Polaris 2009 Ranger RZR 800 EFI, Manual

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2.14
MAINTENANCE
24. Route the cable around the circumference of the PVT cover
up and over to the throttle body.
25. Apply pipe sealant or PTFE Teflon® tape to the threads at
the end of the throttle cable.
NOTE: If using a liquid sealant, do not allow sealant
to contact the internal throttle cable.
26. Screw the throttle cable end into the throttle body.
27. Pull back on the throttle plate arm and insert the throttle
cable and brass bushing. Pull slack out of the cable at the
foot pedal end to ensure it stays in place.
28. Move to the front of the vehicle and route the upper portion
of the cable inside of the brake line.
29. From the left side of the vehicle, hold and align the throttle
cable bracket to the frame support with your left hand.
Reach into the footwell area with your right hand and start
the screws.
NOTE: May require an assistant.
30. Torque the retaining screws to 50 in. lbs. (5.6 Nm) .
31. Install the cable end and retainer into the throttle foot pedal.
32. Move back to the throttle body and check to see that the
throttle plate arm is resting against the stop. If not, turn in
the cable adjuster in (clockwise) until the throttle plate arm
rests on the stop.
33. Install the throttle body cover and PVT inlet duct.
34. Verify the vehicle is still in PARK.
35. Start the engine and allow it to warm up.
36. Measure the distance the throttle pedal moves before the
engine begins to pick up speed. Freeplay should be 1/16" -
1/8" (1.5 - 3 mm).
• If freeplay is correct, proceed to next step.
• If adjustment is required, refer to “ Throttle Freeplay
Adjustment ” procedure.
37. Using a 10 mm open-end wrench, tighten the jam nut
against the throttle body housing. Torque jam nut to
45 in. lbs. (5 Nm).
38. Apply a small amount of grease to the inside of the boot and
slide it over the cable adjuster.
39. Reassemble the vehicle using the appropriate areas of the
Service Manual as a reference if needed.
40. After reassembly, field test unit to ensure proper throttle
operation.
Air Filter Service
It is recommended that the air filter be inspected as part of
pre-ride inspection. When riding in extremely dusty conditions,
apply grease to the seal under the air box cap. In extremely dusty
conditions, air filter replacement will be required more often.
The filter should be inspected using the following procedure.
Removal
1. The air box is located just above the rear LH wheel in the
wheel well area.
2. Unlatch the (3) clips and remove the air box cap. Inspect
the seal. It should adhere tightly to the cover and seal all
the way around.
3. Remove air filter assembly and remove the pre-filter sleeve.
Air Box Location