limit

0.004" (0.10 mm)

0.84245" ± 0.00025" (21.398 ± 0.00635 mm)

0.8438" ± 0.00062" (21.4322 ± 0.0157 mm)

3.14803" ± 0.00028" (79.96 ± 0.007 mm)

0.70902" ± 0.00012" (18.009 ± 0.003 mm)

0.70866" - 0.70846" (18 - 17.995 mm)

0.00047" ± 0.00024" (0.012 ± 0.006 mm)

> 15% Leakdown

0.00098" ± 0.00039" (0.025 ± 0.01 mm)

0.01181" ± 0.00591" (0.30 ± 0.15 mm)

0.0015" ± 0.0006" (0.038 ± 0.015 mm)

0.00236" (0.06 mm)

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Special Tools

ENGINE

Part Number

PU-50105 OIL FILTER WRENCH

PU-45257 VALVE SPRING COMPRESSOR

PU-45652 VALVE PRESSURE HOSE

2871043 FLYWHEEL PULLER

2870390 PISTON SUPPORT BLOCK

PU-45497-1 CAM GEAR SPRING INSTALLATION KIT

PU-45497-2 CAM GEAR TOOTH ALIGNMENT TOOL

PU-45498 CAM SPANNER WRENCH

PU-45838 GEAR HOLDER

PA-44995 WATER PUMP MECHANICAL SEAL INSTALLER

PU-45543 UNIVERSAL DRIVER HANDLE

PA-45483 MAIN SEAL INSTALLER

PU-45658 CRANKSHAFT MAIN SEAL SAVER

PA-45401 WATER PUMP SEAL SAVER

2870975 MITY VAC™ PRESSURE TEST TOOL

PU-45778 OIL SYSTEM PRIMING TOOL

Bosch Automotive Service Solutions: 1-800-328-6657 or http://polaris.service-solutions.com/

Tool Description

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ENGINE

ENGINE COOLING SYSTEM

Cooling System Specifications

Condition

Room Temperature 68° F (20° C)

Thermostat Closed

Thermostat Open 180° F (82° C)

Fan Off

Thermostat Full Open Lift 202° F (94° C)

Fan On

Engine Temperature Overheat Indicator

Engine Protection Ignition Misfire

Engine Protection Shutdown

Item

Cooling System Capacity

Pressure Cap Relief

Polaris Premium Antifreeze

Coolant Temperature °F (°

175° F (79° C)

194° F (90° C)

205° F (96° C)

Moving Vehicle: 235° F (113° C)

Idle Vehicle:

Moving Vehicle: 239° F (115° C)

Idle Vehicle:

Moving Vehicle: 257° F (125° C)

Idle Vehicle:

Specification

RZR / RZR S

RZR 4

13 PSI

2871534 - Quart

2871323 - Gallon

241° F (116° C)

244° F (118° C)

262° F (128° C)

4.8 qts. (4.5 l)

5.5 qts. (5.2 l)

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

burns may result.

Allow the engine to cool before servicing.

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Cooling System Exploded View

ENGINE

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ENGINE

Radiator Removal

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.

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

8. Remove the (2) upper radiator retaining bolts and the (4) bolts retaining the lower radiator mount bracket. Remove the bracket from the frame.

9. Disconnect the fan motor and remove the radiator from the vehicle. Take care not to damage the cooling fins.

10. Reverse procedure for installation.

5. Allow coolant to completely drain.

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

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

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ENGINE

Cooling System Bleeding Procedure

WARNING

Always wear safety glasses and proper shop clothing

when performing the procedures in this manual. Failing

to do so may lead to possible injury or death.

CAUTION

Use caution when performing these procedures.

Coolant may be hot and may cause severe injury or

burns.

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

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

1. Drive the vehicle onto a slight incline 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.

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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.

the engine.

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ENGINE

GENERAL ENGINE SERVICE

Engine Lubrication Specifications

Oil Capacity: Approximately 2 U.S. Quarts (1.9 l)

Oil Type: Polaris PS-4 (PN 2876244)

or PS-4 Extreme Duty (PN 2878920)

Oil Filter: PN 2540086

Filter Wrench: PU-50105 - 2.5” (64 mm)

- Oil Pressure Specification -

27-55 PSI @ 6000 RPM, PS-4 Synthetic

Engine at operating temperature

Oil Pressure Test

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

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

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

NOTE: Use only Polaris PS-4 or Extreme Duty Synthetic 4-Cycle Engine Oil.

Accessible Engine Components

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

• Starter Motor / Drive

• Cylinder Head

• Cylinder

• Piston / Rings

• Rocker Arms

• Water Pump

The following components require engine removal for service:

• Flywheel

• Alternator (Stator)

• Counterbalance Shaft or Bearings

• Gear Train Components

• Camshaft

• Oil Pump / Oil Pump Drive Gear

• Connecting Rod

• Crankshaft

• Crankshaft Main Bearings

• Crankcase

Oil Pressure at 6000 RPM (Engine Hot):

Minimum: 27 PSI Standard: 31 PSI Maximum: 55 PSI

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ENGINE

Oil Flow Chart

This chart describes the flow of oil through the 800 EFI engine. Beginning in the crankcase sump, the oil is drawn through an oil galley to the feed side of the oil pump. The oil is then pumped through 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.

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Engine Removal

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).

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).

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

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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 factory and should be installed to the 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.

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19. Remove the rear stabilizer bar from the linkage on both sides of the vehicle.

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

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

23. Disconnect the T-MAP, IAC and TPS sensor connectors from throttle body.

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

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

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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 injector harness connectors before disconnecting them. The harnesses are different and can not be connected incorrectly (PTO Gray; MAG - Black).

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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 (see Chapter 2 “Shift Cable Inspection / Adjustment”).

30. Disconnect the transmission gear indicator switch harness.

31. Disconnect the CPS harness.

32. Disconnect the stator / alternator harness.

33. Disconnect the transmission speed sensor harness.

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34. Disconnect the cam phase sensor connector.

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

37. Pivot the A-arms upward and rear hub carriers downward and remove the drive shafts from the hub carriers.

38. Grasp the rear drive shafts and pull sharply outward on the shafts to disengage them from the rear gearcase.

36. Remove the through-bolt that attaches the upper Aarm to the rear hub on both sides of the vehicle.

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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.

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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.

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.

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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.

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ENGINE

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. 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).

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

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

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ENGINE

ENGINE DISASSEMBLY AND INSPECTION

Cylinder Head Assembly Exploded View

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Rocker Arms

1. Remove the valve cover.

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

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

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

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

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.

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.

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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.

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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.

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2. Using the Valve Spring Compressor (PU-45257), compress the valve spring and remove the valve keepers.

NOTE: A small parts magnet (A) can aid in the removal of the retainers (B).

NOTE: To prevent damage to the valve seals, do not compress the valve spring more than is needed to remove the valve keepers.

3. Remove spring retainer and spring.

4. The valve seals are now serviceable.

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

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

Cylinder Head Disassembly

1. Carefully remove the cylinder components.

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Valve Spring Free Length:

Std: 1.735" (44.069 mm)

4. Remove valve guide seals.

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

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

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.

3.32

Valve Stem Diameter:

Intake: 0.2356" ± 0.00039"

(5.985 ± 0.01 mm)

Exhaust: 0.2351" ± 0.00039"

(5.972 ± 0.01 mm)

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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.

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 measure each guide and valve combination individually.

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WARNING

Wear eye protection or a face shield during cylinder

head disassembly and reassembly.

Valve Seat Inspection

Inspect valve seat in cylinder head for pitting, burnt spots, roughness, and uneven surface. If any of the above conditions exist, the valve seat must be reconditioned. If the valve seat is cracked, the cylinder

head must be replaced.

Follow the manufacturers instructions provided with the valve seat cutters in the commercially available cylinder head reconditioning kit. Abrasive stone seat reconditioning equipment can also be used. Keep all valves in order with their respective seat.

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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.

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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

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.

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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.

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Valve Lifter Removal / Inspection

1. Remove the valve lifters by reaching into the crankcase and pushing the lifter up through the lifter bore by hand.

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

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

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.

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.

9924707 - 2013–2014 RZR 800 Service Manual

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ENGINE

4. Repeat procedure for second ring.

5. Remove the oil control ring.

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.

3.38

Cylinder Warp: 0.004" (0.1 mm) Max.

9924707 - 2013–2014 RZR 800 Service Manual