Polaris 2011 RANGER RZR Service Manual Download Page 402

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IX.1

Air Filter Service

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.13

All Wheel Drive (AWD) Coil

. . . . . . . . . . . . . . . . . . . 10.15

Authorization Key

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.46

Authorization, Reflash

. . . . . . . . . . . . . . . . . . . . . . . . . . 4.44

AWD, Diagnosis

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.18

AWD, Operation

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.17

Balance Shaft Gear, Removal

. . . . . . . . . . . . . . . . . . . . . 3.42

Ball Joint Service

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.33

Battery Charging

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.27

Battery Installation

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.27

Battery Maintenance

. . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.26

Battery Removal

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.26

Battery Service

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.27

Battery Storage

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.28

Body Removal

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.18

Brake Burnishing

. . . . . . . . . . . . . . . . . . . . . . . . . 9.10

9.19

Brake Caliper Assembly, Front

. . . . . . . . . . . . . . 9.11

9.15

Brake Caliper Assembly, Rear

. . . . . . . . . . . . . . . . . . . . 9.20

Brake Caliper Inspection, Front

. . . . . . . . . . . . . . . . . . . 9.14

Brake Caliper Installation, Front

. . . . . . . . . . . . . . . . . . 9.15

Brake Caliper Removal, Front

. . . . . . . . . . . . . . . . . . . . 9.12

Brake Disc, Front

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.16

Brake Disc, Rear

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.23

Brake Hose and Fitting Inspection

. . . . . . . . . . . . . . . . . 2.34

Brake Pad Assembly, Front

. . . . . . . . . . . . . . . . . . . . . . . 9.9

Brake Pad Inspection

. . . . . . . . . . . . . . . . . . . . . . . . . . . 2.34

Brake Pad Thickness, Front

. . . . . . . . . . . . . . . . . . . . . . . 9.9

Brake Pads, Front

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.8

Brake Pads, Rear

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.18

Brake Pads, Removal, Front

. . . . . . . . . . . . . . . . . . . . . . . 9.8

Brake Pedal, Installation

. . . . . . . . . . . . . . . . . . . . . . . . . . 9.6

Brake Pedal, Removal

. . . . . . . . . . . . . . . . . . . . . . . . . . . 9.6

Brake System Inspection

. . . . . . . . . . . . . . . . . . . . . . . . 2.34

Brake System, Bleeding

. . . . . . . . . . . . . . . . . . . . . . . . . . 9.7

Brake System, Exploded View

. . . . . . . . . . . . . . . . . . . . . 9.5

Brake System, Operation

. . . . . . . . . . . . . . . . . . . . . . . . . 9.4

Brake, Front Pad Assembly

. . . . . . . . . . . . . . . . . . . . . . . 9.9

Break-In Period

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3

Break-In, PVT System (Belt)

. . . . . . . . . . . . . . . . . . . . . . 6.3

Breather Hose Inspection

. . . . . . . . . . . . . . . . . . . . . . . . 2.17

Cab Frame, Assembly / Removal (RZR / RZR S)

. . . . . . 5.4

Cab Frame, Assembly / Removal (RZR 4)

. . . . . . . . . . . . 5.5

Caliper, Front

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.11

Caliper, Rear

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.20

Cam Gear, Reassembly

. . . . . . . . . . . . . . . . . . . . . . . . . . 3.41

Cam Gear, Removal

. . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.40

Camshaft Phase Sensor

. . . . . . . . . . . . . . . . . . . . . . . . . . 4.33

Cargo Box Removal

. . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.20

Centralized Hilliard, Exploded View

. . . . . . . . . . . . . . . 7.16

Charging System

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.24

Charging System, Alternator Tests

. . . . . . . . . . . . . . . . 10.24

Chassis (RZR / RZR S)

. . . . . . . . . . . . . . . . . . . . . . . . . . 5.16

Chassis (RZR 4)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.17

Circuit Breaker

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.20

Clutch Offset Procedure

. . . . . . . . . . . . . . . . . . . . . . . . . . 6.8

Combustion Chamber

. . . . . . . . . . . . . . . . . . . . . . . . . . . 3.29

Communication Problems, Digital Wrench

. . . . . . . . . . 4.40

Compression Test

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.17

Console and Floor Panel Removal (RZR / RZR S)

. . . . 5.21

Console and Floor Panel Removal (RZR 4)

. . . . . . . . . . 5.21

Conversion Table

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.10

Coolant Level Inspection

. . . . . . . . . . . . . . . . . . . . . . . . 2.22

Coolant Strength and Type

. . . . . . . . . . . . . . . . . . . . . . . 2.22

Cooling System Bleeding Procedure

. . . . . . . . . . . . . . . . 3.13

Cooling System Hoses

. . . . . . . . . . . . . . . . . . . . . . . . . . 2.23

Cooling System Specifications

. . . . . . . . . . . . . . . . . . . . 3.11

Cooling System, Pressure Test

. . . . . . . . . . . . . . . . . . . . 3.11

Crankshaft Gear, Removal

. . . . . . . . . . . . . . . . . . . . . . . 3.42

Crankshaft Position Sensor (CPS)

. . . . . . . . . . . . . . . . . . 4.12

Cylinder Head Assembly

. . . . . . . . . . . . . . . . . . . . . . . . 3.31

Cylinder Head Assembly Exploded View

. . . . . . . . . . . 3.24

Cylinder Head Disassembly

. . . . . . . . . . . . . . . . . . . . . . 3.27

Cylinder Honing To De-glaze

. . . . . . . . . . . . . . . . . . . . . 3.35

Cylinder Inspection

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.34

Dash Instruments / Controls / Glovebox

. . . . . . . . . . . . . . 5.7

Decal Replacement

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.41

Decimal Equivalent Chart

. . . . . . . . . . . . . . . . . . . . . . . . 1.12

Diagnostic Code Table

. . . . . . . . . . . . . . . . . . . . . . . . . . 4.36

Diagnostic Codes, Instrument Cluster

. . . . . . . . . . . . . . 10.13

Digital Wrench Communication Errors

. . . . . . . . . . . . . 4.40

Digital Wrench Diagnostic Software

. . . . . . . . . . . . . . . 4.40

Digital Wrench Versions

. . . . . . . . . . . . . . . . . . . . . . . . . 4.40

Digital Wrench, Controller Reprogramming

. . . . . . . . . 4.44

Digital Wrench, Updates

. . . . . . . . . . . . . . . . . . . . . . . . . 4.42

Digital Wrench, Version and Update ID

. . . . . . . . . . . . . 4.41

Drive Belt, Inspection

. . . . . . . . . . . . . . . . . . . . . . . . . . . 6.10

Drive Belt, Installation

. . . . . . . . . . . . . . . . . . . . . . . . . . 6.10

Drive Belt, Removal

. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.10

Drive Clutch, Assembly

. . . . . . . . . . . . . . . . . . . . . . . . . 6.19

Drive Clutch, Exploded View

. . . . . . . . . . . . . . . . . . . . . 6.12

Drive Clutch, Operation

. . . . . . . . . . . . . . . . . . . . . . . . . . 6.2

Drive Clutch, Service

. . . . . . . . . . . . . . . . . . . . . . . . . . . 6.11

Drive Clutch, Shift Weights

. . . . . . . . . . . . . . . . . . . . . . 6.12

Drive Clutch, Spring

. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.11

Drive Shaft Boot Inspection

. . . . . . . . . . . . . . . . . . . . . . 2.25

Driven Clutch, Assembly

. . . . . . . . . . . . . . . . . . . . . . . . 6.23

Driven Clutch, Disassembly

. . . . . . . . . . . . . . . . . . . . . . 6.21

Driven Clutch, Exploded View

. . . . . . . . . . . . . . . . . . . . 6.21

Driven Clutch, Operation

. . . . . . . . . . . . . . . . . . . . . . . . . 6.3

Driven Clutch, Service

. . . . . . . . . . . . . . . . . . . . . . . . . . 6.21

Driveshaft / CV Joint, Handling Tips

. . . . . . . . . . . . . . . . 7.7

ECU Replacement

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.40

EFI Operation Overview

. . . . . . . . . . . . . . . . . . . . . . . . . . 4.9

EFI Priming / Starting Procedure

. . . . . . . . . . . . . . . . . . 4.10

Summary of Contents for 2011 RANGER RZR

Page 1: ...SERVICE MANUAL 2011 RANGER RZR RZR S RZR 4 PN 9923142...

Page 2: ...dures outlined in this Service Manual contact an authorized dealer for service We value your input and appreciate any assistance you can provide in helping make these publications more useful Please p...

Page 3: ...g instructions IMPORTANT IMPORTANT provides key reminders during disassembly assembly and inspection of components TRADEMARKS POLARIS ACKNOWLEDGES THE FOLLOWING PRODUCTS MENTIONED IN THIS MANUAL Locti...

Page 4: ...1 GENERAL INFORMATION 2 MAINTENANCE 3 ENGINE 4 ELECTRONIC FUEL INJECTION 5 BODY STEERING SUSPENSION 6 CLUTCHING 7 FINAL DRIVE 8 TRANSMISSION BRAKES 9 ELECTRICAL 10...

Page 5: ......

Page 6: ...1 3 PUBLICATION NUMBERS 1 3 REPLACEMENT KEYS 1 3 SPECIAL TOOLS 1 3 GENERAL SPECIFICATIONS 1 4 GENERAL 2011 RANGER RZR EPS 1 4 DETAILED 2011 RANGER RZR EPS 1 5 GENERAL 2011 RANGER RZR S EPS INT L 1 6...

Page 7: ...serial number The VIN can be found stamped on a portion of the front left frame rail close to the left front wheel see Figure 1 1 The engine model and serial number can be found on a decal applied to...

Page 8: ...isted or depicted are mandatory while other tools maybe substituted with a similar tool if available Polaris recommends the use of Polaris Special Tools when servicing any Polaris product Dealers may...

Page 9: ...22 in 107 cm x 56 cm Cargo Box Capacity 300 lbs 136 kg Maximum Weight Capacity Payload 740 lbs 335 6 kg Includesrider s cargo accessories and trailer tongue weight Hitch Towing Capacity 1500 lbs 680...

Page 10: ...365 CCA 12 Volt Instrument Type Multifunction Instrument Cluster DC Outlet Standard 12 Volt Relays Chassis EFI Fan Fuel Pump EPS Circuit Breaker Fan Motor 20 Amp Fuses Fuse Relay Box Drive Fuel Pump 1...

Page 11: ...07 cm x 56 cm Cargo Box Capacity 300 lbs 136 kg Maximum Weight Capacity Payload 740 lbs 335 6 kg Includesrider s cargo accessories and trailer tongue weight Hitch Towing Capacity 1500 lbs 680 kg Hitch...

Page 12: ...tandard 12 Volt Relays Chassis EFI Fan Fuel Pump EPS Circuit Breaker Fan Motor 20 Amp Fuses Fuse Relay Box Drive Fuel Pump 10 Amp Lights EFI Accessory 20 Amp Fuses Power Fuse Holder EFI 20 Amp Chassis...

Page 13: ...m x 56 cm Cargo Box Capacity 300 lbs 136 kg Maximum Weight Capacity Payload 900 lbs 408 kg Includesrider s cargo accessories and trailer tongue weight Hitch Towing Capacity 1500 lbs 680 kg Hitch Tongu...

Page 14: ...function Instrument Cluster DC Outlets 2 Standard 12 Volt Relays Chassis EFI Fan Fuel Pump EPS Circuit Breaker Fan Motor 20 Amp Fuses Fuse Relay Box Drive Fuel Pump 10 Amp Lights EFI Accessory 20 Amp...

Page 15: ...1 10 GENERAL INFORMATION 9923142 2011 RANGER RZR RZR S RZR 4 Service Manual Copyright 2010 Polaris Sales Inc MISC SPECIFICATIONS AND CHARTS Conversion Table C to F 9 5 C 32 F F to C 5 9 F 32 C...

Page 16: ...Sales Inc Standard Torque Specifications The following torque specifications are to be used only as a general guideline There are exceptions in the steering suspension and engine areas Always consult...

Page 18: ...oot Pound Ft lb A force of one pound at the end of a lever one foot in length applied in a rotational direction g Gram Unit of weight in the metric system gal Gallon ID Inside diameter in Inch inches...

Page 20: ...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 18 TRANSMISSION LUBRICATION 2...

Page 21: ...SPRING PRELOAD ADJUSTMENT 2 31 SUSPENSION FOX 2 31 SPRING PRELOAD ADJUSTMENT 2 31 SHOCK COMPRESSION ADJUSTMENT 2 32 SUSPENSION WALKER EVANS 2 33 SPRING PRELOAD ADJUSTMENT 2 33 SHOCK COMPRESSION ADJUST...

Page 22: ...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...

Page 23: ...E Air Filter Pre Ride Inspect replace as needed Coolant Level Daily Check level daily change coolant every 2 years Head Lamp Tail Lamp Daily Check operation apply dielectric grease if replacing E Air...

Page 24: ...00 Check for leaks at fill cap fuel line rail and fuel pump Replace lines every two years E Spark Plug 100 H 12 M 600 1000 Inspect replace as needed E Engine Oil Filter Change 100 H 6 M 1000 1600 Perf...

Page 25: ...to proper level on dipstick 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 2 Engi...

Page 26: ...Gearcase Polaris Demand Drive Plus Add lubricant until it is visible at the fill hole threads Check level every 25 hours change fluid yearly 5 Rear Gearcase Polaris ATV Angle Drive Fluid ADF Add lubr...

Page 27: ...bilizer bushing and on the front propshaft yoke Apply grease until all traces of water have been purged out at each of these areas Item Recommended Lube Method Frequency Front Propshaft Yoke s Polaris...

Page 28: ...us Gearcase Lubricant 2 5 Gal 2 Count 2876160 ATV Angle Drive Fluid 8 oz 12 Count 2872276 ATV Angle Drive Fluid 2 5 Gal 2 Count 2877922 Demand Drive Plus Quart 2877923 Demand Drive Plus 2 5 Gallon 287...

Page 29: ...e 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...

Page 30: ...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 n...

Page 31: ...rk position 2 Start the engine and warm it up thoroughly 3 Measure the distance the throttle pedal moves before the engine begins to pick up speed Freeplay should be 1 16 1 8 1 5 3 mm Adjustment 1 Rem...

Page 32: ...uired 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 th...

Page 33: ...e Manual Copyright 2010 Polaris Sales Inc Air Box Air Filter Exploded View Cap Seal Clip 3 Boot Air Box Can Air Intake Duct Breather Seal Fitting Breather Intake Box Air Filter Clamps Front Foam Seal...

Page 34: ...E 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 A...

Page 35: ...ilter with a film of fresh engine oil Check to make sure the O ring is in good condition 12 Installnew filter and turn by hand until filter gasket contacts the sealing surface then turn an additional...

Page 36: ...ndition Follow manufacturer s instructions to perform a cylinder leakage test never use high pressure leakage testers as crankshaft seals may dislodge and leak Exhaust Spark Arrestor Periodically clea...

Page 37: ...e to 30 45 in lbs 3 5 Nm 6 Reinstall the fill plug and torque to 40 50 ft lbs 54 68 Nm GEARCASE LUBRICANT CAPACITY FILL PLUG TORQUE DRAIN LEVEL CHECK PLUG TORQUE Transmission Main Gearcase AGL Plus Ge...

Page 38: ...ck 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 w...

Page 39: ...luid as needed Maintain the lubricant level even with the bottom threads of the fill plug hole 4 Reinstall the fill plug and torque to 8 10 ft lbs 11 14 Nm Lubricant Change The drain plug is located o...

Page 40: ...f the threads of the fill plug hole 3 Add the recommended lubricant as needed 4 Reinstall the fill plug and torque to 40 50 ft lbs 54 68 Nm Lubricant Change The drain plug is located on the bottom rig...

Page 41: ...he front cab 3 View the coolant level in 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...

Page 42: ...lieve 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 h...

Page 43: ...s 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...

Page 44: ...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 CAUTION If wheels are improperly installed it could affect...

Page 45: ...and lift the battery out of the vehicle WARNING CALIFORNIA PROPOSITION 65 WARNING Batteries battery posts terminals and related accessories contain lead and lead compounds and other chemicals known t...

Page 46: ...the rear service panel RZR RZR S Remove the driver and passenger seats RZR 4 Remove both rear passenger seats 2 Remove the cargo box assembly to access the spark plugs see Chapter 5 3 Remove both spar...

Page 47: ...ve 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 componen...

Page 48: ...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 approximatel...

Page 49: ...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 IMPORTANT When tightening the tie rod end jam nuts t...

Page 50: ...stment Suspension spring preload may be adjusted to suit different riding conditions or vehicle payloads 1 Raise and safely support the front or rear of the vehicle off the ground to allow the suspens...

Page 51: ...the clicker clockwise to increase compression damping Turn the clicker counter clockwise to decrease compression damping NOTE The factory setting is 8 clicks from closed RZR S and 10 clicks from clos...

Page 52: ...is turned counter clockwise until it stops the damping is in the fully open position Soft Turn the clicker clockwise to increase compression damping Turn the clicker counter clockwise to decrease comp...

Page 53: ...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...

Page 54: ...2 35 MAINTENANCE 2 9923142 2011 RANGER RZR RZR S RZR 4 Service Manual Copyright 2010 Polaris Sales Inc MAINTENANCE LOG Service Date Hours Miles km Service Performed Comments Dealer Technician...

Page 56: ...D ASSEMBLY EXPLODED VIEW 3 24 ROCKER ARMS PUSH RODS 3 25 CYLINDER HEAD REMOVAL 3 25 CYLINDER HEAD INSPECTION WARP 3 26 VALVE SEAL SPRING SERVICE ON ENGINE 3 26 CYLINDER HEAD DISASSEMBLY 3 27 VALVE INS...

Page 61: ...NE 9923142 2011 RANGER RZR RZR S RZR 4 Service Manual Copyright 2010 Polaris Sales Inc Engine EFI Sensors Valve Cover General Components Exploded View NOTE See chapter 4 for more information on the EF...

Page 62: ...16 24 24 5 2 70 18 2 24 5 2 7 Magneto Cover 6 mm 96 3 10 85 0 35 Oil Baffle Weldment 5 mm 60 6 6 8 0 68 Oil Drain Bolt Crankcase 12 mm 192 24 21 7 2 7 16 21 7 Oil Fill Tube Bolt 5 mm 50 5 5 64 0 56 Oi...

Page 63: ...unter Balance Counter Balance End Play 0 005 0 127 mm Cylinder Head Cylinder Head Surface warp limit 0 00394 0 1 mm Cylinder Head Standard height 3 478 88 35 mm Valve Seat Valve Seat Contacting Width...

Page 64: ...Piston Pin to Pin Bore 0 00047 0 00024 0 012 0 006 mm 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 P...

Page 65: ...871043 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...

Page 66: ...mps and water pump seals for leakage 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 av...

Page 67: ...ne Outlet Hose Radiator Radiator Shroud Radiator Pressure Cap Fan Motor Water Pump Cover Thermostat Housing Outlet Hose Inlet Hose Filler Neck To Top Fitting on Filler Neck To Lower Fitting on Filler...

Page 68: ...allows coolant to flow through the system 7 Squeeze the coolant lines by hand to help purge the system of air 8 Slightly loosen the bleed screw C on the cylinder head to let air escape If no air is p...

Page 69: ...d 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...

Page 70: ...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 f...

Page 71: ...ated 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...

Page 72: ...gnition 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 p...

Page 73: ...daptor 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 an...

Page 74: ...mission bell crank 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...

Page 75: ...o the rear hub on both sides of the vehicle 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...

Page 76: ...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 sta...

Page 77: ...cle components 49 Lift the front portion of the assembly out first to allow the engine valve cover to clear the vehicle frame 50 Remove propshaft from the transmission output shaft 51 Then move assemb...

Page 78: ...ollowing procedure to separate the engine from the assembly 1 Remove the drive belt drive clutch and driven clutch see Chapter 6 2 Remove the 6 fasteners retaining the inner clutch cover to the engine...

Page 79: ...ght 2010 Polaris Sales Inc ENGINE DISASSEMBLY AND INSPECTION Cylinder Head Assembly Exploded View Push Rods Hydraulic Lifters Valves Cylinder Head Coolant Bleeder Springs Spring Retainers Rocker Arms...

Page 80: ...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...

Page 81: ...linder head 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 hol...

Page 82: ...cations Replace spring if measurement is out of specification 4 Remove valve guide seals IMPORTANT It is recommended to replace seals whenever the cylinder head is disassembled Hardened cracked or wor...

Page 83: ...or damaged 4 Measure diameter of valve stem with a micrometer in three places then rotate 90 degrees and measure again six measurements total Compare to specifications 5 Measure valve guide C inside d...

Page 84: ...linder 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 reconditionin...

Page 85: ...nto place a few times 7 Remove valve and check where the Prussian Blue indicates seat contact on the valve face The valve seat should contact the middle of the valve face or slightly above and must be...

Page 86: ...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 PS 4 PLUS Synthetic engine oil 3 Install v...

Page 87: ...pport pistons with Piston Support Block PN 2870390 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...

Page 88: ...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 ne...

Page 89: ...t of round with a telescoping gauge or a dial bore gauge Measure in two different directions front to back and side to side on three different levels 1 2 down from top in the middle and 1 2 up from bo...

Page 90: ...ed inspect cylinder for thinning or peeling If cylinder wear or damage is excessive it will be necessary to replace the cylinder The cylinders are lined with a nicasil coating and are not repairable H...

Page 91: ...od Inspection 1 Measure piston pin bore 2 Measure piston pin O D Replace piston and or piston pin if out of specification 3 Measure connecting rod small end ID Piston to Cylinder Clearance See 800 EFI...

Page 92: ...e NOTE Always check piston ring installed gap after re boring a cylinder or when installing new rings A re bored cylinder should always be scrubbed thoroughly with hot soapy water rinsed and dried com...

Page 93: ...and washer 3 Install Flywheel Puller PN 2871043 and remove flywheel A 4 Use caution when removing the wire holddown B and the stator assembly D Do not tap or bump the gear stator housing cover or the...

Page 94: ...tarter bendix G wire holddown plate H and the woodruff key I from the crankshaft The stator does not have to be removed at this point 6 Remove the gear stator housing bolts and remove the gear stator...

Page 95: ...0 Inspect the cam gear teeth and check to make sure there is spring tension offsetting the teeth between the two gears If there is no tension check the springs inside of the cam gear assembly 11 The c...

Page 96: ...the spring Perform this procedure with all three tapered pins Do not push the pins too far through or the springs will pop out NOTE Do not remove the tapered pins at this time 17 Note in photograph t...

Page 97: ...clockwise from the timing mark NOTE For ease of installing the Cam Gear Alignment Tool PU 45497 2 use a twisting motion when pushing down on the tool 21 To remove the balance shaft gear the flat side...

Page 98: ...t gear if needed 26 Rotate the water oil pump gear S so that all four bolts are visible though the gear Remove the four bolts with a hex wrench Pull out the pump 27 Inspect the oil pump rotors for wea...

Page 99: ...apered end of the valve dowel in first If the valve is installed incorrectly oil pressure and oil priming problems will occur 31 Carefully press the gear off the assembly while supporting the housing...

Page 100: ...ft while supporting the housing 37 Remove thrust plate U 38 Remove PTO end engine mount Remove crankcase bolts Tap on the reinforced areas on the cases using soft hammer Carefully separate the two cra...

Page 101: ...crankshaft main journal bearings for abnormal wear It is recommended to replace the bearings anytime the engine is disassembled Camshaft Inspection 1 Thoroughly clean the cam shaft 2 Visually inspect...

Page 102: ...all oil pick up A if removed Torque to specification 2 Install oil baffle weldment B Torque bolts to specification 3 Install the balance shaft Inspect balance shaft clearance C in both gearcase halves...

Page 103: ...to the top gearcase halve NOTE Do not apply sealant to cam relief hole E 7 Assemble the crankcase halves Apply LocTite 242 PN 2871949 to the threads and pipe sealant to the bolt flanges Torque bolts...

Page 104: ...ning the piston pin holes to ensure proper alignment of the pistons to the connecting rods upon assembly Partially install the piston pins into the pistons NOTE To help align the pistons slide a rod t...

Page 105: ...ors on the oil pump shaft NOTE The application of lubrication aids in priming the oil pump during initial engine start up 19 Align the bolt holes and install oil pump assembly into crankcase Rotate th...

Page 106: ...the crankshaft gear to 250 F 121 C on a hot plate J 23 Use extreme caution when removing the crankshaft gear from the hot plate Use a pair of pliers and leather gloves when handling the crankshaft gea...

Page 107: ...the keyway on the balance shaft gear NOTE If the timing mark on the camshaft gear does not align properly remove the camshaft gear and tool Use the Cam Spanner Wrench PU 45498 to rotate the cam to th...

Page 108: ...TE Install the water pump seal N with the seal lip facing out towards the crankcase Use of a hydraulic press is recommended for this procedure 29 Install a new crankshaft seal P into the gear stator h...

Page 109: ...ls 34 Apply Crankcase Sealant PN 2871557 to the outside edges of the crankcase halves see arrows where the crankcases mate see the following photos This helps to prevent coolant leakage 35 Install the...

Page 110: ...eller with the washer and a new nut Q Torque the nut to specification 39 Install water pump cover R with new O ring seal Torque bolts to specification in proper sequence see Page 3 4 40 Sparingly appl...

Page 111: ...329 NOTE Verify stator wires are routed properly under the wire hold down bracket 3 Install the flywheel washer nut and key Torque flywheel nut to specification 4 Install stator housing with new O rin...

Page 112: ...push rods D and install into lifters 5 Lubricate rockers E with engine oil 6 Verify pushrods are engaged in lifters 7 Install rockers Be sure that tab of fulcrum F is seated in head stand off Torque...

Page 113: ...ce to specification 11 Install thermostat J new O ring and thermostat housing Torque to specification 12 Install 3 8 coolant hose fitting L and torque to specification 13 Install temperature sender K...

Page 114: ...t the transmission rear gearcase assembly while setting the engine in place 2 Lightly tighten all fasteners evenly to eliminate any gaps that may be present in the mounting areas 3 Torquefastenerstosp...

Page 115: ...ith unleaded fuel which has a minimum pump octane number of 87 R M 2 2 Check oil level indicated on dipstick Add oil if necessary Refer to Chapter 2 Engine Oil Level 3 Drive slowly at first to gradual...

Page 116: ...Over Dead battery Starter motor does not turn Engine seized rusted or mechanical failure Engine Runs But Will Not Idle Restricted fuel supply Low compression Crankcase breather restricted Engine Idle...

Page 117: ...ulty Ignition or kill switch circuit faulty Poor connections in ignition system Ignition timing incorrect Sheared flywheel key Cooling System Overheating Low coolant level Air in cooling system Wrong...

Page 118: ...4 20 FUEL PUMP REPLACEMENT 4 21 FUEL TANK REMOVAL RZR RZR S 4 24 FUEL TANK REMOVAL RZR 4 4 26 FUEL TANK INSTALLATION 4 28 IDLE AIR CONTROL IAC 4 29 IAC TEST REPLACEMENT 4 29 THROTTLE POSITION SENSOR...

Page 119: ...when the fuel reaches the bottom of the filler neck Leave room for expansion of fuel Never start the engine or let it run in an enclosed area Gasoline powered engine exhaust fumes are poisonous and c...

Page 120: ...software installs on laptop computers equipped with a CD drive and serial port connection and is designed to replace multiple shop tools often used to test EFI components It also includes step by ste...

Page 121: ...system Dirt even in small quantities can cause significant problems Do not use compressed air if the system is open Cover any parts removed and wrap any open joints with plastic if they will remain op...

Page 122: ...nifold Absolute Pressure Sensor T MAP 3 Crankshaft Position Sensor CPS 4 Fuel Injectors 5 Fuel Filter 6 Fuel Pump Regulator Fuel Level Sender located in fuel tank 7 Fuel Rail 8 Engine Coolant Sensor E...

Page 123: ...rubber intake boot between the throttle body and the cylinder head 3 Crankshaft Position Sensor CPS Located in the magneto cover between the engine and transmission just in front of the rear gear cas...

Page 124: ...ottle body above the TPS 9 Camshaft Phase Sensor Located in the engine block above the oil filter The sensor can be accessed through the right rear wheel well 10 Engine Coolant Temperature Sensor ECT...

Page 125: ...9923142 2011 RANGER RZR RZR S RZR 4 Service Manual Copyright 2010 Polaris Sales Inc FUEL TANK Exploded View Fuel Flow Fuel Filters Fuel Pump Assembly Quick Connect Fuel Line Fuel Rail Fuel Injectors...

Page 126: ...n Overview The EFI system is designed to provide peak engine performance with optimum fuel efficiency and lowest possible emissions The ignition and injection functions are electronically controlled m...

Page 127: ...TROL UNIT ECU Operation Overview The ECU is the brain or central processing computer of the entire EFI fuel ignition management system During operation sensors continuously gather data which is relaye...

Page 128: ...nt 1 Remove the 2 retaining screws holding the ECU 2 With the ignition turned off disconnect the wire harness from the ECU 3 To install reverse the procedure and tighten screws to specification TEMP M...

Page 129: ...tion This signal serves as a reference for the control of ignition timing by the ECU Synchronization of the CPS and crankshaft position takes place during the first two revolutions each time the engin...

Page 130: ...under CPS Test IMPORTANT In order to remove the CPS the rear portion of the exhaust system and the mounting bracket between the transmission and rear gearcase will need to be removed 3 Remove the exh...

Page 131: ...ting bracket fasteners when the transmission and rear gearcase are installed in the vehicle 1 Clean bolt threads with solvent and allow them to dry Coat the circumference of the first 4 threads of the...

Page 132: ...olt 5 Remove the special tool and attach an extension to the torque wrench Torque the bottom bolt that attaches the bracket to the rear gearcase through the hole in the frame support Bottom Rear Gearc...

Page 133: ...it from heat and vibration When the key switch is on the fuel rail is pressurized and the EFI relay provides voltage to the injectors During engine operation the ECU completes the ground circuit energ...

Page 134: ...se of filters and the detergent additives in the gasoline Symptoms that could be caused by dirty clogged injectors include rough idle hesitation stumble during acceleration or triggering of fault code...

Page 135: ...not be connected incorrectly PTO Gray MAG Black NOTE The harness connector and locking spring is bonded to the fuel injectors with an epoxy DO NOT attempt to disconnect the Bosch connector from the f...

Page 136: ...h is not promptly turned to the start position If the engine fails to start If the engine is stopped with the key switch on as in the case of an accident In these situations the check engine light wil...

Page 137: ...If the fuel pressure is out of specification replace the fuel pump assembly 6 If the pump did not activate Step 5 disconnect the harness connector from the fuel pump Connect a DC voltmeter across ter...

Page 138: ...the Fuel Pump Service Tool PU 50326 over the fuel pump PFA nut Using a 1 2 drive ratchet or breaker bar loosen and remove the PFA nut Discard the PFA nut NOTE Apply downward force on the fuel pump fl...

Page 139: ...s may require flashlight and mirror If debris like mud or sand is present fuel tank should be flushed and cleaned out prior to installation of new fuel pump assembly IMPORTANT It is recommended to rem...

Page 140: ...tion marks are still aligned between fuel pump and fuel tank 17 Torque PFA nut to specification using the Fuel Pump Service Tool PU 50326 and a calibrated torque wrench 18 Verify alignment of fuel pum...

Page 141: ...r tank removal NOTE A small amount of fuel may come out of the fuel line or tank Properly drain fuel into a suitable container 4 Disconnect the fuel pump electrical harness 5 Remove the fuel tank vent...

Page 142: ...the rear RH fender well and remove the fender well from the vehicle see chapter 5 11 Remove the 3 shift lever support bracket bolts and place the bracket out of the way of the fuel tank but do not rem...

Page 143: ...anel NOTE Remove the fuel tank cap and carefully lift the rocker panel up over the fuel tank filler neck 4 Remove the rocker panel from the vehicle 5 Remove the lower bolt retaining the seat belt mech...

Page 144: ...out of the way for removal of fuel tank 9 Disconnect the fuel pump electrical harness 10 Remove the fuel tank vent hose clamp with a suitable pliers and remove the vent line from the tank vent fitting...

Page 145: ...RZR S only Reinstall the rear RH panel divider and secure with fasteners RZR 4 5 Reinstall the seat belt mechanism and secure the lower bolt 6 Reinstall the RH rocker panel and all previously removed...

Page 146: ...the resistance values at each of the following pin locations of the IAC If any of the readings are out of specification replace the IAC IAC Replacement 1 Remove the seats rear service panel and the re...

Page 147: ...e following method With the test leads connected and the meter set to the ohms scale observe the reading at the following pin locations of the TPS TPS Tester Regulator The TPS reading can be checked b...

Page 148: ...be repositioned to obtain the proper voltage reading 1 Remove the seats rear service panel and the rear cargo box see Chapter 5 2 Loosen the hose clamps retaining the throttle body 3 Remove the thrott...

Page 149: ...for proper set up and testing Verify the 9 volt tester battery is new 2 Plug the TPS Tester harness into the new TPS 3 Set your voltmeter to read DC Volts Insert the red and black voltmeter probes int...

Page 150: ...it is faulty it must be replaced With the ignition key switch on the sensor should have battery voltage present on the Red Dark Blue wire and ground present on the Brown wire NOTE Use Digital Wrench...

Page 151: ...or and start the engine After a few seconds the fan should turn on and the Check Engine indicator should display on the instrument cluster This indicates all other components are working properly Refe...

Page 152: ...hich 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...

Page 153: ...nge from 0 to 9 This number represents the total number of trouble code present example 2 means there are 3 codes present The second number located top right can be 2 to 6 digits in length This number...

Page 154: ...Grounded 746 5 P1691 Driver Circuit Short to B 3 P1692 Driver Circuit Grounded 4 P1693 Fan Relay Driver Circuit Driver Circuit Open Grounded 1071 5 P1481 Driver Circuit Short to B 3 P1482 Driver Circ...

Page 155: ...9 12 C1070 IC CAN Communication with EPS EPS Off Line EPS DM1 not seen 520230 31 U0131 Idle Air Control Valve IAC M17 IAC Stepper Pin 1 Driver Circuit Open Grounded 520267 5 P1505 Driver Circuit Short...

Page 156: ...ooty exhaust smoke rough idle poor fuel economy engine runs rough misses poor performance bog engine loads up backfire Air intake restricted inspect intake duct Air filter dirty plugged Poor fuel qual...

Page 157: ...data contained within the original ECU is transferred to the replacement ECU Refer to procedure and carefullyfollow all instructions provided in Digital Wrench Guided Diagnostic Available Guided diagn...

Page 158: ...n 5 Once connected proceed with using Digital Wrench Digital Wrench Serial Number Location Open the configuration screen by clicking on the wrench icon The serial number is located on the right side o...

Page 159: ...gital Wrench Version 3 1 Updates IMPORTANT You must already have version 3 1 installed before adding these updates They will not install if you have version 3 0 or older on your PC 6 If the update fil...

Page 161: ...d the dealership is more likely to cause a reprogramming problem than one dedicated to Digital Wrench diagnostics only OBTAINING THE LATEST UPDATE Reprogramming updates are provided periodically and c...

Page 162: ...lect the model year product line and vehicle description by selecting the Change Vehicle Type icon 5 Select the Special Tests icon 6 Select Engine Controller Reprogramming 7 Select the file you want t...

Page 163: ...the same file type from the list that you selected previously while in Digital Wrench Enter the VIN along with the customer s name and address When completed click the Authorize button once to procee...

Page 164: ...al Copyright 2010 Polaris Sales Inc 15 At this point the reflash process will begin Do not touch the vehicle or PC during the process 16 Once the ECU reprogramming procedure is complete click the Fini...

Page 166: ...VER RZR 4 5 18 FRONT BUMPER 5 18 REAR BUMPER 5 19 HOOD AND FRONT BODY WORK 5 19 REAR FENDER FLAIR AND TIE DOWN REMOVAL 5 20 CARGO BOX ASSEMBLY REMOVAL 5 20 ROCKER PANELS CONSOLE AND FLOOR 5 21 STEERIN...

Page 167: ...SHOCK RZR S 5 43 FOX 2 0 PIGGYBACK SHOCK RZR 4 5 44 FOX SHOCK SERVICE 5 45 GENERAL SERVICE INFORMATION 5 45 FRONT SHOCK SERVICE INFORMATION 5 45 REAR SHOCK SERVICE INFORMATION 5 46 FOX SHOCK REBUILD...

Page 168: ...stle Nuts 80 ft lbs 108 Nm Wheel Nuts Cast Rims 90 ft lbs 122 Nm Wheel Nuts Steel Rims 27 ft lbs 37 Nm Tie Rod End Jam Nut 13 ft lbs 18 Nm Seat Belt to Seat Base 40 ft lbs 54 Nm Tilt Shock Upper Faste...

Page 169: ...lign the rear mount holes Fasten the rear cab frame brackets to vehicle with four 5 16 18 bolts and 5 16 18 nuts Tighten bolts to 16 18 ft lbs 22 24 Nm Fasten the two self tapping screws to the rear i...

Page 170: ...acket on each side Tighten tap screws to 15 ft lbs 20 Nm 3 Insert strap from safety net over front coupler post on front cab frame Fasten the front of the cab frame to the base brackets and mid cab fr...

Page 172: ...ice Manual Copyright 2010 Polaris Sales Inc Dash Instruments Controls Glovebox A Instrument Cluster Speedo B Headlight Switch C AWD 2WD or AWD 2WD TURF Switch D 12 Volt Accessory Receptacle E Key Swit...

Page 173: ...Copyright 2010 Polaris Sales Inc Hood Front Body Work Center Access Hood Hood Dash Front Bumper Front RH Fender Flair Front LH Fender Flair Winch Pocket Cover Push Rivets Push Rivets T27 Screws 1 4 T...

Page 174: ...ce Manual Copyright 2010 Polaris Sales Inc Front Bumper Rear Bumper Headlight O Ring T25 Screw T27 Screw T30 Screws Bulb Front Bumper Support Front Bumper Radiator Screen Winch Pocket Cover RH Tail Li...

Page 175: ...S Seat Base Asm Cap Plate Spring Lever Latch Body Grommets Seat Seat Back Seat Bottom Hoop Tube Nuts 41 57 in lbs 4 6 6 4 Nm 48 in lbs 5 4 Nm 41 57 in lbs 4 6 6 4 Nm Driver 3 Point Seat Belt Rear Seat...

Page 176: ...Belts Mounting RZR 4 Latch 3 Point Seat Belts Plunger 40 ft lbs 54 Nm Front Seats 3 Point Seat Belts 40 ft lbs 54 Nm 40 ft lbs 54 Nm Front Seat Base Rear Seat Base Rear Seat Support Rubber Bumpers 40...

Page 177: ...R S RH Rocker Console Cover LH Rocker Lower Floor Rear Front Push Rivets U Type Support Bracket Rear Support Bracket Push Rivets Support Bracket Front Support Bracket Self Tapping Screws Self Tapping...

Page 178: ...cker Console Cover LH Rocker Lower Floor Rear Front Push Rivets U Type Support Bracket Rear Support Bracket Support Bracket Torx Self Tapping Screws Self Tapping Screw Nuts Self Tapping Screw Upper Fl...

Page 179: ...ar LH Fender Flair Fender Rear LH Fender Cargo Box Tie Down Bracket Panel Divider Rear RH Panel Divider Rear Main Service Panel Supports Heat Shield Grommet Push Rivets Rivets T27 Tie Down Bracket Tor...

Page 180: ...ar LH Cargo Box Push Fender Flair Rear LH Fender Flair Fender Rear LH Fender Cargo Box Tie Down Bracket Floor Rear RH Floor Rear Console Cover Supports Heat Shield Grommet Rivet T27 Tie Down Bracket T...

Page 181: ...2 2011 RANGER RZR RZR S RZR 4 Service Manual Copyright 2010 Polaris Sales Inc Chassis Main Frame RZR RZR S Main Frame Bolt In Brace Skid Plate Rear Bumper Support 15 ft lbs 20 Nm 15 ft lbs 20 Nm 17 ft...

Page 182: ...Sales Inc Chassis Main Frame RZR 4 Main Frame Bolt In Brace Rear Rear Bumper Support 15 ft lbs 20 Nm 15 ft lbs 20 Nm 17 ft lbs 23 Nm 6 8 ft lbs 8 11 Nm Front Frame Washers Self Tapping Screws Nylok N...

Page 183: ...l 3 Lift the panel upward and towards the front of the vehicle to remove it Rear Console Cover RZR 4 1 Remove the rear passenger seats 2 Turn both latches 1 4 turn to disengage the cover 3 Pull out on...

Page 184: ...engage the rear portion of the hood 2 Tilt the hood back to disengage the front tabs and remove the hood from the vehicle Front Body Dash Removal 1 Remove the hood as previously described 2 Remove the...

Page 185: ...4 Remove the 3 Torx screws from the bottom side of the fender and the upper push rivet from the top side Remove the fender from the vehicle 5 Remove the 4 fasteners that retain the tie down brackets t...

Page 186: ...ve the Torx screws retaining the rear portion of the floor and remove the lower floor from the vehicle Rear Floor Removal RZR 4 1 Remove all four seats and both rocker panels see Rocker Panel Removal...

Page 187: ...ng Steering Wheel Cap Pivot Tube Steering Shaft Cotter Pin Gear Box Bearing Bushing Oil Locking Shock Asm Asm 17 ft lbs 23 Nm 17 ft lbs 23 Nm 12 14 ft lbs 16 19 Nm Nut 42 5 ft lbs 58 Nm 42 5 ft lbs 58...

Page 188: ...d lift the steering wheel off the shaft Steering Shaft Removal Non EPS Models 1 Remove the pinch bolt retaining the lower portion of the steering shaft to the steering gear box assembly 2 Remove the f...

Page 189: ...rcumference of the new upper bearing race Slide the new upper bearing onto the steering shaft and press it into the pivot tube by hand NOTE Use care not to allow any of the Loctite to get in the beari...

Page 190: ...ng Bracket 20 24 ft lbs 27 33 Nm Boot Rod End Tie Rod RH Boot LH Boot Spacer Bearing Steering Cap Pivot Tube Cotter Pin Gear Box Bearing Oil Locking Shock Asm Asm 17 ft lbs 23 Nm 17 ft lbs 23 Nm 12 14...

Page 191: ...e upper steering shaft to the power steering unit 3 Remove the fastener retaining the upper portion of the steering wheel tilt shock to the pivot tube Swing the shock down out of the way 4 Lift the st...

Page 192: ...t to pop the steering wheel off the shaft taper 6 Once the steering wheel pops loose completely remove the nut and lift the steering wheel off the shaft Power Steering Unit Removal 1 Remove the upper...

Page 193: ...power steering unit remove the 4 nuts from the mount bracket 5 Carefully remove the power steering unit and mount bracket from the vehicle as an assembly 6 If replacing the power steering unit remove...

Page 194: ...he pinch bolt that retains the lower steering shaft to the gear box assembly and torque to 30 ft lbs 41 Nm 3 Install the power steering unit and reassemble the vehicle see Power Steering Unit Installa...

Page 195: ...ecification 3 Install the tilt shock and torque fastener to specification 4 Be sure the front wheels are pointing straight ahead and install the steering wheel and retaining nut Torque the nut to spec...

Page 196: ...ttach shock to A arm with spacer D and fastener A see FRONT STABILIZER BAR Exploded View Torque lower shock bolt to specification 14 Remove lower ball joint pinch bolt E from bearing carrier 15 Using...

Page 197: ...A arm Lower A arm Grease Screws Ball Joint Pinch Bearing CV Shield Bushings Pivot Tube Bushing Grease Zerk Ball Joint Carrier Bolts Zerk Pivot Tube Upper Fastener Lower Fastener Upper A arm Lower A a...

Page 198: ...er to use in the following process 4 Use a press and correct size driver to remove the ball joint from the A arm NOTE The driver must fit the ball joint housing in the A arm This will allow the ball j...

Page 199: ...ch side of the vehicle see Exploded View 3 Remove the bolts that attach the upper portion of the linkages to the sway bar clamps and remove the linkages from the vehicle see Exploded View 4 Inspect th...

Page 200: ...ket 8 Remove the 4 bolts retaining the upper radiator mount bracket and remove the bracket from the frame 9 Lift up on the stabilizer bar and remove it from the vehicle 10 Inspect the stabilizer bar f...

Page 201: ...d View on page 5 Replace if worn Discard hardware 4 If not replacing the A arm thoroughly clean the a arm and pivot tubes 5 Insert new A arm bushings and pivot tubes into new A arm Lower A arm Removal...

Page 202: ...ew A arm bushings and pivot tubes into new A arm Installation 1 Install lower A arm assembly onto vehicle frame Torque new fasteners to specification 2 Attach lower A arm to bearing carrier Torque new...

Page 203: ...rm Screws Bearing CV Bushings Pivot Tube Carrier Pivot Grease Zerk Shield Tube Bushings Pivot Tube Pivot Tube Bushings Upper Fastener Lower Fastener Lower Fastener Upper Fastener Upper A arm Lower A a...

Page 204: ...the stabilizer bar linkage bushing on each side of the vehicle 3 Remove the 4 fasteners retaining the stabilizer bar bracket to the frame 4 Remove the stabilizer bar and bracket from the frame as an a...

Page 205: ...emove the fastener retaining the stabilizer bar to the linkage on each side of the vehicle 3 Remove the 4 fasteners retaining the stabilizer bar to the bracket 4 Remove the stabilizer bar from the bra...

Page 206: ...o the surface 2 3 inches from the flame tip is recommended Keep the torch moving to prevent damage 2 Apply the decal on one edge first Slowly lay down remainder of the decal while rubbing lightly over...

Page 207: ...o specification refer to exploded views Shock Replacement 1 Using a spring compressor compress the shock spring far enough to remove the spring retainer 2 Remove the spring and adjusting cam from the...

Page 208: ...7 1 Lock Nut 4 1 Reservoir 18 1 Bearing External 5 Shock Oil 2870995 19 1 Bearing External 6 1 Decal 20 2 Retaining Ring Wire 7 2 Bearing Spherical 21 1 Spring Guide 8 4 Retaining Ring 22 1 Piston Dam...

Page 209: ...ylon Ball Air Valve 6 1 Bearing Cap Asm 21 1 Preload Ring Jam Nut 7 1 Bearing Asm 22 1 Preload Ring 8 1 Spacer 23 1 Damping Adjust Asm Piston 9 1 Plate Top Out 24 1 Damping Adjust Asm Concentric Adjus...

Page 210: ...s Shock Oil 2870995 qt SHOCK VALVING COMPRESSION REBOUND 1 300 x 0 008 1 250 x 0 006 1 300 x 0 008 1 250 x 0 006 0 800 x 0 004 1 250 x 0 008 1 250 x 0 008 1 100 x 0 006 1 100 x 0 006 1 000 x 0 006 1 0...

Page 211: ...2 1 300 x 0 012 0 900 x 0 010 1 250 x 0 012 0 800 x 0 010 1 100 x 0 012 0 700 x 0 015 1 100 x 0 012 0 620 x 093 Back Up 1 000 x 0 015 0 900 x 0 015 0 800 x 0 015 1 125 x 093 Top Out Piston Orifice 0 0...

Page 212: ...ty glasses and ear protection during these procedures 1 Safety Glasses 2 Latex Gloves 3 Lint Free Towels 4 Assembly Lube lithium based grease 5 Loctite 271 6 12 Tie Wrap Zip Tie 7 MAPP Gas or Propane...

Page 213: ...ings and O rings from both ends of the shock If your shock has polyurethane bushings and sleeves remove them from both ends of the shock Fig 1 5 Note and record the setting on the Compression Adjuster...

Page 214: ...g 6 Gently pull the IFP out of the reservoir tube using the IFP Depth Setting Tool and place it on a clean lint free towel Remove the shock from the vise and pour shock oil from body and reservoir tub...

Page 215: ...h compressed air in a well ventilated area If compressed air is not available dry parts using clean lint free paper towels and let sit in a well ventilated area to allow the remaining solvent to evapo...

Page 216: ...lock nut Torque the nut to 18 ft lbs 24 Nm using a torque wrench and 9 16 socket Remove shaft assembly from vise and set it aside on a clean lint free paper towel 5 Clamp the body cap of the shock se...

Page 217: ...damping piston at least 1 4 below the surface of the oil during this process 19 Bring the damping piston up until it is approximately 1 4 below the surface of the oil Using the mallet give 2 3 sharp...

Page 218: ...ll the reservoir away from the FOX Nitrogen Safety Needle using a smooth straight motion Keep the reservoir as straight as possible to prevent the safety needle from bending As the safety needle is pu...

Page 219: ...1 Body 19 1 Body Reservoir 3 1 Seal Head 20 1 Cap End 4 1 Seal Head 21 1 Piston Reservoir 5 1 Bushing Shaft 22 1 Valve 6 1 O Ring 23 1 Bumper 7 1 Seal 24 1 Washer 8 1 Wiper D Type 25 1 Nut Spring Ret...

Page 220: ...008 700 x 010 1 45 x 008 1 10 x 008 875 x 090 1 10 x 008 1 00 x 008 1 50 x 015 900 x 008 1 45 x 015 1 00 x 090 1 30 x 015 NOTE Valve shim stacks listed as they would appear on the shaft when shock ro...

Page 221: ...rientation The face of the piston with the greater number of relief ports will always face the rebound valve stack WARNING Walker Evans shocks contain high pressure nitrogen gas Extreme caution must b...

Page 222: ...ove the valve cap from the end of the reservoir 4 Carefully depressurize the shock 5 Using a snap ring pliers remove the retaining ring from the reservoir 6 Carefully remove the cap from the reservoir...

Page 223: ...PORTANT Seal kits are available and should be installed at this time if seals or O rings are damaged or worn 12 Place the shock rod in a vise so the threaded part is facing up Using an 11 16 socket re...

Page 224: ...eads of the rod facing up 2 Place the compression valve stack on the rod in the reverse order of disassembly 3 Place the valve piston on top of the compression stack IMPORTANT If unsure of the valve s...

Page 225: ...Using a 3 32 Allen wrench remove the IFP bleed screw 10 Apply a thin film of oil to the IFP O ring and wear band Insert the IFP into the reservoir until it is completely submerged Allow air to escape...

Page 226: ...es on the damping piston You will see the released air bubbles come to the surface of the oil 16 Add oil to the body tube until the surface of the oil is at the top of the shock body threads NOTE Duri...

Page 227: ...is at 200 psi 31 Reinstall the Schrader valve cap 32 Clean all oil residue from the shock and reservoir with solvent and dry with low pressure compressed air in a well ventilated area 33 Check shock f...

Page 228: ...ASSEMBLY 6 7 CLUTCH OFFSET PROCEDURE 6 8 DRIVE BELT 6 10 BELT REMOVAL INSPECTION INSTALLATION 6 10 PVT BREAK IN DRIVE BELT CLUTCHES 6 10 DRIVE CLUTCH SERVICE 6 11 SPRING SPECIFICATIONS 6 11 SHIFT WEIG...

Page 229: ...sheave moves inward and contacts the drive belt This motion pinches the drive belt between the spinning sheaves and causes it to rotate which in turn rotates the driven clutch At lower RPM the drive b...

Page 230: ...hifting or backshifting PVT Break In Drive Belt Clutches A proper break in of the clutches and drive belt will ensure a longer life and better performance Break in the clutches and drive belt by opera...

Page 231: ...hen exposed to low ambient temperatures Warm engine at least 5 min then with transmission in neutral advance throttle to approx 1 8 throttle in short bursts 5 to 7 times The belt will become more flex...

Page 232: ...al Copyright 2010 Polaris Sales Inc PVT SYSTEM SERVICE PVT Covers and Ducting Components Inner Clutch Clamps Outer Cover Outer Push Rivets Outlet Duct Clutch Inlet Duct Screws Clutch Cover Clutch Cove...

Page 233: ...clutch cover removal RZR RZR S Remove the 2 fasteners from the rear seat base as shown and remove it from the vehicle RZR 4 Remove the 2 fasteners and seat latch plunger A RZR 4 Slide the rear seat b...

Page 234: ...ween the engine and inner clutch cover Both surfaces must be clean to ensure adhesion of silicone sealant 4 Install and properly align the inner clutch cover 5 Install the bolts and washers that retai...

Page 235: ...utch drag or hard shifting while at idle speed a clutch offset adjustment is required Washers located behind the driven clutch on the transmission input shaft may need to be added or removed in order...

Page 236: ...lutch counterclockwise several times to ensure the belt is tight and riding at the proper height in the clutch The belt should now be resting evenly between the drive clutch stationary and moveable sh...

Page 237: ...measurements with a new drive belt Replace if necessary 3 Belts with thin spots burn marks etc should be replaced to eliminate noise vibration or erratic PVT operation See the Troubleshooting Chart at...

Page 238: ...ect to during operation it should always be inspected for tolerance limits during any clutch operation diagnosis or repair With the spring resting on a flat surface measure its free length from the ou...

Page 239: ...rolling engagement RPM and shifting patterns Shift weights should not be changed or altered without first having a thorough understanding of their positioning and the effects they may have on belt to...

Page 240: ...cover bushing is manufactured with a Teflon coating Wear is determined by the amount of Teflon remaining on the bushing 5 Inspect area on shaft where bushing rides for wear galling nicks or scratches...

Page 241: ...e rollers pins and thrust washers in sets of three Also inspect to see if roller and bushing are separating Bushing must fit tightly in roller Use the Roller Pin Tool PN 2870910 to replace rollers and...

Page 242: ...ect the contact surface of the weight The surface should be smooth and free of dents or gall marks Inspect the weight pivot bore and pivot bolts for wear or galling If weights or bolts are worn or bro...

Page 243: ...ce as an assembly if worn damaged or if problems were noted 5 Inspect surface of shaft for pitting grooves or damage Measure the outside diameter and compare to specifications Replace the drive clutch...

Page 244: ...g new bushing Moveable Sheave Bushing Inspection Replace the cover bushing if more brass than Teflon is visible on the bushing Refer to bushing replacement in this chapter EBS Clutch Bushing Tool Kit...

Page 245: ...ide 11 Pull bushing removal tool and adapter from puller rod Remove bushing from tool and discard Drive Clutch Bushing Installation 1 Place main adapter Item 8 on puller 2 Apply Loctite 609 evenly to...

Page 246: ...ver onto puller rod placing outside of cover toward vise 4 Install nut on rod and hand tighten Turn puller barrel to apply more tension if needed 5 Turn clutch cover counterclockwise on puller rod unt...

Page 247: ...lock nuts on the bolts 6 Reinstall clutch spring 7 Reinstall cover aligning X mark with other marks 8 Torque cover bolts evenly to specification T Spider Torque 200 ft lbs 271 Nm CAUTION Be sure the s...

Page 248: ...ompression Tool PN 8700220 Using Compression Extensions PN PS 45909 apply and hold downward pressure on the outer spring retainer Carefully remove the snap ring Remember the outer spring retainer cont...

Page 249: ...moveable sheave 7 Remove the inner spring retainer from the inner sheave Inspect for wear and replace as needed 8 Check the rollers in the stationary sheave for wear If rollers are worn a new driven c...

Page 250: ...Assembly 1 Install the inner spring retainer if removed Do not apply oil or grease to the bearings 2 Align the X marks on each of the sheaves during reassembly 3 Install the spring into the inner reta...

Page 251: ...ecified operating range Incorrect drive clutch spring too high spring rate Driveclutch shiftweightsincorrectforapplication too light Drive clutch binding Driven clutch binding Converter sheaves greasy...

Page 252: ...nt terrain as outlined in Owner s Safety and Maintenance Manual Water ingestion Cover seals or ducts leaking Operator error Find leak and repair as necessary Instruct operator on guidelines for operat...

Page 254: ...RALIZED HILLIARD EXPLODED VIEW 7 16 ALL WHEEL DRIVE OPERATION 7 17 AWD DIAGNOSIS 7 18 GEARCASE REMOVAL DISASSEMBLY INSPECTION 7 19 GEARCASE ASSEMBLY 7 22 GEARCASE INSTALLATION 7 24 REAR BEARING CARRIE...

Page 255: ...he nut and 2 cone washers from the front wheel hub assembly 5 Remove the fastener retaining the steering tie rod end to the front bearing carrier PART NUMBER TOOL DESCRIPTION 2872608 Roll Pin Removal...

Page 256: ...ly close tolerances and minimal wear the bearings must be inspected visually and by feel While rotating bearings by hand inspect for rough spots discoloration or corrosion The bearings should turn smo...

Page 257: ...of any excess compound and install the snap ring Bearing Carrier Installation 1 Install drive shaft axle through the backside of the bearing carrier 2 Install the upper and lower ball joint ends into...

Page 258: ...tall wheel and 4 wheel nuts Torque wheel nuts to specification 11 Rotate wheel and check for smooth operation Bend both ends of cotter pin around end of spindle in different directions T Front Caliper...

Page 259: ...isc see Chapter 9 CAUTION Do not hang the caliper by the brake line Use wire to hang caliper to prevent damage to the brake line 5 Remove the front wheel hub assembly 6 Remove the upper ball joint pin...

Page 260: ...soft faced hammer or brass drift to separate the outer CV joint from the drive shaft NOTE If using a brass drift be sure to tap on the inner race of the joint only 4 Make sure the circlip remains on...

Page 261: ...boot back 4 Use a soft faced hammer or brass drift to separate the plunging joint from the drive shaft NOTE If using a brass drift be sure to tap on the inner race of the joint only 5 Make sure the c...

Page 262: ...ot over the joint and position the boot lips into the grooves on the joint housing and shaft Make sure the boot is not dimpled or collapsed 19 Install and secure the small clamp on the boot using the...

Page 263: ...e drive shaft if necessary 3 Install drive shaft into the front bearing carrier 4 Install the upper ball joint end into the front bearing carrier 5 Install the upper pinch bolt and torque to specifica...

Page 264: ...be removed to gain better access to the propshaft roll pin 2 Remove the gear selector cap and remove the retaining screw 3 Remove the Torx screws retaining the center console to access the propshaft 4...

Page 265: ...pin NOTE Front wheel can be removed to gain better access to the propshaft roll pin 2 Remove both front seats 3 Remove the gear selector cap 4 Remove the retaining screw and the gear selector handle 5...

Page 266: ...t portion of the propshaft use a NEW roll pin Support Bearing Replacement RZR 4 1 Follow steps 1 8 of the Removal Installation RZR 4 procedure 2 Remove the bearing support upper and lower half and the...

Page 267: ...l the front portion of the propshaft onto the front grease and install a NEW roll pin 11 Reinstall the center console selector handle and front seats PROPSHAFT U JOINT SERVICE Disassembly 1 Remove int...

Page 268: ...t 2 Tighten vise to force bearing caps in 3 Using a suitable arbor fully seat the bearing cap in one side Continually check for free movement of bearing cross as bearing caps are assembled 4 Install s...

Page 269: ...2 22 Spring Wireform 2 6 Ball Bearing Double Row 1 23 H Clip Spring 20 7 Bushing 1 24 Nylon Spacer 2 8 Bushing 1 25 Torsion Spring Retainer 1 9 Oil Seal 2 26 Backlash Spacer 1 10 Oil Seal 1 27 Ring G...

Page 270: ...exes the rollers inside the ring gear to an engagement position While in the engagement position the front drive will be in an over running condition not engaged until the rear wheels lose traction On...

Page 271: ...icated in Step 5 A wear band with an interrupted wear mark may indicate a warped plate which may cause intermittent operation See the following illustrations 5 Check to make sure the coil is seated in...

Page 272: ...t gearcase and remove the harness from the retaining dart 5 Remove the vent line from the front gearcase 6 Remove the 4 bolts securing the front gearcase to frame 7 Remove the gearcase from the front...

Page 273: ...ble and should not be removed 4 Remove and inspect the armature plate Refer to AWD Diagnosis for detailed inspection process 5 Remove the torsion spring retainer and torsion spring from the top of the...

Page 274: ...O ring 11 Remove the roll cage assembly and rollers from the clutch housing Use a shop towel to cover the housing in order to retain all the rollers NOTE Rollers are spring loaded Take care not to all...

Page 275: ...rcase disassembly section replace all O rings seals and worn components 2 Install pinion shaft assembly and install internal snap ring NOTE If bearing replacement was required press new bearing onto t...

Page 276: ...and install the retainer on top of the torsion spring 8 Check the action of the torsion spring by rotating in both directions to ensure the spring and retainer are installed properly 9 Be sure the ar...

Page 277: ...sembly onto the gearcase housing Install the 7 cover plate screws and torque to specification Gearcase Installation 1 Install the gearcase back into the vehicle through the LH wheel well area between...

Page 278: ...D wire harness 6 Refer to FRONT DRIVE SHAFT Drive Shaft Installation and install both front drive shafts into the gearcase 7 Add the proper lubricant to the front gearcase Refer to Chapter 2 for fluid...

Page 279: ...the nut and 2 cone washers from the rear wheel hub assembly 5 Remove the two brake caliper mounting bolts CAUTION Do not hang the caliper by the brake line Use wire to hang caliper to prevent damage t...

Page 280: ...r scratches wear or damage Replace rear bearing carrier if damaged Bearing Installation 5 Thoroughly clean the rear bearing carrier housing and the outer race on the new bearing Be sure that all oil r...

Page 281: ...ft axle splines 4 Install rear wheel hub assembly cone washers and hand tighten the castle nut Install washers with domed side out 5 Install brake caliper mounting bolts and torque to 18 ft lbs 24 Nm...

Page 282: ...the 4 wheel nuts and remove the rear wheel 3 Remove the cotter pin and loosen the rear wheel hub castle nut Remove the nut and 2 cone washers from the rear wheel hub assembly 4 Remove the two brake c...

Page 283: ...r gearcase NOTE Take care when removing to prevent damaging the seal 9 Inspect the axle splines and CV boots for any damage Outer CV Joint Boot Replacement 1 Using a side cutters cut away and discard...

Page 284: ...shaft and apply a light coat of grease prior to reassembly 10 Slide the small boot clamp and boot small end first onto the drive shaft and position the boot in it s groove machined in the shaft 11 In...

Page 285: ...to the grooves on the joint housing and shaft Make sure the boot is not dimpled or collapsed 18 Install and tighten the large clamp using the appropriate clamp tool 19 While pulling out on the CV shaf...

Page 286: ...oot from the shaft IMPORTANT If the grease in the joint is obviously contaminated with water and or dirt the joint should be replaced 7 Thoroughly clean the joint with an appropriate solvent and dry t...

Page 287: ...plunging joint s external surfaces and place the excess grease in the boot 18 Pull the boot over the joint and position the boot lips into the grooves on the joint housing and shaft Make sure the boo...

Page 288: ...gearcase and reinstall the drive shaft Use a rubber mallet to tap on the outboard end of the drive shaft if necessary NOTE Take care when installing the drive shaft to prevent damaging the seal 3 Sli...

Page 289: ...8 Torque wheel hub nut to 80 ft lbs 108 Nm and install a NEW cotter pin Tighten nut slightly if necessary to align cotter pin holes 9 Install wheel and 4 wheel nuts Torque wheel nuts to specification...

Page 290: ...e removal 3 RZR S Only Remove the upper A arm bolts lower rear A arm bolts and suspension plate NOTE If accessory rear rack cab frame is installed remove the 4 bolts retaining it to the rear suspensio...

Page 291: ...NOT intended to be disassembled and replaced Pinion and ring gear shimming information is NOT provided The components are matched at the factory which requires special OEM tooling in order to properly...

Page 292: ...from each side of the gearcase housing Replace the O ring in the gearcase cover 7 Remove the input shaft seal using a seal puller or other suitable method 8 Inspect the input shaft by rotating the ass...

Page 293: ...r suitable method 2 Install new seals on each side of the gearcase housing using a standard seal installer or other suitable method Install a new O ring in the gearcase cover 3 If removed install each...

Page 294: ...his section IMPORTANT When reinstalling the transmission to rear gearcase mount bracket it is extremely important to torque all 7 fasteners to specification Refer to the Installation procedure listed...

Page 295: ...acket Rear Mount LH 1 15 Screw Flange Head 2 5 Mount Rear 1 16 Seal Oil 2 6 Nut Flanged 4 17 Screw Flange Head 4 7 Assembly Rear Housing RH 1 18 Screw 8 8 N A 1 19 Dowel 2 9 Assembly Tapered Roller Be...

Page 296: ...des the clutch gear away from the engagement dogs that are attached to the differential gear assembly This unlocks the rear differential When Differential Lock is selected on the switch power is remov...

Page 297: ...REAR DRIVE SHAFT on page 7 29 2 Remove the exhaust pipe and exhaust silencer to allow for gearcase removal 3 Remove the upper A arm bolts lower rear A arm bolts and suspension plate NOTE If accessory...

Page 298: ...hile pulling the rear gearcase back further to disengage it 9 Remove the vent line and lift the rear gearcase upward and on its side to remove it from the vehicle Gearcase Disassembly IMPORTANT The pi...

Page 299: ...e the bearing from the top portion of the differential assembly Inspect the bearing for smoothness and wear 6 Remove the shim s from the differential assembly Be sure to keep the shims together for re...

Page 300: ...tating the assembly in the gearcase housing while checking for any looseness or roughness Inspect the pinion gear for chipped worn or broken teeth If damaged replace the gearcase assembly NOTE In the...

Page 301: ...osen and remove the lock pin assembly from the gearcase housing 18 Carefully remove the shift yoke assembly from the gearcase cover 19 Inspect the shift lever A shift lever spring B shift return sprin...

Page 302: ...d area as shown to remove the differential cover 3 Remove the upper differential gear 4 Use a scribe to mark the ring gear and differential case Remove the 8 bolts that secure the ring gear to the dif...

Page 303: ...3 Install the side differential gears and thrust washers and slide the cross pin into position with the hole side facing the hole in the differential case 4 Install a new roll pin 5 Install the upper...

Page 304: ...e cover using a standard seal installer or other suitable method 4 Install a new O ring in the gearcase cover 5 Install a new pinion shaft seal using a standard seal installer or other suitable method...

Page 305: ...the lock pin assembly and tighten 11 Install the differential assembly into the gearcase housing and install a new lightly greased O ring onto the cover 12 Assemble the gearcase halves and install the...

Page 306: ...o the Installation procedure listed on page 4 14 NOTE Special tool PA 48873 will be required to torque the mounting bracket fasteners when the transmission and rear gearcase are installed in the vehic...

Page 307: ...shing Pin Lock 1 28 Bearing Tapered Roller 1 10 Bearing Ball 2 29 Screw Flange Head 10 11 Plug Drain 1 30 Case Diff Cover Half 1 12 Shim Kit 2 31 Thrust Washer Pinion 2 13 Gear Clutch 1 32 Gear Diff P...

Page 308: ...ake Disc Bolts Retaining Sealed Ball Bearing Bearing Front Tire Washers 27 ft lbs 37 Nm 80 ft lbs 108 Nm Ring Carrier Steel Front Rim Aluminum Wheel Nuts 30 ft lbs 90 1 4 turn Studs Wheel Nuts Rear Ri...

Page 310: ...IONS 8 2 SHIFT LEVER 8 2 REMOVAL INSTALLATION 8 2 SHIFT CABLE INSPECTION ADJUSTMENT 8 3 TRANSMISSION SERVICE 8 4 TRANSMISSION REMOVAL SERVICE NOTES 8 4 TRANSFER CASE DISASSEMBLY 8 4 TRANSFER CASE REAS...

Page 311: ...ft cable nut to specification ITEM TORQUE VALUE Transmission Fill Plugs 40 50 ft lbs 54 67 Nm Transmission Drain Level Plugs 30 45 in lbs 0 2 0 3 Nm Transmission Case Screws 23 27 ft lbs 31 36 Nm Shif...

Page 312: ...mount to move the upper jam nut 4 Adjust the shift cable so there is the same amount of cable travel when shifting slightly past the detents of HIGH H gear and PARK P 5 Thread the upper or lower jam...

Page 313: ...all instructions before beginning disassembly NOTE Exploded views are located at the end of this chapter for additional information 1 Place the transmission in the neutral position 2 Drain both the t...

Page 314: ...ress and standard bearing removal tools Discard removed bearings as they become damaged by the removal process 10 Remove the intermediate pinion shaft assembly from the housing Check bearings and gear...

Page 315: ...n shaft assembly The shaft can be disassembled as shown using a press and standard bearing removal tools 14 Remove the upper snap ring from the top side of the 21T main pinion gear and remove the gear...

Page 316: ...s shown 2 Install the front output pinion shaft assembly NOTE Bearing is pressed onto the shaft 3 Install the shims bearing cup and alignment dowels into the retaining bracket 4 Install a new output s...

Page 317: ...thin coat of sealant to the mating surfaces Apply lubricant to the seal lip 7 Install the transfer case cover Align the dowels 1 7 and insert the cover screws note position of the longest screw 4 Tor...

Page 318: ...ews from the front of the transmission and 2 from the backside as shown NOTE Shift cable bracket removal is required 2 Place the transmission shift housing onto a flat surface as shown Lift the transm...

Page 319: ...s for inspection as the removal process damages the bearing 7 Remove the reverse idler snap ring upper washer gear needle bearing and lower washer from the idler shaft NOTE The reverse idler shaft is...

Page 320: ...the park reverse spacer from the clutch shaft 13 Pull back fully on gear selector arm to bring shift collar up and disengage the shift collar from the clutch yoke Lifting on the clutch shaft may aid i...

Page 321: ...ce as required 21 Remove the set screw retaining the pivot pin 22 Locate the retaining ring on the shifter assembly and move the retaining ring out of the groove to allow the shifter assembly to slide...

Page 322: ...case for inspection as the removal process damages the bearing Transmission Shift Housing Reassembly 1 Install a new shift cable lever seal and press it flush with the case Apply lubricant to the sea...

Page 323: ...holes and install clutch yoke pivot pin 6 Install the pivot pin set screw and torque to specification 7 Assemble the clutch shaft with new needle bearings Press a new ball bearing onto the end of the...

Page 324: ...ed Torque the detent sleeve assembly to specification TURN THE OUTER DETENT SCREW ONLY UNTIL LIGHT SHIFTING RESISTANCE IS FELT AT THIS TIME PLACE THE TRANSMISSION IN NEUTRAL 12 With the transmission i...

Page 325: ...equired 16 Install the park flange and torque the 5 screws to specification 17 Install the reverse clutch assembly onto the park flange Note the orientation of the needle bearing 18 Install the retain...

Page 326: ...aft using care not to damage the seal surfaces 21 Install the shift cable bracket 7 shift housing case screws to the front of the transmission Torque to specification 22 Install the 2 shift housing ca...

Page 327: ...pivot arm bushings Linkage rod adjustment and rod end positioning Shift selector rail travel Worn broken or damaged internal transmission components NOTE To determine if shifting difficulty is caused...

Page 328: ...8 19 TRANSMISSION 8 9923142 2011 RANGER RZR RZR S RZR 4 Service Manual Copyright 2010 Polaris Sales Inc TRANSMISSION EXPLODED VIEW Shift Housing Transfer Case Exploded View Transfer Case Shift Housing...

Page 330: ...8 PAD INSPECTION ASSEMBLY INSTALLATION 9 9 BRAKE BURNISHING PROCEDURE 9 10 FRONT CALIPER SERVICE 9 11 CALIPER EXPLODED VIEW RZR RZR S RZR S INT L 9 11 CALIPER EXPLODED VIEW RZR 4 9 11 CALIPER REMOVAL...

Page 331: ...Limit Rear Brake Pad Thickness 298 007 7 57 178 mm 180 4 6 mm Rear Brake Disc Thickness 188 4 78 mm 170 4 32 mm Rear Brake Disc Runout 010 254 mm Item Torque ft lbs Torque Nm Front Caliper Mounting B...

Page 332: ...oducts BRAKE NOISE TROUBLESHOOTING Dirt or dust buildup on the brake pads and disc is the most common cause of brake noise squeal caused by vibration If cleaning does not reduce the occurrence of brak...

Page 333: ...ward and becomes self adjusting Fluid from the reservoir fills the additional area created when the caliper piston moves outward Brake fluid level is critical to proper system operation Too little flu...

Page 334: ...Brake Master Cylinder LH Front Rear Calipers Brake Line LH Rear Line 1 2 1 1 2 2 1 3 All Flare Style Fittings 12 15 ft lbs 16 20 Nm 3 1 1 2 2 15 ft lbs 20 Nm 3 Fitting Switch Caliper Banjo Style Fitt...

Page 335: ...ecure the master cylinder to the frame Installation 1 Reverse Steps 1 5 for master cylinder installation Refer to the torque specifications in the illustration 2 After installing the foot brake check...

Page 336: ...r may be drawn into master cylinder 7 Repeat procedure until clean fluid appears in bleeder hose and all air has been purged Add fluid as necessary to maintain level in reservoir 8 Tighten bleeder scr...

Page 337: ...r so to avoid kinking or bending brake line 5 Push caliper piston into caliper bore slowly using a C clamp or locking pliers with pads installed NOTE Brake fluid will be forced through compensating po...

Page 338: ...g bracket and make sure dust boots are fully seated Install pads with friction material facing each other 3 Install caliper onto front hub and torque mounting bolts to specification Front Brake Pad Th...

Page 339: ...nstall reservoir cap 7 Install wheel and torque wheel nuts to specification Brake Burnishing Procedure It is required that a burnishing procedure be performed after installation of new brake pads to e...

Page 340: ...sy D Boot E Square O ring thick F Square O ring thin G Piston H Caliper Mount I Brake Pads A B C D E F G H Apply Silicone Grease Apply Polaris DOT 4 Brake Fluid to Component I 47 in lbs 5 3 Nm D A B C...

Page 341: ...iner below the caliper to catch brake fluid when removing the line Remove brake line from caliper 5 Loosen brake pad adjustment set screw 2 3 turns to allow brake pad removal after the caliper is remo...

Page 342: ...lable caliper piston pliers to extract the pistons from the caliper IMPORTANT Do not remove the caliper pistons with a standard pliers The piston sealing surfaces will become damaged if a standard pli...

Page 343: ...itting or wear Measure piston diameter and replace if damaged or worn beyond service limit 3 Inspect the brake disc and pads as outlined in this chapter In mm RZR RZR S Front Caliper Piston Bore I D S...

Page 344: ...unting bracket and make sure the dust seal boots are fully seated Install the brake pads Clean the disc and pads with brake parts cleaner or denatured alcohol to remove any dirt oil or grease Caliper...

Page 345: ...assembly and installation NOTE If new pads are installed refer to FRONT BRAKE PADS Brake Burnishing Procedure FRONT BRAKE DISC Disc Runout 1 Mount dial indicator as shown to measure disc runout Slowl...

Page 346: ...t to 80 ft lbs 108 Nm and install a new cotter pin 7 Install the front brake caliper see FRONT CALIPER SERVICE 8 Follow bleeding procedure outlined earlier in this chapter 9 Field test unit for proper...

Page 347: ...caliper so as not to kink or bend brake line 5 Push caliper piston into the caliper bore slowly using a C clamp or locking pliers with pads installed NOTE Brake fluid will be forced through compensati...

Page 348: ...n back off 1 2 turn 6 Verify fluid level in reservoir is up to the MAX line inside reservoir and install reservoir cap 7 Install wheel and torque wheel nuts to specification Brake Burnishing Procedure...

Page 349: ...emove brake line from caliper 5 Loosen the brake pad adjustment set screw to allow brake pad removal after the caliper is removed 6 Remove the two caliper mounting bolts and remove the caliper A Brake...

Page 350: ...he caliper body piston and retaining bracket with brake cleaner or alcohol NOTE Be sure to clean seal grooves in caliper body Caliper Inspection 1 Inspect caliper body for nicks scratches or wear Meas...

Page 351: ...ting motion while pushing inward Piston should slide in and out of bore smoothly with light resistance 3 Lubricate the mounting bracket pins with silicone grease and install the rubber dust seal boots...

Page 352: ...ly inspect disc for scoring scratches or gouges Replace the disc if any deep scratches are evident 2 Use a 0 1 micrometer and measure the disc thickness at eight different points around the pad contac...

Page 353: ...l isreleased If the brake drags re check assembly and installation TROUBLESHOOTING Brakes Squeal Poor Brake Performance Air in system Water in system brake fluid contaminated Caliper or disc misaligne...

Page 354: ...USTER INSTALLATION 10 14 ALL WHEEL DRIVE COIL 10 15 HEAD LIGHTS 10 15 HEADLIGHT ADJUSTMENT 10 15 HEADLAMP BULB REPLACEMENT 10 16 HEADLAMP HOUSING REMOVAL INSTALLATION 10 16 TAIL BRAKE LIGHTS 10 17 BUL...

Page 355: ...DED VIEW 10 35 STARTING SYSTEM TESTING FLOW CHART 10 36 ELECTRONIC POWER STEERING EPS 10 37 EPS OPERATION 10 37 EPS 8 WAY WIRE HARNESS CONNECTOR 10 37 PROPER EPS SYSTEM DIAGNOSING 10 37 EPS SYSTEM BRE...

Page 356: ...ltimeter reading K M etc and the position of the decimal point For resistance readings isolate the component to be tested Disconnect it from the wiring harness or power supply Under Dash Components Th...

Page 357: ...to LOW There should be continuity between switch pins 2 and 3 4 and 5 Move the switch to OFF There should be continuity between switch pins 1 and 2 4 and 5 NOTE Pins 7 and 8 provide power and ground t...

Page 358: ...nuity between switch pins A E and F C and D Turn the ignition key to ON There should be continuity between pins C and D E and F Turn the ignition key to START There should be continuity between pins A...

Page 359: ...F There should be continuity between switch pins 1 and 2 4 and 5 Turn Signal Switch INT L 1 Disconnect the Turn Signal switch harness by depressing the connector locks and pulling on the connector Do...

Page 360: ...and can be accessed through the rear LH wheel well area Speed Sensor Testing Special Tools Required Static Timing Light Harness PN 2871745 Hall Sensor Probe Harness PN 2460761 1 Disconnect the 3 wire...

Page 361: ...the switch is pushed to activate TURF a ground signal is provided to the ECU from the AWD 2WD TURF Switch Depending on engine speed and gear position criteria the ECU energizes the Rear Diff Solenoid...

Page 362: ...ons NOTE Some features are not applicable to all models IMPORTANT The use of a high pressure washer may damage the instrument cluster Wash the vehicle by hand or with a garden hose using mild soap Cer...

Page 363: ...nd adjustable by the user a flashing wrench symbol alerts the operator that the preset service interval has been reached and maintenance should be performed The wrench icon will flash for 10 seconds u...

Page 364: ...ng Total hours can not be reset Programmed Service Interval The initial factory service interval setting is 50 hours Each time the engine is started the engine hours are subtracted from the service in...

Page 365: ...lease the button 5 Repeat steps 3 4 twice to set the 10 minute and 1 minute segments After completing the 1 minute segment step 4 will save the new settings and exit the clock mode Units of Measuremen...

Page 366: ...is accessible only when the check engine MIL has been activated Use the following procedure to display diagnostic trouble codes that were activated during current ignition cycle causing the MIL to ill...

Page 367: ...g the dash and rubber mount NOTE Do not remove the rubber mount from the dash panel Only remove the rubber mount if necessary The bezel is a snap on assembly and is a serviceable part Instrument Clust...

Page 368: ...m meter IMPORTANT Verify all wires and wiring connections have been tested properly with a known good volt ohm meter before suspecting a component failure 80 of all electrical issues are caused by bad...

Page 369: ...re harness from the headlamp bulb Be sure to pull on the connector not on the wiring 2 Remove the O rings A from the headlamp brackets on both sides of the headlamp 3 Remove the adjustment screw B fro...

Page 370: ...12 volts and that a ground path is present If a tail light brake light or turn signal INT L Only does not work the bulb may need to be replaced 1 Remove bulb by turning the rubber base 1 4 turn and pu...

Page 372: ...e tested using an ohmmeter or voltmeter 1 With the engine and temperature sensor at room temperature 68 F 20 C disconnect the harness 2 With the meter in the ohms mode place the meter leads onto the s...

Page 373: ...se box under the dash the fuses provide overload protection for wiring and components such as the instrument cluster ECU EFI system main harness lights accessories and power steering The relays assist...

Page 375: ...attery voltage Brown Relay coil ground Orange 12 Vdc power input from key switch to enable relay White Provides12Vdc powerforlights drive and accessory circuits EFI RELAY COLOR FUNCTION Red White 20 A...

Page 376: ...des power to the following system Rear Differential Solenoid REAR DIFF SOLENOID RELAY INT L COLOR FUNCTION Red Dark Green 10 Amp fuse protected 12 Vdc battery voltage Dark Green White ECU input to ena...

Page 377: ...harge ammeter indication is positive 5 With lights and other electrical loads off the break even point should occur at approximately 1500 RPM or lower 6 With the engine running turn the lights on and...

Page 378: ...ds to the wires leading from the alternator Y1 to Y2 Y1 to Y3 Y2 to Y3 4 Refer to the following table for approximate AC Voltage readings according to RPM Test each leg at the specified RPM in the tab...

Page 379: ...elow the Break Even RPM Con tinued problems would call for battery inspection Yes Inspect the wiring harness between the panel and the stator for remove the recoil and flywheel Inspect the flywheel ma...

Page 380: ...BS Sealed Maintenance Free Voltage 12 Vdc Nominal Capacity 10 HR Rate 18 AH CCA 310 Nominal Open Circuit Voltage 12 8 Vdc or more Recommended Charging Rate 1 8A 5 10 HR or 9 0A 1 HR ALL EPS AND RZR 4...

Page 381: ...re further battery testing and charging See the following chart and Load Test NOTE Maintenance Free batteries should be kept at a high state of charge during storage If the battery is stored or used a...

Page 382: ...is complete NOTE Allow the battery to stand disconnected for at least 1 2 hours after being properly charged If the voltage drops below 12 6 volts charging was ineffective or the battery needs to be r...

Page 383: ...te Faulty starter drive Faulty starter drive gears or starter motor gear Faulty flywheel gear or loose flywheel Voltage Drop Test The Voltage Drop Test is used to test for bad connections When perform...

Page 384: ...ould be 0 3 ohms or less Remember to subtract meter lead resistance 2 Measure resistance between insulated brush and starter housing Reading should be infinite OL Inspect insulation on brush wires for...

Page 385: ...or segment and the armature shaft The reading should be infinite no continuity 5 Check commutator bars for discoloration Bars discolored in pairs indicate shorted coils requiring replacement of the st...

Page 386: ...arter onto the engine case Hand tighten each of the starter bolts Torque the bottom bolt first to 9 ft lbs 12 Nm Then torque the top bolt to the same specification NOTE It is important to tighten the...

Page 387: ...its groove Starter Solenoid Bench Test Test the start solenoid by powering the solenoid using battery voltage for a maximum of 5 seconds With the solenoid energized resistance should read about 0 0 5...

Page 388: ...xploded View 1 Rubber Ring 2 Brush Spring 3 Thrust Washer 4 Gear Assembly 5 O Ring 6 Brush Complete 7 O Ring 8 Thrust Washer 9 Shaft Complete 10 Gear Assembly 11 Through Bolt 12 Cover 13 Stopper 14 Sn...

Page 389: ...ia the 2 wire connection With the solenoid energized resistance should read about 0 5 10 between the two terminals If resistance measurement is out of specification replace the starter solenoid see St...

Page 390: ...t cluster will illuminate During this time the vehicle will have no power steering operation You will be able to connect and communicate with the vehicle s Engine Controller but not the Power Steering...

Page 402: ...ssis RZR 4 5 17 Circuit Breaker 10 20 Clutch Offset Procedure 6 8 Combustion Chamber 3 29 Communication Problems Digital Wrench 4 40 Compression Test 2 17 Console and Floor Panel Removal RZR RZR S 5 2...

Page 403: ...ning 3 35 Engine Cylinder Inspection 3 34 Engine Cylinder Installation 3 49 Engine Cylinder Removal 3 32 Engine Flywheel Stator Installation 3 56 Engine Flywheel Stator Removal 3 38 Engine Flywheel Re...

Page 404: ...ts Side 5 6 O Oil Pump Priming 3 58 Oil Pump Disassembly 3 43 Oil Pump Reassembly 3 44 Oil Pump Removal 3 43 P Periodic Maintenance Chart 2 3 Piston Ring Installed Gap 3 37 Piston to Cylinder Clearanc...

Page 405: ...Tools Final Drive 7 2 Specification Chart Maintenance 2 18 Specification Balance Shaft Gear Bolt Torque 3 52 Specification Cam Lobe Height 3 46 Specification Cam Thrust Plate Fastener Torque 3 50 Spe...

Page 406: ...ecifications Body Steering Suspension 5 3 Torque Specifications Brakes 9 2 Torque Specifications Clutching 6 2 Torque Specifications Final Drive 7 2 Torque Specifications Transmission 8 2 Torque Speci...

Page 407: ...IX 6...

Page 408: ...PN 9923142 Printed in USA RANGER RZR RANGER RZR S RANGER RZR 4...

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