Polaris RZR 800 2013 Manual Download Page 364

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7.52

9924707 - 2013–2014

RZR

800 Service Manual

Gearcase Exploded View

Ref#

Description

Qty

Ref#

Description

Qty

Screw

N/A

Screw

Axle, Spool

Bracket, Rear Mount, RH

Housing, Rear, LH

Bracket, Rear Mount, LH

Screw, Flange Head

Mount, Rear

Seal, Oil

Nut, Flanged

Screw, Flange Head

Assembly, Rear Housing, RH

Screw

N/A

Dowel

Assembly, Tapered Roller Bearing

Plug, Drain w/O-Ring

Shim

Plug, Fill w/O-Ring

FINAL DRIVE

Summary of Contents for RZR 800 2013

Page 1: ...rocedures outlined in this manual require a sound knowledge of mechanical theory tool use and shop procedures in order to perform the work safely and correctly Read the text and be familiar with the s...

Page 2: ...in part is expressly prohibited Printed in U S A Understanding Manual Safety Labels and Directions Throughout this manual important information is brought to your attention by the following symbols WA...

Page 3: ...Vac Registered Trademark of Neward Enterprises Inc Torx Registered Trademark of Textron Hilliard Trademark of the Hilliard Corporation Warn Trademark of Warn Industries FOX Registered Trademark of FO...

Page 4: ......

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

Page 6: ......

Page 7: ...SPECIAL TOOLS 1 5 GENERAL SPECIFICATIONS 1 6 MODEL 2013 2014 RZR 800 1 6 MODEL 2013 2014 RZR EPS 800 1 6 MODEL 2014 RZR 800 XC 1 7 MODEL 2013 2014 RZR EPS 800 1 7 MODEL 2013 2014 RZR S 800 1 9 MODEL...

Page 8: ...AD GROUP MODEL YEAR CHASSIS DRIVE LINE ENGINE MOTOR CODE CATEGORY OPTION REGION 1st 2nd 3rd 4th 5th 6th 7th 8th 9th 10th Z 1 4 V H 7 6 A D digits that would transfer to 17 digit VIN and are used in di...

Page 9: ...Polaris ORV refer to the vehicle identification number VIN and engine serial number The VIN can be found stamped on the rear upper frame rail behind the left rear fender near the air box Figure 1 1 T...

Page 10: ...9924712 2014 RZR S 800 Z14VE76AD AL AS AV AW 9924707 9924709 2014 RZR S INT L 800 Z14VE76FI FX 9924707 9924708 2014 RZR 4 EPS 800 Z14XE7EAL 9924707 9924729 NOTE When ordering service parts be sure to...

Page 11: ...re mandatory while other tools may be substituted with a similar tool if available Polaris recommends the use of Polaris Special Tools when servicing any Polaris product Dealers may order special tool...

Page 12: ...des rider s cargo accessories and trailer tongue weight Hitch Towing Capacity 1500 lbs 680 kg Hitch Tongue Capacity 150 lbs 68 kg MODEL 2013 2014 RZR EPS 800 MODEL NUMBER R13VH7EAI Z14VH7EAI AK AL AW...

Page 13: ...omestic Twin Cylinder Liquid Cooled 4 Stroke Engine Number 1204670 RZR800 13 Engine Displacement 760cc H O Number of Cylinders 2 Bore Stroke mm 80 x 76 5 mm Compression Ratio 11 1 Compression Pressure...

Page 14: ...Front Suspension Independent Dual A arm w Anti Sway Bar Front Travel 9 in 23 cm Rear Suspension Rolled IRS w Anti Sway Bar Rear Travel 9 5 in 24 cm Shock Preload Adjustment Front Rear Cam Adjustment T...

Page 15: ...ider s cargo accessories and trailer tongue weight Hitch Towing Capacity 1500 lbs 680 kg Hitch Tongue Capacity 150 lbs 68 kg MODEL 2013 2014 RZR S INT L 800 MODEL NUMBER R13VE76FI FX Z14VE76FI FX Cate...

Page 16: ...Electrical Alternator Rated Output 500 Watts 3000 RPM Headlights Halogen 2 Halogen Low 55 W High 60 W Engine Headlights LED 2 Dual Beam LED Low 27 Watts High 40 Watts Tail Brake 2 6 Watts 2 27 Watts S...

Page 17: ...Threaded Spanner Wrench Adjustment Toe Out 1 8 1 4 in 3 6 4 mm Wheels Brakes Front Wheel Type Size Aluminum 12 x 6 Rear Wheel Type Size Aluminum 12 x 8 Front Tire Type Size ITP 900XCT 27 x 9 R12 Maxx...

Page 18: ...cessories and trailer tongue weight Hitch Towing Capacity 1500 lbs 680 kg Hitch Tongue Capacity 150 lbs 68 kg MODEL 2013 2014 RZR 4 EPS 800 MODEL NUMBER R13XE7EAI Z14XE7EAL Category Dimension Capacity...

Page 19: ...ated Output 500 Watts 3000 RPM Headlights Halogen 2 Halogen Low 55 W High 60 W Headlights LED 2 Dual Beam LED Engine Low 27 Watts High 40 Watts Tail Brake 2 6 Watts 2 27 Watts Starting System Electric...

Page 20: ...ut 1 8 1 4 in 3 6 4 mm Wheels Brakes Front Wheel Type Size Aluminum 12 x 6 Rear Wheel Type Size Aluminum 12 x 8 Front Tire Type Size ITP 900XCT 27 x 9 R12 Maxxis Bighorn 26 x 9 R12 Rear Tire Type Size...

Page 21: ...mile mi x 1 6 km km x 0 6214 mile ounces oz x 28 35 grams g fluid ounces fl oz x 29 57 cubic centimeters cc cubic centimeters cc x 03381 fluid ounces grams g x 0 035 ounces pounds lb x 0 454 kg kilog...

Page 22: ...48 55 76 80 110 1 2 13 50 69 75 104 110 152 1 2 20 55 76 90 124 120 166 Metric Bolt Torque Specification Bolt Size Grade 4 6 4 8 8 8 8 9 10 9 12 9 Ft Lbs Nm Dry Threads M3 3 5 5 7 1 1 3 1 5 2 1 5 2 M...

Page 23: ...7 64 12 28 4 6 mm 1 3 4 5 1 9 16 1 4 20 7 1 3 4 12 1 43 64 1 4 28 3 2 4 1 2 1 25 32 5 16 18 F 2 12 1 59 64 5 16 24 I 2 1 4 4 1 2 2 1 32 3 8 16 O 2 1 2 4 2 1 4 3 8 24 Q 2 3 4 4 2 1 2 7 16 14 U 3 4 2 3...

Page 24: ...13 32 0 4063 27 64 0 4219 11 mm 0 4331 7 16 0 4375 29 64 0 4531 15 32 0 4688 12 mm 0 4724 31 64 0 4844 1 2 0 500 13 mm 0 5118 33 64 0 5156 17 32 0 5313 35 64 0 5469 14 mm 0 5512 9 16 0 5625 37 64 0 57...

Page 25: ...NERS 2 10 SHIFT CABLE INSPECTION ADJUSTMENT 2 10 FUEL SYSTEM AND AIR INTAKE 2 11 FUEL SYSTEM 2 11 FUEL LINE 2 11 FUEL PUMP FUEL FILTERS 2 11 VENT LINES 2 12 THROTTLE PEDAL INSPECTION 2 12 THROTTLE FRE...

Page 26: ...LLATION 2 29 BATTERY OFF SEASON STORAGE 2 29 BATTERY CHARGING MAINTENANCE FREE 2 29 SPARK PLUG SERVICE 2 29 ENGINE TO FRAME GROUND 2 31 STEERING 2 31 STEERING INSPECTION 2 31 STEERING WHEEL FREEPLAY 2...

Page 27: ...ately if the oil level begins to rise Monitor the oil level and if it continues to rise discontinue use and determine the cause or see your dealer Break In Period The break in period consists of the f...

Page 28: ...ange after the first 25 hours or one month of operation Front Gearcase Oil Demand Drive 25 H 1 M 250 400 Initial fluid level inspection add lubricant if needed Rear Gearcase Oil ATV Angle Drive Fluid...

Page 29: ...t 100 H 12 M 1000 1600 Inspect replace as needed Radiator 100 H 12 M 1000 1600 Inspect clean external surfaces Cooling Hoses 100 H 12 M 1000 1600 Inspect for leaks Engine Assembly Mounts 100 H 12 M 10...

Page 30: ...eafter Change more often 25 hours in severe duty conditions or short trip cold weather operation 2 Engine Coolant Polaris 60 40 Coolant Maintain coolant level in coolant reservoir bottle Check level d...

Page 31: ...at 25 hours change according to intervals 5 Rear Gearcase Polaris ATV Angle Drive Fluid ADF Add lubricant until it is visible at the fill hole threads Initial level check at 25 hours change according...

Page 32: ...nd 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 Premium U Joint...

Page 33: ...lon 2870465 Oil Pump for 1 Gallon Jug Grease Specialized Lubricants 2871312 Grease Gun Kit 2871322 Premium All Season Grease 3 oz cartridge 24 Count 2871423 Premium All Season Grease 14 oz cartridge 1...

Page 34: ...the maintenance schedule Check that all cotter pins are in place Refer to specific fastener torques listed in each chapter Shift Cable Inspection Adjustment Shift cable adjustment may be necessary if...

Page 35: ...engine or let it run in an enclosed area Engine exhaust fumes are poisonous and can result in loss of consciousness or death in a short time Never drain the fuel when the engine is hot Severe burns ma...

Page 36: ...There should be minimal freeplay between the throttle cable and the cable pull lever If there is excessive play due to cable stretch or misadjustment it will cause a delay in throttle response especi...

Page 37: ...and slide it over the cable adjuster to its original position 9 Reinstall the PVT intake duct and tighten the hose clamp 10 Reinstall the air intake box and 2 push rivets 11 Reinstall the cargo box al...

Page 38: ...e more frequently if vehicle is operated in wet conditions or at high throttle operation for extended periods Installation 1 Clean the air box thoroughly 2 Place the filter ring over the end of the fi...

Page 39: ...ean cloth 6 Reinstall the dipstick completely but do not lock it NOTE Make certain the dipstick is inserted all the way into the filler tube to keep the angle and depth of dipstick consistent 7 Remove...

Page 40: ...n area around oil drain plug at bottom of engine CAUTION Oil may be hot Do not allow hot oil to come into contact with skin as serious burns may result 5 Place a drain pan beneath engine crankcase and...

Page 41: ...engine does NOT have decompression components Compression readings will vary in proportion to cranking speed during the test A smooth idle generally indicates good compression Low engine compression i...

Page 42: ...2 18 9924707 2013 2014 RZR 800 Service Manual Copyright 2013 Polaris Sales Inc 4 Reinstall the arrestor and torque the screw to specification Spark Arrestor Screw 40 in lbs 4 5 Nm MAINTENANCE...

Page 43: ...8 Nm 30 45 in lbs 3 5 Nm Transmission Lubrication Transmission Specifications Specified Lubricant AGL Gearcase Lubricant PN 2878068 Approximate Capacity at Change Main Gearcase 24 oz 710 ml Transfer C...

Page 44: ...lubricant change on only one gearcase at a time Access the drain plugs through the drain holes in the skid plate Transfer Case Lubricant Change 1 Remove the fill plug and the level check plug refer to...

Page 45: ...t Gearcase Lubrication The front gearcase lubricant level should be checked and changed in accordance with the maintenance schedule Be sure vehicle is positioned on a level surface when checking or ch...

Page 46: ...ication 6 Add the recommended fluid Maintain the lubricant level even with the bottom threads of the fill plug hole 7 Reinstall the fill plug and torque to specification Fill Drain Plug 8 10 ft lbs 11...

Page 47: ...l the fill plug and torque to specification Fill Plug 40 50 ft lbs 54 68 Nm Lubricant Change The drain plug is located on the bottom right side of the rear gearcase 1 Remove the fill plug 2 Place a dr...

Page 48: ...g procedure 1 Position the vehicle on a level surface 2 Remove the hood from the front cab 3 View the coolant level in the recovery bottle 4 If the coolant level is below the MIN line inspect the cool...

Page 49: ...s 36 in lbs 4 Nm Radiator 1 Check radiator A air passages for restrictions or damage 2 Carefully straighten any bent radiator fins 3 Remove any obstructions with compressed air or low pressure water C...

Page 50: ...e 2 Place the transmission in PARK P and stop the engine 3 Loosen the wheel nuts slightly If wheel hub removal is required remove the cotter pin and loosen the hub nut slightly 4 Elevate the appropria...

Page 51: ...ginal equipment size and type The use of non standard size or type tires may affect vehicle handling WARNING Operating with worn tires will increase the possibility of the vehicle skidding easily with...

Page 52: ...ead compounds and other chemicals known to the State of California to cause cancer and birth defects or other reproductive harm WASH HANDS AFTER HANDLING WARNING Battery electrolyte is poisonous It co...

Page 53: ...fe It can also hinder vehicle performance Follow the battery charging procedure in Chapter 10 Electrical before installing the battery 1 Ensure the battery is fully charged 2 Place the battery in the...

Page 54: ...nd carbon buildup Look for a sharp outer edge with no rounding or erosion of the electrodes 7 Clean with electrical contact cleaner or a glass bead spark plug cleaner only CAUTION A wire brush or coat...

Page 55: ...d steering components Steering should move freely through the entire range of travel without binding Check routing of all cables hoses and wiring to be sure the steering mechanism is not restricted or...

Page 56: ...any worn steering components Steering should move freely through entire range of travel without binding Elevate front end of machine so front wheels are off the ground Check for any looseness in fron...

Page 57: ...ment A The difference between measurements A and B is the vehicle toe alignment The recommended vehicle toe tolerance is 1 8 to 1 4 0 3 to 0 6 cm toe out This means the measurement at the front of the...

Page 58: ...ion preload WARNING Uneven adjustment may cause poor handling of the vehicle which could result in an accident and serious injury or death Always adjust both the left and right spring preloads equally...

Page 59: ...31 in 10 9 cm 4 99 in 12 7 cm NOTE Refer to the shock illustration within this procedure for spring preload measurement location 1 Raise and safely support front or rear of vehicle off the ground to a...

Page 60: ...ys check the brake pedal travel and inspect the brake fluid reservoir level before each operation If the fluid level is low add DOT 4 brake fluid only Recommended Brake Fluid DOT 4 Brake Fluid PN 2872...

Page 61: ...ld be changed when the friction material is worn to 040 1 mm 4 Check surface condition of the brake discs 5 Measure the thickness of the front and rear brake discs 6 The disc s should be replaced if t...

Page 63: ...3 14 COOLING SYSTEM BLEEDING PROCEDURE 3 15 GENERAL ENGINE SERVICE 3 17 ENGINE LUBRICATION SPECIFICATIONS 3 17 OIL PRESSURE TEST 3 17 ACCESSIBLE ENGINE COMPONENTS 3 17 OIL FLOW CHART 3 18 ENGINE REMO...

Page 64: ...ENDIX REMOVAL INSPECTION 3 42 FLYWHEEL STATOR REMOVAL INSPECTION 3 43 ENGINE CRANKCASE DISASSEMBLY INSPECTION 3 44 CAMSHAFT INSPECTION 3 53 ENGINE REASSEMBLY 3 55 CRANKCASE REASSEMBLY 3 55 FLYWHEEL ST...

Page 70: ...l 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 Oil Filter Pipe Fitting 20 mm 35 4 47 5 5 4 Oil Pick Up 5 mm 60 6 6 8...

Page 71: ...nter Balance End Play 0 005 0 127 mm Cylinder Head Cylinder Head Surface warp limit 0 00394 0 10 mm Cylinder Head Standard height 3 478 88 35 mm Valve Seat Valve Seat Contacting Width Intake 0 0472 0...

Page 72: ...n 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 Piston...

Page 73: ...45497 1 CAM GEAR SPRING INSTALLATION KIT PU 45497 2 CAM GEAR TOOTH ALIGNMENT TOOL PU 45498 CAM SPANNER WRENCH PU 45838 GEAR HOLDER PA 44995 WATER PUMP MECHANICAL SEAL INSTALLER PU 45543 UNIVERSAL DRIV...

Page 74: ...rotection required in your area CAUTION Using tap water in the cooling system will lead to a buildup of deposits which may restrict coolant flow and reduce heat dissipation resulting in possible engin...

Page 76: ...e front RH side of the vehicle 4 Drain the coolant from the radiator by removing the lower coolant hose from the radiator as shown Properly dispose of the coolant 5 Allow coolant to completely drain 6...

Page 77: ...s in the cooling system are found 1 Drive the vehicle onto a slight incline or use properly weight rated ramps If an incline is not available slightly elevate the front of the vehicle 2 Place the vehi...

Page 78: ...he radiator filler neck 10 Add Polaris Premium Antifreeze to the radiator filler neck if the level goes down If no bubbles are seen at the filler neck the system should be purged of air WARNING Be sur...

Page 79: ...into the crankcase and attach the gauge 3 Start engine and allow it to reach operating temperature while monitoring the gauge NOTE Use only Polaris PS 4 or Extreme Duty Synthetic 4 Cycle Engine Oil O...

Page 80: ...s oil to bypass the filter element At this point the oil is supplied to the main oil galley through a crankcase passage Oil is then diverted three ways from the main oil galley with the first path ent...

Page 81: ...per shop clothing when performing the procedures in this manual Failing to do so may lead to possible injury or death 1 If vehicle was recently operated allow it to cool down before attempting to perf...

Page 82: ...move cover 16 Remove the high tension leads from the spark plugs and disconnect the ignition coil harness IMPORTANT Mark or note which ignition coil wire goes to which cylinder and ignition coil post...

Page 83: ...4 fasteners retaining the stabilizer bar and bracket and remove the assembly from the vehicle 21 Remove the engine breather hose from the valve cover 22 Loosen the hose clamp between the throttle bod...

Page 84: ...es NOTE The fuel injector harness connector and locking spring is bonded to the fuel injectors with an epoxy mix DO NOT attempt to disconnect the connector from the fuel injectors Damage will occur to...

Page 85: ...t of the mount NOTE If the upper jam nut is moved shift cable adjustment will be required during engine installation see Chapter 2 Shift Cable Inspection Adjustment 30 Disconnect the transmission gear...

Page 86: ...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 outwa...

Page 87: ...cooling system vacuum NOTE Use a portable wet vac or syphon to prevent any coolant from spilling 42 Remove the upper coolant hose from the thermostat housing outlet to relieve any coolant vacuum crea...

Page 88: ...engine hoist is the only recommended method for removing and installing the engine transmission rear gearcase assembly 47 Using an engine hoist hook a chain between the engine transmission mounting p...

Page 89: ...Transmission Separation Once the engine transmission rear gearcase assembly has been removed from the vehicle the engine and transmission will need to be separated to allow engine servicing Use the f...

Page 91: ...air to prevent personal injury 3 Check the ends of the push rods A for nicks grooves roughness or excessive wear 4 The push rods A can be visually checked for straightness while they are installed in...

Page 92: ...ax Valve Seal Spring Service On Engine NOTE The following procedure is only for servicing the top end of the valve train when replacing valve springs or replacing valve seals In some cases the valve t...

Page 93: ...r and spring 4 The valve seals are now serviceable Cylinder Head Disassembly 1 Carefully remove the cylinder components 2 Place the hydraulic lifters C pushrods D and rocker arms E in a safe clean are...

Page 94: ...alve stems mount valve in a drill or use V blocks and a dial indicator 3 Check end of valve stem A for flaring pitting wear or damage Inspect split keeper groove B for wear or flaring of the keeper se...

Page 95: ...a wire brush metal scraper or abrasive cleaners to clean the bottom of the cylinder head Extensive damage to the cylinder head may result Wear safety glasses during cleaning Valve Seat Reconditioning...

Page 96: ...ght cut 4 Inspect the cut area of the seat If the contact area is less than 75 of the circumference of the seat rotate the pilot 180 and make another light cut If the cutter now contacts the uncut por...

Page 97: ...t If the seat is too narrow widen using the 45 cutter and re check contact point on the valve face and seat width after each cut NOTE When using an interference angle the seat contact point on the val...

Page 98: ...ng and install Valve Spring Compressor PU 45257 Install split keepers with the gap even on both sides NOTE A small magnet can be used to aid in the installation of the keepers 7 Repeat procedure for r...

Page 99: ...ters and cam as an assembly If replacing the lifters the camshaft should also be replaced Piston Removal 1 Remove the circlip Mark the piston with a white pen to ensure proper orientation if reused du...

Page 100: ...er expander section The top rail has a locating tab on the end which fits into a notch B in the upper oil ring land of the piston To Remove A Remove the top rail first followed by the bottom rail B Re...

Page 101: ...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 bottom Record measurements If cylinder is taper...

Page 102: ...and below the bore at the end of each stroke Release the hone at regular intervals and inspect the bore to determine if it has been sufficiently de glazed and to check for correct cross hatch NOTE Do...

Page 103: ...ace piston and or piston pin if out of specification Piston Pin O D See 800 EFI Engine Service Specifications page 3 9 3 Measure connecting rod small end ID Connecting Rod Small End I D See 800 EFI En...

Page 104: ...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 completely Wipe cylinder bore with...

Page 105: ...nut and washer 3 Install Flywheel Puller PN 2871043 and remove flywheel A CAUTION Do not thread the puller bolts into the flywheel more than 1 4 or stator coils may be damaged 4 Use caution when remo...

Page 106: ...eller E Remove part of the water pump seal behind the impeller 3 Remove flywheel nut and washer 4 Install Flywheel Puller PN 2871043 and remove flywheel F CAUTION Do not thread the puller bolts into t...

Page 107: ...ent and timing during reassembly of the gears NOTE If replacing one of the gears it is recommended that all of the gears be replaced A gear kit is available 9 Use the Cam Gear Tooth Alignment Tool PU...

Page 108: ...mall flathead screwdriver between the two gears Remove the top gear The springs should stay in place CAUTION Wear safety glasses at all times Use caution when working with the top gear The springs cou...

Page 109: ...h with 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 photog...

Page 110: ...ter 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 s...

Page 111: ...so that the bolts are at equal length 25 Install the Flywheel Puller PN 2871043 and remove the crankshaft gear if needed 26 Rotate the water oil pump gear S so that all four bolts are visible though t...

Page 112: ...for signs of possible obstructions Use compressed air to blow out any debris 30 Reinstall the valve dowel chamfered end first Install the spring washer and bolt Torque to specification Oil Pressure Re...

Page 113: ...ut the bearing shaft assembly 33 Place the shaft in a press to remove the bearing 34 Press shaft into the new bearing 35 Press the bearing shaft assembly using the bearing s outer race Do not use the...

Page 114: ...s using soft hammer Carefully separate the two crankcase halves NOTE Only remove the oil baffle if the baffle is damaged When removing the oil baffle bolts use a heat gun to heat the bolts and loosen...

Page 115: ...ear It is recommended to replace the bearings anytime the engine is disassembled Camshaft Inspection 1 Thoroughly clean the cam shaft 2 Visually inspect each cam lobe for wear chafing or damage 3 Meas...

Page 116: ...shaft Journal Bore I D MAG 1 656 0 00039 42 07 0 010 mm CTR 1 637 0 00039 41 58 0 010 mm PTO 1 617 0 00039 41 07 0 010 mm 6 Calculate oil clearance by subtracting journal O D s from journal bore I D s...

Page 117: ...e any debris This will ensure proper sealing when installing bolts 1 Install oil pick up A Torque bolt to specification 2 Install oil baffle weldment B Torque bolts to specification Oil Baffle Weldmen...

Page 118: ...E 7 Assemble the crankcase halves Apply LocTite 242 PN 2871949 to the threads and pipe sealant to the bolt flanges Torque bolts to specification following torque pattern at beginning of this chapter C...

Page 119: ...aps of the rings every 120 see illustration below 13 Install piston assemblies into cylinder aligning the piston pin holes to ensure proper alignment of the pistons to the connecting rods upon assembl...

Page 120: ...ston circlips cover all engine passages The clip could fall into the engine during installation 16 Install camshaft thrust plate G with new bolts Torque bolts to specification NOTE New bolts have patc...

Page 121: ...d with This Side Out This indicates the side of the gear that faces outward or away from the case NOTE Before assembly clean the bolts and bolt holes with Loctite Primer N commercially available to re...

Page 122: ...n when removing the crankshaft gear from the hot plate Use a pair of pliers and leather gloves when handling the crankshaft gear 24 Install the crankshaft gear I onto the crankshaft NOTE For assembly...

Page 123: ...aft 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 the proper position NOTE Cam Sp...

Page 124: ...ow seal surface to come in contact with contaminants during installation Thoroughly clean parts tools and hands before installation NOTE To remove the water pump seal the gear stator housing must be r...

Page 125: ...ly install tapered end of the Crankshaft Seal Protection Tool PA 45658 through the paper side of the crankshaft seal back to front Leave the seal protector installed Check the crankshaft seal lips to...

Page 126: ...per sequence to specification Remove seal protectors from the shaft ends once the cover is secure Gear Stator Housing Bolt 96 12 in lbs 10 85 1 35 Nm Torque in proper sequence NOTE Before assembly cle...

Page 127: ...wheel Stator Installation NOTE Before assembly clean the bolts and bolt holes with Loctite Primer N commercially available to remove any debris This will ensure proper sealing when installing bolts 1...

Page 128: ...to specification and follow proper bolt torque sequence at the beginning of this chapter Stator Housing Bolts 96 12 in lbs 10 85 1 35 Nm Torque in proper sequence Cylinder Head Reassembly NOTE Before...

Page 129: ...Inc 3 Lubricate threads top of washers and underside of bolt head with engine oil Install head bolts C and torque to specification in sequence 4 Lubricate push rods D and install into lifters 5 Lubric...

Page 130: ...he reed has a tab and will assemble one way only Torque breather bolts to specification Breather Bolts 20 5 in lbs 2 5 0 55 Nm NOTE When applying RTV do not get any RTV inside the reed assembly 9 Plac...

Page 131: ...Priming CAUTION After any reassembly or rebuild the engine must be primed using the Oil Priming Adapter PU 45778 and a 3 4 full oil filter before initial start up Follow the steps in this section to...

Page 132: ...emble the engine to the transmission on a work bench prior to installation 1 Support the transmission rear gearcase assembly while setting the engine in place 2 Lightly tighten all fasteners evenly to...

Page 133: ...ling system as described in this Chapter under Cooling System Bleeding Procedure Engine Break In Period The break in period consists of the first 25 hours of operation or the time it takes to use 14 g...

Page 134: ...ricted fuel supply Low compression Crankcase breather restricted Engine Idles But Will Not Accelerate Spark plug fouled weak spark Broken throttle cable Obstruction in air intake Air box removed reins...

Page 135: ...key Cooling System Overheating Low coolant level Air in cooling system Wrong type mix of coolant Faulty pressure cap or system leaks Restricted system mud or debris in radiator fins causing restricti...

Page 137: ...TION OVERVIEW 4 13 ECU SERVICE 4 13 ECU REPLACEMENT 4 13 PRESSURE SENSOR T MAP 4 14 OPERATION OVERVIEW 4 14 T MAP SENSOR TEST 4 14 T MAP SENSOR REPLACEMENT 4 14 CRANKSHAFT POSITION SENSOR CPS 4 15 OPE...

Page 138: ...41 IGNITION COIL HT LEAD REPLACEMENT 4 41 IGNITION COIL TESTS 4 41 EFI DIAGNOSTICS 4 42 INSTRUMENT CLUSTER TROUBLE CODE DISPLAY 4 42 EFI TROUBLESHOOTING 4 46 DIGITAL WRENCH OPERATION 4 47 DIGITAL WRE...

Page 139: ...nd water and change clothing Always stop the engine and refuel outdoorsor in a well ventilated area Special Tools PART NUMBER TOOL DESCRIPTION 2201519 A Throttle Position Sensor TPS Tester PU 47466 TP...

Page 140: ...ef valve that can be used to bleed off pressure once you have completed the fuel pressure test Fuel Pressure Gauge Adaptor PV 48656 Digital Wrench Diagnostic Software PU 47063 B This dealer only softw...

Page 141: ...es 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 open for any length of time New part...

Page 143: ...er s seat RZR RZR S or under the left rear passenger seat RZR 4 2 Temperature and Manifold Absolute Pressure Sensor T MAP Located in the rubber intake boot between the throttle body and the cylinder h...

Page 144: ...ylinder head 5 Fuel Pump Regulator Fuel Gauge Sender Assembly Located under the passenger seat RZR RZR S or under the right rear passenger seat RZR 4 6 Throttle Body Located between the rubber air box...

Page 145: ...se 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 Located in the cylinder head next to th...

Page 147: ...any dripping fuel Squeeze the connector tabs together and push the locking slide back 2 Pull on the fuel line for removal 3 To install the line s verify the connections are clean and free of debris 4...

Page 148: ...led injection of the fuel occurs every other crankshaft revolution or once for each 4 stroke cycle The total amount of fuel needed for one firing of a cylinder is injected during each cycle When the i...

Page 149: ...The memory in the ECU is operational the moment the battery cables are connected To prevent engine over speed and possible failure an RPM limiting feature is programmed into the ECU If the maximum RP...

Page 150: ...Test The T MAP sensor is a non serviceable item If it is faulty it must be replaced IMPORTANT This sensor should only be tested using the Digital Wrench Diagnostic Software dealer only T MAP Sensor R...

Page 151: ...signal corresponding to specific crankshaft position This signal serves as a reference for the control of ignition timing by the ECU Synchronization of the CPS and crankshaft position takes place dur...

Page 152: ...he vehicle is secure before beginning this service procedure 2 If not done already disconnect the CPS harness connector see illustration under CPS Test IMPORTANT In order to remove the CPS the rear po...

Page 153: ...will be required to torque the mounting bracket fasteners when the transmission and rear gearcase are installed in the vehicle This tool is specifically designed to access the critical transmission to...

Page 154: ...ket to the transmission Upper Transmission Bolt Middle Transmission Bolt Bottom Transmission Bolt 5 Remove the special tool and attach an extension to the torque wrench Torque the bottom bolt that att...

Page 155: ...ng to gain access to the bolts Middle Rear Gearcase Bolt Upper Rear Gearcase Bolt 7 Torque the remaining bolt that attaches the bracket to the front side of the rear gearcase Front Rear Gearcase Bolt...

Page 156: ...ion indicating that they are opening and closing When temperatures prohibit touching listen for a buzzing or clicking sound with a screwdriver or mechanic s stethoscope Disconnect the electrical conne...

Page 157: ...ay MAG Black The fuel injectors are non serviceable If diagnosis indicates a problem with either injector test the resistance of the fuel injector s by measuring between the two harness pin terminals...

Page 158: ...nect the Bosch connector from the fuel injectors Damage will occur to the injector and or harness if attempting to separate at that location Separate the fuel injector from the vehicle harness as show...

Page 159: ...n these instances If the key switch 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 sit...

Page 160: ...56 Route clear hose into a portable gasoline container or the vehicle s fuel tank 5 Turn on the key switch to activate the pump and check the system pressure on the gauge If system pressure of 45 psi...

Page 161: ...een discharged by touching a ground source such as the engine or frame 3 Disconnect the fuel pump electrical harness 4 While holding a shop towel over the fuel line connector disconnect the quick conn...

Page 162: ...loat arm is not bent when removed from the tank 8 Transfer old fuel pump to a suitable container capable of safely holding fuel The fuel pump will retain some fuel 9 Inspect the inside of the fuel tan...

Page 163: ...caught or bent during installation 14 Gently push down on fuel pump flange ensuring flange is centered 15 Roughly align orientation mark on fuel pump between the orientation marks on fuel tank to ens...

Page 164: ...to activate Cycle the key several times to prime the system Fuel Tank Removal RZR RZR S IMPORTANT Syphon as much fuel from the tank as possible before attempting to remove it from the vehicle WARNING...

Page 165: ...a suitable pliers and remove vent line from the tank vent fitting 6 Remove rear seat base assembly from the vehicle by removing the 2 fasteners retaining the rear seat base 7 Remove shift knob and ce...

Page 166: ...he way 10 Remove the 3 Torx fasteners from 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...

Page 167: ...plications 1 Remove the rear passenger seats along with the rear service panel 2 Remove the driver s seat and disconnect the negative battery cable from the battery 3 Remove the push rivets and T27 To...

Page 168: ...H panel divider Remove the panel divider from the vehicle see Chapter 5 7 Remove the rear seat support by removing the 5 16 fastener and 7 16 fastener retaining the right side of the rear seat support...

Page 169: ...a suitable pliers and remove vent line from the tank vent fitting 11 While holding a shop towel over the fuel line connector disconnect the quick connect fuel line from the fuel pump Move the fuel li...

Page 170: ...e battery cable Test the fuel pump by turning the ignition key on and listening for the pump to activate Check for leaks 12 Finally install the rear service panel along with the seats IDLE AIR CONTROL...

Page 171: ...securely tighten the hose clamps 9 Reinstall the rear cargo box rear service panel and seats see Chapter 5 THROTTLE POSITION SENSOR TPS Operation Overview The throttle position sensor TPS is used to i...

Page 172: ...1 3 4 k 6 k TPS Tester Regulator The TPS reading can be checked by using the Throttle Position Sensor TPS Tester 2201519 A Set up the TPS Tester Wire Harness PU 47466 and TPS Tester Regulator 547927 a...

Page 173: ...hrottle body 3 Remove the throttle body from the intake track and plug the intake boots with a clean shop towel 4 Disconnect the vehicle harness from the TPS 5 Remove the 2 Phillips head mounting scre...

Page 174: ...TPS Tester according to the instructions Refer to TPS Tester Regulator 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 v...

Page 175: ...age present on the Red Dark Blue wire and ground present on the Brown wire NOTE Use Digital Wrench Diagnostic Software dealer only if you suspect this sensor is faulty Cam Phase Sensor Replacement 1 A...

Page 176: ...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 Refer to Chapter 3 a...

Page 177: ...ich ignition coil wire goes to which cylinder and ignition coil post The engine will misfire if the spark plug wires are installed incorrectly The spark plug wires are marked with PTO and MAG from the...

Page 178: ...uring current ignition cycle causing the MIL to illuminate Diagnostic trouble codes will remain stored in the gauge even if MIL turns off until the key is turned off NOTE If there is a diagnostic prob...

Page 179: ...t the diagnostic mode press and hold the MODE button or turn the ignition key OFF once the codes are recorded DIAGNOSTIC TROUBLE CODE TABLE Component Condition SPN FMI Digital Wrench P Code Throttle P...

Page 180: ...put Driver Circuit Open 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 t...

Page 181: ...C1065 EPS Software Error Software Error 520229 12 C1070 IC CAN Communication with EPS EPS Off Line EPS DM1 not seen 520230 31 U0131 EPS Power Save Condition EPS Key On Engine Off 5 Minute Power Save T...

Page 182: ...ough misses poor performance bog engine loads up backfire Air intake restricted inspect intake duct Air filter dirty plugged Poor fuel quality old fuel Fouled spark plug TPS setting incorrect Injector...

Page 183: ...mmercially Available refer to diagnostic software user manual or HELP section for minimum requirements Diagnostic Software Version Always use the most current version of the Digital Wrench software to...

Page 184: ...Wrench connector 3 Connect the Vehicle Interface Cable to the Digital Wrench diagnostic connector 4 Turn the ignition key to the ON position select the appropriate vehicle and wait for the status to d...

Page 185: ...Wrench portal website should appear in a new web browser 5 Click on Digital Wrench Version Updates IMPORTANT You must already have the current version installed before adding an update Updates will no...

Page 187: ...ly to cause a reprogramming problem than one dedicated to Digital Wrench diagnostics only OBTAINING THE LATEST UPDATE Reprogramming updates are provided periodically and contain the most recent calibr...

Page 188: ...cial Tests icon 6 Select Engine Controller Reprogramming 7 Select the file you want to load into the ECU then click the Continue icon to proceed to the Integrity Check and obtain a Request Code 8 Copy...

Page 189: ...the Authorize button once to proceed 12 An Authorization Key will appear in the upper left corner of the screen Copy CTRL C this key exactly as it appears 13 Enter or paste CTRL C the Authorization K...

Page 191: ...16 REAR CARGO BOX FENDERS RZR RZR S 5 17 REAR CARGO BOX FENDERS RZR 4 5 18 CHASSIS MAIN FRAME RZR RZR S 5 19 CHASSIS MAIN FRAME RZR 4 5 20 BODY COMPONENT REMOVAL 5 21 SEATS 5 21 REAR SERVICE PANEL RZR...

Page 192: ...R RZR 5 45 REMOVAL INSTALLATION 5 45 REAR STABILIZER BAR RZR S RZR 4 5 46 REMOVAL INSTALLATION 5 46 DECAL REPLACEMENT 5 48 SHOCKS SPRINGS FASTENERS 5 48 EXPLODED VIEW RZR RZR S 5 48 EXPLODED VIEW RZR...

Page 193: ...DELS 5 63 REAR SHOCK SERVICE RZR 4 BASE MODELS 5 63 FOX 2 0 PODIUM TOP FILL DISASSEMBLY 5 64 FOX 2 0 PODIUM TOP FILL REASSEMBLY 5 67 WALKER EVANS SHOCK EXPLODED VIEWS 5 72 WALKER EVANS 2 0 SHOCK 5 72...

Page 194: ...Fastener 12 ft lbs 16 Nm Steering Pivot Tube Fasteners 23 ft lbs 31 Nm Steering Wheel to Shaft 28 ft lbs 38 Nm Upper Steering Shaft to Power Steering Unit EPS Models 15 ft lbs 20 Nm Lower Steering Sha...

Page 195: ...hicle with four M10x1 5x25 bolts and M10x1 5 nuts Tighten bolts to specification Fasten the two self tapping screws to the rear inner portion of the bracket on each side Tighten screws to specificatio...

Page 197: ...0 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 frame using the 3 8 16 x 1 1 4 bolts and 3 8 16 Nyloc...

Page 211: ...e 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 the top wh...

Page 212: ...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 front bumper see BODY COMPONENT REMO...

Page 213: ...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...

Page 214: ...s 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 2 Remove the T27...

Page 216: ...lower portion of the steering shaft to the steering gear box assembly 2 Remove the fastener retaining the upper portion of the steering wheel tilt shock to the pivot tube 3 Remove the 2 fasteners that...

Page 217: ...Install the steering wheel and hand tighten the nut 11 Reinstall the steering shaft assembly in the vehicle Install the lower portion of the steering shaft onto the steering gear box assembly Refer t...

Page 219: ...cle 2 Remove the pinch bolt retaining the 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...

Page 220: ...e steering wheel cap 3 Loosen the nut and back it half way off the steering shaft 4 Place the assembly in a vise 5 Using a large bronze drift and hammer strike the steering shaft nut to pop the steeri...

Page 221: ...remove the 4 bolts that retain the power steering unit to the mount bracket WARNING Electronic Power Steering EPS units are programmed to be vehicle specific and are not interchangeable between produ...

Page 222: ...mble the vehicle see Power Steering Unit Installation procedure Power Steering Unit Installation 1 If the power steering unit was removed from the mount bracket reinstall it prior to vehicle installat...

Page 223: ...upper steering shaft is properly positioned on the power steering stub shaft CAUTION Striking the steering wheel or steering shaft can permanently damage the EPS unit and cause a Power Steering Fault...

Page 224: ...upper A arm Completely remove the ball joint end from the bearing carrier 5 Remove the front bumper to allow A arm bolt removal 6 Loosen and remove the upper A arm through bolt fastener C and remove u...

Page 225: ...on 20 Insert new bushings and pivot tube into new A arm 21 Install new lower A arm assembly onto vehicle frame Torque new bolt to specification 22 Insert lower A arm ball joint end into the bearing ca...

Page 227: ...ts and remove the caliper from the brake disc see Brakes chapter Remove and discard the upper ball joint pinch bolt If necessary remove the lower front shock fastener from the A arm to gain enough cle...

Page 228: ...ion Adapter and Spacer 5 Tighten the Press Asm screw and fully install the ball joint into the arm 6 After the new ball joint is fully installed into the A arm install a new retaining ring 7 Repeat th...

Page 229: ...xploded View RZR Remove the nut and linkage bushings and remove the linkages from the vehicle RZR S INT L Remove the bolts that attach the upper portion of the linkages to the stabilizer bar clamps an...

Page 230: ...ning screws from recovery bottle and filler neck Allow the recovery bottle and filler neck to hang down to access the 4 bolts retaining the upper radiator mount bracket 8 Remove the 4 bolts retaining...

Page 232: ...taching the upper A arm to the frame and remove the upper A arm from the vehicle 3 Examine bushings and pivot tubes see Exploded View on page 5 43 Replace if worn Discard hardware 4 If not replacing t...

Page 233: ...arrier 4 Remove the 2 fasteners J attaching the lower A arm to the frame Remove the A arm from the vehicle 5 Examine bushings and pivot tubes see Exploded View Replace if worn Discard hardware 6 If no...

Page 234: ...t low speeds before putting into service Rear Upper Lower A arm Bolts RZR 33 ft lbs 45 Nm RZR S RZR 4 40 ft lbs 54 Nm Lower Rear Bearing Carrier Bolts RZR 38 ft lbs 52 Nm RZR S RZR 4 40 ft lbs 54 Nm S...

Page 235: ...d exhaust silencer from the vehicle NOTE The exhaust silencer can be removed through the side of the vehicle after the exhaust pipe is detached from the header pipe 2 Remove the retaining nut from the...

Page 236: ...r installation Torque the stabilizer bolts to specification Stabilizer Mounting Bolts 18 ft lbs 24 Nm REAR STABILIZER BAR RZR S RZR 4 Removal Installation 1 Remove the exhaust pipe and exhaust silence...

Page 237: ...bar from the bracket bracket can remain attached to the frame 5 Inspect the stabilizer bar for straightness Inspect the bushings and replace if needed 6 Reverse the procedure for installation Torque...

Page 238: ...ed to reduce or eliminate the whitish stress marks that are sometimes left after a fender or cab is bent flexed or damaged CAUTION Do not flame treat painted plastic components Painted plastic surface...

Page 239: ...fasteners to 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 ca...

Page 240: ...17 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 D...

Page 241: ...CK VALVING COMPRESSION REBOUND 1 300 x 0 008 1 100 x 0 008 1 300 x 0 008 1 100 x 0 010 0 900 x 0 006 1 000 x 0 010 1 250 x 0 006 0 900 x 0 012 1 100 x 0 006 0 800 x 0 012 1 000 x 0 006 0 700 x 0 012 0...

Page 242: ...sm 2 1 Body Cap 13 1 Preload Ring Jam Nut 3 1 Body 14 1 Preload Ring 4 1 Eyelet 15 1 Damping Adjust Asm Piston 5 1 Shaft 16 1 Damping Adjust Asm Concentric 6 1 Bearing Cap Asm 17 2 Bearing External 7...

Page 243: ...1 600 x 0 006 1 425 x 0 008 1 425 x 0 010 1 425 x 0 008 1 350 x 0 010 1 425 x 0 008 1 250 x 0 012 1 425 x 0 008 1 100 x 0 012 1 100 x 0 004 0 950 x 0 012 1 425 x 0 012 0 800 x 0 010 1 350 x 0 012 1 5...

Page 244: ...k Seal Protector Sleeve Bosch Automotive Service Solutions 1 800 328 6657 or http polaris service solutions com FOX PODIUM Piggyback Disassembly IMPORTANT To prevent damage or marks to the shock the u...

Page 245: ...the IFP located in the reservoir 15 Push downward on the IFP tool while pulling upward on the shock shaft to remove the shock shaft assembly 16 Remove the center screw and O ring from the IFP 17 Remo...

Page 246: ...e vehicle Remove the component from the vehicle before flame treating Disassembly 1 Use the appropriate shock body holding tool PS 45281 A to properly secure the shock body assembly into a vice for se...

Page 247: ...hocks and related high pressure service equipment The pressure must be released from the shock before disassembly It is strongly recommended you wear safety glasses and ear protection during these pro...

Page 248: ...the use of special tools and a soft jaw vise is recommended WARNING FOX shocks contain high pressure nitrogen gas Extreme caution must be used while handling and working with FOX shocks and related h...

Page 249: ...shim it must be installed in time with the compression ports 9 Install the piston assembly onto shock rod Be sure rebound side of the piston is facing up 10 Lubricate and install the rebound valve sta...

Page 250: ...t as it submerges in the shock oil until no more air bubbles rise out of the shock oil 24 Hold pressure downward on IFP tool Stroke shock rod assembly up and down 1 4 6 35 mm to work the air bubbles o...

Page 251: ...nstall and depress the reservoir cap past the retaining ring groove 44 Install the reservoir cap retaining ring WARNING CHARGE THE SHOCK USING NITROGEN GAS ONLY DO NOT FILL WITH ANY OTHER GASES Doing...

Page 252: ...ef Qty Description Ref Qty Description 1 1 Body Cap Asm 12 1 Preload Ring 2 1 Air Valve Asm 13 1 Retaining Ring 3 1 Body 14 1 Bumper 4 1 Shaft 620 O D 15 2 Spherical Bearing 5 1 Eyelet 16 1 Spiral Ret...

Page 253: ...012 1 425 x 0 008 1 350 x 0 012 1 425 x 0 008 1 250 x 0 012 1 425 x 0 008 1 100 x 0 012 1 100 x 0 004 0 950 x 0 015 1 425 x 0 012 0 850 x 0 012 1 350 x 0 012 1 570 x 0 128 Top Out 1 250 x 0 015 1 100...

Page 254: ...all disassembly and reassembly operations This prevents dirt or foreign particles from entering the shock which causes premature failure 1 If your shock DOES NOT have a spring installed skip to Step 4...

Page 255: ...with a small flat blade screwdriver 9 Install the cap removal tool onto the shock body Insert the retaining ring in the groove between the cap and body Fig 4 10 Tap upward on the cap removal tool to...

Page 256: ...e shock has been rebuilt several times body cap assembly replacement is recommended as the air valve assembly is not serviceable 19 Push the IFP out of the shock body Note the orientation of the IFP a...

Page 257: ...bearing bushing requires service replace the bearing assembly 28 Inspect the piston valve and compression rebound valve shims Remember to keep the valve shims in their specified order Replace the pist...

Page 258: ...ng 8 Install the 5 8 shock shaft seal protector tool onto the shock shaft Install the body cap Fig 15 and then the bearing assembly Fig 16 onto the shock shaft 9 Install the compression valve shim sta...

Page 259: ...ion of the bleed shim tabs as the assembly would be installed on the shock shaft Fig 19 11 Install the piston valve as shown in the photo Fig 20 Install the lock nut and torque to specification Keep t...

Page 260: ...shed 18 Replace the o ring in the body cap Apply Loctite 638 Green two threads wide for 360 degrees to the first two threads of the body cap DO NOT ALLOW thread lock to come into contact with the o ri...

Page 261: ...ounds upwards it has come into contact with the IFP If this occurs the IFP position must be reset 26 Secure the shock assembly in a bench vise 27 Use the Top Fill Shock Fill Tool to charge the shock t...

Page 262: ...0 OD 5 1 O Ring 24 1 Bump Stop 6 1 Seal 25 N A 7 1 Wiper 26 1 Shaft Loop 8 3 O Ring 27 1 Shaft Spacer 1 235 x 1 985 9 1 Piston Clicker 28 2 O Ring 10 2 Clicker Bolt 29 1 Screw 8 32 11 1 Clicker Knob 3...

Page 263: ...Information SHOCK DESIGN DETAILS Travel 5 313 135 mm Extended Length 16 313 414 4 mm IFP Location 3 00 0 13 76 2 3 3 mm Nitrogen Pressure 100 psi 689 kPa 10 Gas Shock Oil 2874124 qt RZR 800 XC SHOCK...

Page 264: ...rogen Pressure 100 psi 689 kPa 10 Gas Shock Oil 2874124 qt RZR 800 XC SHOCK VALVING COMPRESSION REBOUND 1 550 x 0 008 1 500 x 0 010 1 000 x 0 008 1 100 x 0 010 1 550 x 0 008 1 450 x 0 015 1 550 x 0 00...

Page 265: ...st be released from the shock before disassembly It is strongly recommended you wear safety glasses and ear protection during these procedures Special Tools PART NUMBER DESCRIPTION 2200421 Gas Shock R...

Page 266: ...before disassembly It is strongly recommended you wear safety glasses and ear protection during these procedures 1 Clean and carefully remove shock from the vehicle 2 Back preload adjuster all the way...

Page 267: ...P Tool PS 45908 and cycle the Internal Floating Piston IFP a few times to purge the shock oil from the reservoir 11 Remove the floating piston from the shock reservoir using the IFP Tool PS 45908 12 C...

Page 268: ...g the clicker valve stack Place the valve stack on a clean shop towel in order of removal IMPORTANT Keep the valve stack in the order it was removed If unsure of order refer to Shock Valving under the...

Page 269: ...over torque the nut or damage to the valve stack can occur Lock Nut 14 ft lbs 19 Nm NOTE Make sure Top Out washers are orientated as shown 9 Assemble the clicker valve stack on top of the fastener and...

Page 270: ...3 Using a 3 32 Allen wrench remove IFP bleed screw 14 Apply a thin film of oil to IFP O ring and wear band Insert IFP into reservoir until completely submerged Allow air to escape as you install the p...

Page 271: ...shock rod apply 2 3 sharp blows to the rod eyelet with a rubber mallet driving the piston down into the shock body This opens the valves on the damping piston You will see the released air bubbles com...

Page 272: ...properly 31 Push the shock rod assembly completely into the shock body It should go all the way down smoothly without interference If it does not disassemble and reassemble per this procedure 32 Secur...

Page 273: ...and set the preload to the specified measurement see Chapter 2 40 Set the compression adjuster knob to the recommended setting or the original setting upon removal see Chapter 2 41 Remove the shock fr...

Page 275: ...DUCTING COMPONENTS 6 7 PVT DISASSEMBLY 6 8 PVT ASSEMBLY 6 9 CLUTCH OFFSET PROCEDURE 6 11 DRIVE BELT NON EBS 6 13 BELT REMOVAL 6 13 BELT INSPECTION 6 13 BELT INSTALLATION 6 13 DRIVE BELT EBS 6 14 BELT...

Page 276: ...nual Copyright 2013 Polaris Sales Inc CLUTCH DISASSEMBLY INSPECTION 6 25 CLUTCH ASSEMBLY 6 27 DRIVEN CLUTCH SERVICE EBS 6 28 CLUTCH DISASSEMBLY 6 28 BUSHING SERVICE 6 31 CLUTCH ASSEMBLY 6 32 EXPLODED...

Page 277: ...l 2870386 Piston Pin Puller 2870910 Roller Pin Tool PU 50518 Universal Clutch Compressor Bosch Automotive Service Solutions 1 800 328 6657 or http polaris service solutions com Part Number Special Sup...

Page 278: ...e Drive Belt The internal components of the drive clutch and driven clutch control engagement initial vehicle movement clutch upshift and backshift During the development of the Polaris vehicle the PV...

Page 279: ...hifting 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 operating at slower s...

Page 280: ...only Plowing snow dirt etc utility use Use Low only Stuck in mud or snow Shift the transmission to Low carefully use fast aggressive throttle application to engage clutch WARNING Excessive throttle m...

Page 282: ...Chapter 5 3 Remove the 2 screws from the rear of the center console RZR RZR S only 4 Remove the rear seat base assembly from the vehicle to allow outer clutch cover removal RZR RZR S Remove the 2 fast...

Page 283: ...on input shaft if present 10 Install the Drive Clutch Holder PN 9314177 A 11 Remove drive clutch retaining bolt and remove drive clutch using the Drive Clutch Puller PA 48595 B Drive Clutch Puller PA...

Page 284: ...of grease to the splines on the shaft 10 Install the driven clutch washer lock washer and retaining bolt Torque to specification see next page 11 Clean end of taper on crankshaft and the taper bore in...

Page 285: ...CAUTION Do not start the engine with the outer clutch cover removed Serious injury may result 2 Inspect the drive clutch belt to sheave clearance If the belt is contacting either sheave remove the dr...

Page 286: ...Nm 8 Install the clutch cover outlet duct and tighten the clamps 9 Sit in the driver s seat apply the brake and start the engine Place the gear selector in high range and test the vehicle for drive c...

Page 287: ...ain does not move and the drive clutch engages the belt 2 Inspect belt for loose cords missing cogs cracks abrasions thin spots or excessive wear Compare belt measurements with a new drive belt Replac...

Page 288: ...the belt Hour glassing occurs when the drive train does not move and the drive clutch engages the belt 2 Inspect belt for loose cords missing cogs cracks abrasions thin spots or excessive wear Compar...

Page 289: ...h have been designed for the PVT system These shift weights have many factors designed into them for controlling engagement RPM and shifting patterns Shift weights should not be changed or altered wit...

Page 290: ...nspection Replace the cover bushing if more brass than Teflon is visible on the bushing Refer to bushing replacement in this chapter 5 Inspect area on shaft where bushing rides for wear galling nicks...

Page 291: ...er coil surfaces Also check to see that spring coils are parallel to one another Distortion of the spring indicates stress fatigue requiring replacement Drive Clutch Spring Specifications Part Number...

Page 292: ...arance 0 0 005 0 0 127 mm 2 Inspect sheave surfaces Replace the entire clutch if worn damaged or cracked Spider Removal 1 Install clutch in holding fixture PN 2871358 A and loosen the spider countercl...

Page 293: ...galling or flat spots replace 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 28...

Page 294: ...Inspect surface of shaft for pitting grooves or damage Measure the outside diameter and compare to specifications Replace the drive clutch assembly if shaft is worn or damaged Shaft Diameter Standard...

Page 295: ...nstructions 1 9915111 Instructions Additional Special Tools Qty Part Tool Description 1 2871226 Clutch Bushing Replacement Tool Kit 1 2870386 Piston Pin Puller Clutch Bushing Replacement Tool Kit PN 2...

Page 296: ...eat around outside of bushing until tiny smoke tailings appear 9 Turn sheave counter clockwise on puller rod until it comes free Lift sheave off puller 10 Remove nut from puller rod and set aside 11 P...

Page 297: ...r of clutch cover 3 With main adapter on puller insert cover 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 need...

Page 298: ...200 ft lbs 271 Nm 5 After the spider has been torqued remove the clutch assembly from the holding fixture and inspect the shaft and sheave alignment marks made during disassembly IMPORTANT If the mar...

Page 299: ...when removing snap ring to prevent serious personal injury Use caution when removing the snap ring pressure is loaded by the compression spring 1 Remove driven clutch from transmission input shaft 2...

Page 300: ...ring Remember the outer spring retainer contains strong spring pressure NOTE Spring is compression only and has no torsional wind 4 With the snap ring A removed and spring pressure relieved remove th...

Page 301: ...the clutch assembly if more brass than Teflon is visible on the bearing 10 Inspect driven clutch sheave faces for wear or damage 11 Clean and inspect splines on helix and transmission input shaft 12 L...

Page 302: ...Carefully install the snap ring DRIVEN CLUTCH SERVICE EBS Clutch Disassembly 1 Remove driven clutch from the transmission input shaft Do not attempt disassembly of the driven clutch from the outside...

Page 303: ...y using a T25 Torx driver 4 Place the driven clutch into the Universal Clutch Compressor PU 50518 5 Press down on the top of the spider assembly pushing the spider onto the shaft Remove snap ring A an...

Page 304: ...ers for wear replace if worn 9 Remove the clutch assembly from the holding tool 10 Press out the spring pins I in the inner sheave 11 Pull out the clutch roller pins J and rollers K 12 Press the shaft...

Page 305: ...tch Bushing Replacement Tool Kit PN 2871226 Item Qty Part Tool Description 2 1 5020628 P 90 Drive Driven Clutch Bushing Install Tool 3 1 5020629 Drive Clutch Cover Bushing Removal Installation Tool al...

Page 306: ...te 609 evenly to bushing bore inside moveable sheave 4 Install sheave face down on puller 5 Install new bushing on installation tool Item 2 and install assembly into sheave 6 Install left hand thread...

Page 307: ...th sides 5 Install the roller pin into the sheave assembly on both sides The flat side of the roller pin faces downward when the shaft side is laying flat on the bench 6 Install the spring pins C to s...

Page 308: ...kip tooth spider or use the X on top of the spider and align it with the skip tooth on the shaft 11 Place the driven clutch into the Universal Clutch Compressor PU 50518 12 Press down on the top of th...

Page 309: ...assembly NOTE If the cam assembly helix is difficult to install be sure the sheaves are aligned To align the sheaves place the clutch assembly on a flat surface with the cam assembly helix side down P...

Page 311: ...ting range Incorrect drive clutch spring too high of rate Drive clutch shift weights incorrect for application too light Drive clutch binding Driven clutch binding Converter sheaves greasy belt slipag...

Page 312: ...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 operation in wet terrain as outl...

Page 313: ...7 15 SUPPORT BEARING REPLACEMENT RZR 4 7 17 PROPSHAFT U JOINT SERVICE 7 18 DISASSEMBLY 7 18 ASSEMBLY 7 18 FRONT GEARCASE CENTRALIZED HILLIARD 7 20 CENTRALIZED HILLIARD EXPLODED VIEW 7 20 ALL WHEEL DRI...

Page 314: ...PLODED VIEW 7 52 REAR GEARCASE RZR S INT L 7 53 GENERAL OPERATION 7 53 GEARCASE REMOVAL 7 54 GEARCASE DISASSEMBLY 7 56 DIFFERENTIAL DISASSEMBLY 7 60 DIFFERENTIAL ASSEMBLY 7 61 GEARCASE ASSEMBLY 7 62 G...

Page 315: ...ype PU 48951 Axle Boot Clamp Tool Bosch Automotive Service Solutions 1 800 328 6657 or http polaris service solutions com TORQUE SPECIFICATIONS Wheel and Hub Torque Table ITEM NUT TYPE SPECIFICATION A...

Page 316: ...s 3 Remove the 4 wheel nuts and remove front wheel 4 Remove the cotter pin and loosen the front wheel hub castle nut Remove the nut and 2 cone washers from the front wheel hub assembly 5 Remove the fa...

Page 317: ...ace with a drift punch in the reliefs as shown 3 Drive bearing out evenly by tapping on outer race only Once bearing is at bottom of casting support casting on outer edges so bearing can be removed 4...

Page 318: ...llation 1 Install drive shaft axle through the backside of the bearing carrier 2 Install the upper and lower ball joint ends into the front bearing carrier 3 Install pinch bolts and torque to specific...

Page 319: ...n Front Caliper Mounting Bolts 31 34 ft lbs 42 46 Nm CAUTION New bolts have a pre applied locking agent which is destroyed upon removal Always use new brake caliper mounting bolts upon assembly 7 Inst...

Page 320: ...Drive Shaft Removal 1 Elevate front of vehicle and safely support machine under the frame area CAUTION Serious injury may result if machine tips or falls Be sure machine is secure before beginning th...

Page 321: ...are protected during handling to avoid damage Do not allow boots to come into contact with sharp edges or hot engine and exhaust components The drive shaft is not to be used as a lever arm to positio...

Page 322: ...pe and quantity of grease by using all the grease included with the boot kit DO NOT use a substitute grease and DO NOT overfill or under fill the CV joint Boot Replacement Grease Requirement Outer CV...

Page 323: ...haft 11 Install a NEW circlip on the end of the shaft 12 Grease the joint with the special joint grease provided in the boot replacement kit Fill the cavity behind the balls and the splined hole in th...

Page 324: ...clamp pliers CV Boot Clamp Pliers Earless Type 8700226 Drive Shaft Installation 1 Install new spring ring on drive shaft Apply an anti seize compound to splines 2 Align splines of drive shaft with fro...

Page 325: ...ly grease to drive shaft axle splines 7 Install front wheel hub assembly cone washers and hand tighten the castle nut Install washers with domed side out 8 Torque wheel hub nut to specification and in...

Page 326: ...tion Bend both ends of cotter pin around end of spindle in different directions PROPSHAFT SERVICE Removal Installation RZR RZR S 1 Locate the propshaft roll pin and use the Roll Pin Removal Tool PN 28...

Page 327: ...he vehicle 8 Reverse removal steps to reinstall propshaft IMPORTANT Use a NEW roll pin upon reassembly Removal Installation RZR 4 1 Locate the propshaft roll pin and use the Roll Pin Removal Tool PN 2...

Page 328: ...the propshaft remove the bearing support upper lower half from the shaft 10 Remove the fasteners retaining the front plastic skid plate to allow for propshaft removal 11 Using care slide the rear por...

Page 329: ...he shaft and install the new bearing 5 Install a new retaining ring and slide the bearing tight against the retaining ring 6 Apply Loctite 242 to the set screw threads and torque the 2 bearing set scr...

Page 330: ...for correct re positioning during installation 2 Support inner yoke as shown and drive outer yoke down bearing cap out with a soft face hammer 3 Support U joint in vise as shown and drive inner yoke...

Page 331: ...to contain bearing cap just installed Repeat procedure for other side 5 Install outer yoke aligning marks made at disassembly and repeat Steps 1 3 to install bearing caps on outer yoke 6 Seat all bear...

Page 332: ...1 5 Ball Bearing 2 23 Spring Wireform 2 6 Ball Bearing Double Row 1 24 H Clip Spring 20 7 Bushing 1 26 Nylon Spacer 2 8 Bushing 1 27 Torsion Spring Retainer 1 9 Oil Seal 2 28 Backlash Spacer 1 10 Oil...

Page 333: ...engaged while the wheels are spinning severe drive shaft and front gearcase damage could result AWD Engagement When the AWD switch is activated the AWD coil is powered by a 12 Vdc input which creates...

Page 334: ...be two distinct wear bands one band inside the other If only one band of wear is present or if there is wear between the two bands inspect the coil area as indicated in Step 5 A wear band with an inte...

Page 335: ...ONT DRIVE SHAFT Drive Shaft Removal and remove both front drive shafts from the front gearcase 3 Remove the propshaft see PROPSHAFT SERVICE 4 Disconnect the wire harness above the front gearcase and r...

Page 336: ...nd properly dispose of gearcase fluid Remove any metal particles from the drain plug magnet 2 Remove the 7 cover screws and remove the cover plate assembly 3 Remove the LH output hub assembly from the...

Page 337: ...ure plate Refer to AWD Diagnosis for detailed inspection process 5 Remove the torsion spring retainer and torsion spring from the top of the ring gear 6 Remove the clutch housing ring gear and roll ca...

Page 338: ...seal and 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...

Page 339: ...components Check each for excessive wear or damage Gearcase Assembly 1 As mentioned during gearcase disassembly section replace all O rings seals and worn components 2 Install pinion shaft assembly an...

Page 340: ...the ring gear grooves line up with the roll cage slots see below 6 Install the torsion spring by wrapping each leg of the spring around the dowel pin on the ring gear 7 Align the spring retainer dowel...

Page 341: ...gear and roll cage assembly into the gearcase housing 11 Install a new O ring on the cover plate assembly NOTE Be sure the square O ring is placed flat on the cover surface If the O ring is twisted f...

Page 342: ...ropshaft 3 Install the 4 bolts that secure the front gearcase to the frame and torque to 30 ft lbs 41 Nm 4 Install the vent line Front Gearcase Mounting Bolts 30 ft lbs 41 Nm 5 Connect the AWD wire ha...

Page 343: ...ide play by grasping the top and bottom of the tire firmly and checking for movement The tire should rotate smoothly without binding or rough spots 3 Remove the 4 wheel nuts and remove rear wheel 4 Re...

Page 344: ...ways between inner and outer race Bearing Replacement Bearing Removal 1 Remove outer snap ring 2 From the back side of the bearing carrier tap on the outer bearing race with a drift punch in the relie...

Page 345: ...he bearing 8 Wipe the housing clean of any excess compound and install the snap ring Bearing Carrier Bushing Replacement Check bearing carrier bushings and pivot tubes for excessive wear or damage If...

Page 346: ...earing Carrier Bolts RZR 38 ft lbs 52 Nm RZR S RZR 4 40 ft lbs 54 Nm 3 Apply grease to drive shaft axle splines 4 Install rear wheel hub assembly cone washers and hand tighten the castle nut Install w...

Page 347: ...end of spindle in different directions REAR DRIVE SHAFT Drive Shaft Removal 1 Elevate rear of vehicle and safely support machine under the frame area CAUTION Serious injury may result if machine tips...

Page 348: ...of the bearing carrier by pulling the bearing carrier assembly outward and tipping it down to remove the shaft 8 Grasp the rear drive shaft and pull sharply outward on the shaft to disengage it from t...

Page 349: ...race only 5 Make sure circlip is on the shaft and not left in the joint 6 Remove the CV boot from the shaft CAUTION Complete disassembly of the CV joint is NOT recommended The internal components are...

Page 350: ...ce flush with grease Place any remaining grease into the boot CAUTION The grease provided in the replacement kit is specially formulated for wear resistance and durability DO NOT use substitutes or mi...

Page 351: ...Before you remove your instrument be sure the small end of the boot is in the correct location on the shaft 20 Install and tighten the small clamp on the boot using the appropriate clamp tool Axle Boo...

Page 352: ...patterns Intermixing the internal components could result in looseness binding and or premature failure of the joint IMPORTANT If the grease in the joint is obviously contaminated with water and or di...

Page 353: ...the inner race 14 Align the circlip with the lead in chamfer 15 Use a soft faced hammer to tap the joint onto the drive shaft until you reach the end of the splines and the joint locks in place 16 Pul...

Page 354: ...drive shaft Apply anti seize compound to splines 2 Align splines of drive shaft with rear gearcase and reinstall the drive shaft Use a soft faced hammer to tap on the outboard end of the drive shaft i...

Page 355: ...lbs 45 Nm RZR S RZR 4 40 ft lbs 54 Nm 5 Apply grease to drive shaft axle splines 6 Install rear wheel hub assembly cone washers and hand tighten the castle nut Install washers with domed side out 7 In...

Page 356: ...Wheels 27 ft lbs 37 Nm Aluminum Wheels 30 ft lbs 90 1 4 turn REAR GEARCASE Gearcase Removal 1 Drain the fluid from the rear gearcase and remove the rear drive shafts from each side of the rear gearca...

Page 357: ...arcase use a screwdriver to hold back the coupler while pulling the rear gearcase back further to disengage it 8 Remove the vent line and lift the rear gearcase upward and on its side to remove it fro...

Page 358: ...ing gear axle spool assembly The bearings are a slip fit and will slide off the axel spool NOTE Record the thickness of the shim pack located under each bearing Keep the shims together for reassembly...

Page 359: ...nc 5 Inspect the ring gear for chipped worn or broken teeth If damaged replace the gearcase assembly NOTE In the event damage to the gears or housing requires replacement the entire assembly must be r...

Page 360: ...e housing while checking for any looseness or roughness Inspect the pinion gear teeth for chipped worn or broken teeth If damaged replace the ring gear and pinion gear as a set NOTE In the event damag...

Page 361: ...andard seal installer Apply a thin coat of case sealant 2871557 to gearcase mating surfaces upon cover installation 3 If removed install each axle spool bearing race using standard bearing installatio...

Page 362: ...e appropriate sides of the axle spool Install the bearings The bearings are a slip fit and will slide onto the axle spool 5 Install ring gear axle spool assembly into the housing 6 Install the gearcas...

Page 363: ...Installation procedure listed on page 4 15 NOTE Special tool PA 48873 will be required to torque the mounting bracket fasteners when the transmission and rear gearcase are installed in the vehicle Re...

Page 364: ...1 2 Screw 2 12 Axle Spool 1 3 Bracket Rear Mount RH 1 13 Housing Rear LH 1 4 Bracket Rear Mount LH 1 14 Screw Flange Head 2 5 Mount Rear 1 15 Seal Oil 2 6 Nut Flanged 4 16 Screw Flange Head 4 7 Assem...

Page 365: ...ear differential becomes unlocked for tighter turns An electrical solenoid mounted in the rear gearcase housing actuates the shift yoke The solenoid plunger extends out to move the shift yoke and slid...

Page 366: ...g traction Gearcase Removal 1 Drain the fluid from the rear gearcase and remove the rear drive shafts from each side of the rear gearcase See REAR DRIVE SHAFT page 7 35 2 Remove the exhaust pipe and e...

Page 367: ...case to the transmission 7 Remove the 4 fasteners and remove the rear mount from the rear gearcase 8 Pull the rear gearcase towards the rear of the vehicle to disengage it from the transmission NOTE I...

Page 368: ...d ring gear shimming information is NOT provided in this Service Manual due to OEM manufacturing requirements 1 Remove the remaining cover bolts from the rear gearcase 2 Remove the cover from the gear...

Page 369: ...e the shim s from the differential assembly Be sure to keep the shims together for reassembly 9 Inspect each differential bearing and race for signs of wear or damage If bearing replacement is require...

Page 370: ...erential solenoid from the gearcase if servicing the solenoid shift lever shift lever spring or shift yoke If none of these items are being serviced the solenoid can remain installed in the gearcase 1...

Page 371: ...the shift lever A shift lever spring B shift return springs C shift yoke D and lock pin bushing E Inspect the components for excessive wear or damage and replace as needed NOTE The pinion shaft assemb...

Page 372: ...Use a brass punch in the recessed 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 tha...

Page 373: ...d differential case for excessive wear or damage Replace components if needed Differential Assembly 1 Thoroughly clean the differential components prior to reassembly 2 Install the lower differential...

Page 374: ...5 108 Nm Gearcase Assembly 1 Replace all worn components 2 If removed install new bearing races using standard bearing installation tools and an arbor press WARNING Wear the appropriate safety equipme...

Page 375: ...removed onto the appropriate sides of the differential assembly Install the bearings by hand as they are a slip fit 7 If previously removed assembly the shift lever A shift lever spring B shift return...

Page 376: ...tall the differential assembly into the gearcase housing 12 Assemble the gearcase halves and install the bolts that secure the cover to the housing Torque the bolts in a criss cross pattern to 23 27 f...

Page 377: ...Installation procedure listed on page 4 15 NOTE Special tool PA 48873 will be required to torque the mounting bracket fasteners when the transmission and rear gearcase are installed in the vehicle Re...

Page 378: ...ged 2 25 Seal 1 7 Assembly Rear Housing RH 1 26 Bushing Dowel 2 8 Plug Fill w O Ring 1 27 Solenoid Diff Lock 1 9 Bushing Pin Lock 1 28 Bearing Tapered Roller 1 10 Bearing Ball 2 29 Screw Flange Head 1...

Page 381: ...ION 8 3 SHIFT CABLE INSPECTION ADJUSTMENT 8 3 TRANSMISSION SERVICE 8 4 TRANSMISSION REMOVAL SERVICE NOTES 8 4 TRANSFER CASE DISASSEMBLY 8 4 TRANSFER CASE REASSEMBLY 8 8 TRANSMISSION SHIFT HOUSING DISA...

Page 382: ...5 in lbs 15 18 Nm Gear Position Sensor Screws 25 40 in lbs 3 5 Nm Pivot Pin Set Screw 100 125 in lbs 11 14 Nm Park Flange Screws 130 155 in lbs 15 18 Nm Transmission Isolator Mounting Screws 23 27 ft...

Page 383: ...moving out of desired range 1 Locate the shift cable in the rear LH wheel well area 2 Inspect shift cable clevis pin pivot bushings and dust boot Replace if worn or damaged 3 If adjustment is required...

Page 384: ...a unit Removal of the transmission is not possible without removing the engine and differential The shift housing cannot be removed without first disassembling the transfer case NOTE Refer to the Eng...

Page 385: ...ear gear case and transmission transfer case 5 Inspect the driveshaft splines for wear and the O rings for damage Replace if found to be worn or damaged 6 Remove the LH front isolator mount bracket Re...

Page 386: ...he housing Check bearings and gear teeth for wear or damage and replace as needed The shaft can be disassembled as shown using a press and standard bearing removal tools 11 Disassemble the output pini...

Page 387: ...e the front output pinion 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...

Page 388: ...red bearing preload must be checked and or adjusted for proper transmission operation 1 Install the intermediate shaft seal circled flush or slightly below the case Install circlips and gear onto the...

Page 389: ...haft 5 10 times both clockwise and counter clockwise 7 Place a 23 mm 12 point socket over the splines of the output shaft Attach an Inch Pound in lbs dial indicator torque wrench to the socket Check t...

Page 390: ...g race 14 Reinstall the output pinion shaft bracket and the three retaining bolts into the transfer case Torque bolts to specification Retaining Bolts 23 27 ft lbs 31 37 Nm 15 Rotate output shaft 5 10...

Page 391: ...he shims and bearing cup Apply a thin coat of sealant to the mating surfaces Apply lubricant to the seal lip Apply Sealant PN 2871557 To Case Mating Surfaces 20 Install the transfer case cover Align t...

Page 392: ...and the transfer case cover 25 After removing the cover remove the intermediate shaft bearing cup and shim s from the cover The bearing cup is a slip fit 26 A If the rolling torque measurement from st...

Page 393: ...s of the output shaft Attach an Inch Pound in lbs dial indicator torque wrench to the socket Check the intermediate pinion shaft assembly bearing rolling preload by rotating the output shaft both cloc...

Page 394: ...screws 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 tra...

Page 395: ...to remove the shaft bearing if required NOTE Do not pull bearing from case for inspection as the removal process damages the bearing 7 Remove the reverse idler snap ring upper washer gear needle beari...

Page 396: ...e Replace parts as required 10 Remove the spacer contact pins springs drum gear and washer from the shift housing Replace any worn or damaged components 11 Remove the outer detent screw spring and bal...

Page 397: ...collar 15 Remove the wave spring and ball bearing cage assembly from the shift collar as shown 16 Inspect the ball bearing channels on both ends of the shift collar for excessive wear or damage 17 Re...

Page 398: ...pect the shaft bearing and replace if required using a shop press Inspect the gears for damage and or wear Replace the shaft if required 25 Remove the screw from the end of the shift cable lever and r...

Page 399: ...e lever X facing out and torque the retaining screw to specification Shift Cable Lever Screw 15 20 ft lbs 20 27 Nm 3 Assemble the input shaft with new ball bearings if required NOTE Install new bearin...

Page 400: ...tall the shift collar onto the clutch shaft Pull back fully on gear selector arm to bring the shift yoke arms up and engage the shift shoes onto the center groove of the shift collar Shifting the clut...

Page 401: ...s shown with transmission in neutral Torque retaining screws to specification Apply Lubricant to shift drum components Gear Position Sensor Screws 25 40 in lbs 3 5 Nm 13 Complete the shift detent scre...

Page 402: ...w retaining ring 19 Install the input shaft seal and verify it is fully seated Install the intermediate shaft seal circled flush or slightly below the case Apply lubricant to both seal lips 20 Place t...

Page 403: ...f the transmission Torque to specification Shift Housing Screws 23 27 ft lbs 31 37 Nm 22 Install the 2 shift housing case screws to the backside as shown Torque to specification NOTE Shift cable brack...

Page 404: ...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 by an internal tra...

Page 407: ...RAKE BLEEDING FLUID CHANGE 9 10 FRONT BRAKE PADS 9 11 PAD REMOVAL 9 11 PAD INSPECTION 9 13 PAD ASSEMBLY INSTALLATION 9 13 BRAKE BURNISHING PROCEDURE 9 14 FRONT CALIPER SERVICE 9 15 CALIPER EXPLODED VI...

Page 408: ...SEMBLY 9 27 CALIPER INSPECTION 9 28 CALIPER ASSEMBLY 9 29 CALIPER INSTALLATION 9 29 REAR BRAKE DISC 9 30 DISC INSPECTION 9 30 DISC REPLACEMENT 9 31 TROUBLESHOOTING 9 32 BRAKES SQUEAL POOR BRAKE PERFOR...

Page 409: ...s RZR RZR S 300 007 7 62 178 mm 0 180 4 6 mm RZR 4 297 007 7 54 178 mm Front Brake Disc Thickness 0 188 4 78 mm 0 170 4 32 mm Front Brake Disc Runout 0 010 0 254 mm Rear Brake System Item Standard Ser...

Page 410: ...ine Banjo Bolts Caliper Attachment 15 20 Brake Line Banjo Bolt Master Cylinder Attachment 15 20 Front Brake Disc to Hub Bolts 18 24 Rear Brake Disc to Hub Bolts 28 38 Brake Switch 12 15 16 20 Master C...

Page 411: ...fluid reservoir Make sure the brake pedal returns freely and completely Adjust stop pin on front caliper after pad service Check and adjust master cylinder reservoir fluid level after pad service Mak...

Page 412: ...ads and or disc hub to clean imbedded material from disc or pads Pad s dragging on disc noise or premature pad wear because of improper adjustment Master cylinder reservoir overfilled Master cylinder...

Page 413: ...comes 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 fluid will all...

Page 415: ...id will damage finished surfaces Do not allow brake fluid to come in contact with finished surfaces NOTE Make note of front and rear brake line locations to master cylinder 4 Loosen the brake line ban...

Page 416: ...linder This procedure should be used to change fluid or bleed brakes during regular maintenance CAUTION Always wear safety glasses CAUTION Brake fluid will damage finished surfaces Do not allow brake...

Page 417: ...3 Nm 9 Repeat procedure Steps 5 8 for the remaining calipers 10 Add brake fluid to MAX level inside reservoir Master Cylinder Fluid Level Between the MIN and MAX line shown on the reservoir 11 Instal...

Page 418: ...ith pads installed NOTE Brake fluid will be forced through compensating port into master cylinder fluid reservoir when piston is pushed back into caliper Remove excess fluid from reservoir as required...

Page 419: ...ad Assembly Installation 1 Lubricate mounting bracket pins with a light film of silicone grease and install rubber dust boots 2 Compress mounting bracket and make sure dust boots are fully seated Inst...

Page 420: ...reservoir cap Master Cylinder Fluid Up to MAX line inside reservoir 7 Install wheel and torque wheel nuts to specification Wheel Nuts Steel Wheels 27 ft lbs 37 Nm Aluminum Wheels 30 ft lbs 90 1 4 tur...

Page 421: ...9 9 15 9924707 2013 2014 RZR 800 Service Manual Copyright 2013 Polaris Sales Inc FRONT CALIPER SERVICE Caliper Exploded View RZR RZR S RZR S INT L Caliper Exploded View RZR 4 BRAKES...

Page 422: ...rting vehicle so that it does not tip or fall Severe injury may occur 3 Clean caliper area before removal 4 Place a container below the caliper to catch brake fluid when removing the line Remove brake...

Page 423: ...efore disassembly and prepare a clean work area for disassembly 4 Use a commercially available caliper piston pliers to extract the pistons from the caliper IMPORTANT Do not remove the caliper pistons...

Page 424: ...al grooves in caliper body Caliper Inspection 1 Inspect caliper body for nicks scratches pitting or wear Measure bore size and compare to specifications Replace if damaged or worn beyond service limit...

Page 425: ...er Caliper Assembly 1 Install new O rings in the caliper body Be sure the grooves are clean and free of residue or brakes may drag upon assembly 2 Coat pistons with clean Polaris DOT 4 Brake Fluid Ins...

Page 426: ...mounting bolts to specification IMPORTANT If disc scraper was removed reinstall it upon caliper installation RZR 4 Only Front Caliper Mount Bolt 31 34 ft lbs 42 46 Nm 3 Torque the banjo bolt to the p...

Page 427: ...service Inspect for fluid leaks and firm brakes Make sure the brake is not dragging when pedal is released If the brake drags re check assembly and installation NOTE If new pads are installed refer t...

Page 428: ...vice Limit 0 170 4 32 mm Brake Disc Thickness Variance Service Limit 0 002 0 051 mm difference between measurements Disc Replacement 1 Remove the front brake caliper see FRONT CALIPER SERVICE 2 Remove...

Page 429: ...service Inspect for fluid leaks and firm brakes Make sure the brake is not dragging when pedal is released If the brake drags re check assembly and installation REAR BRAKE PADS Pad Removal 1 Elevate a...

Page 430: ...uid reservoir when piston is pushed back into caliper Remove excess fluid from reservoir as required 6 Push caliper mounting bracket inward and slip outer brake pad past the edge to remove 7 Remove th...

Page 431: ...entering brake system 5 Install adjustment set screw and turn clockwise until stationary pad contacts disc then back off 1 2 turn 6 Verify fluid level in reservoir is up to the MAX line inside reserv...

Page 432: ...vehicle CAUTION Use care when supporting vehicle so that it does not tip or fall Severe injury may occur 2 Remove the 4 wheel nuts and rear wheel 3 Clean caliper area before removal 4 Place a containe...

Page 433: ...er pad retainer pin inward and slip brake pads past the edge and remove from the caliper 3 Remove mount bracket B and dust boots G and H 4 Using a hammer and a small punch remove the piston C from the...

Page 434: ...andard 1 191 30 25 mm Service Limit 1 192 30 28 mm RZR 4 Rear Caliper Piston Bore I D Standard 1 505 38 23 mm Service Limit 1 507 38 28 mm 2 Inspect piston for nicks scratches wear or damage Measure d...

Page 435: ...unting bracket pins with silicone grease and install the rubber dust seal boots 4 Compress the mounting bracket and make sure the dust seals are fully seated Install the brake pads Clean the disc and...

Page 436: ...place 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 contact surface Replace disc if worn beyond service limi...

Page 437: ...Bolts 28 ft lbs 38 Nm CAUTION Always use new brake disc mounting bolts The bolts have a pre applied locking agent which is destroyed upon removal 6 Install wheel hub assembly washers and castle nut To...

Page 438: ...ionary pad Worn or damaged master cylinder or components Damaged break pad noise insulator Brake pads dragging Brake caliper dragging Pedal Vibration Disc damaged Disc worn runout or thickness varianc...

Page 439: ...R LOCATION 10 10 SPEED SENSOR TESTING 10 10 REAR DIFF SOLENOID INT L 10 11 DIFFERENTIAL SOLENOID OVERVIEW 10 11 DIFFERENTIAL SOLENOID CIRCUIT OPERATION 10 11 ALL WHEEL DRIVE COIL 10 12 OPERATION OVERV...

Page 440: ...ERY SPECIFICATIONS 10 32 GENERAL BATTERY INFORMATION 10 32 BATTERY REMOVAL INSTALLATION 10 33 BATTERY OFF SEASON STORAGE 10 33 BATTERY TESTING 10 33 OCV OPEN CIRCUIT VOLTAGE TEST 10 33 LOAD TEST 10 33...

Page 441: ...the resistance The resistance of the component is equal to tested value minus the lead resistance Become familiar with the operation of your meter Be sure leads are in the proper jack for the test be...

Page 442: ...If there is no continuity or if resistance is greater than 0 5 ohms clean the switch terminals Re test and replace switch if necessary Headlamp Switch 1 Disconnect the headlamp switch harness by depr...

Page 443: ...tion key to START There should be continuity between switch pins A and B C and D Ignition Key Switch INT L 1 Disconnect the key switch harness by lifting the connector lock and pulling on the connecto...

Page 444: ...3 Move the switch to 2WD NONE OFF There should be no continuity between any pins AWD 2WD TURF Switch INT L 1 Disconnect the AWD 2WD TURF switch harness by depressing the connector locks and pulling o...

Page 445: ...t between the 5 sets of outputs HI BEAM LO BEAM L TURN R TURN HORN If any of the tests fail replace the switch assembly Hazard Switch INT L 1 Disconnect the harness from the Hazard switch 2 Test betwe...

Page 446: ...tect when the throttle pedal has returned to the rest position NOTE The throttle pedal lever is designed to have a few degrees of freeplay prior to engaging the throttle arm that pulls the throttle ca...

Page 447: ...reading is more than 2 26k Ohms Replace sensor if reading is less than 6 46k Ohms TRS Removal 1 Remove the drivers seat and disconnect the negative battery cable 2 Remove the 2 bolts securing the TRS...

Page 448: ...ic Timing Light Harness PN 2871745 Hall Sensor Probe Harness PN 2460761 1 Disconnect the 3 wire harness from the speed sensor and remove the sensor from the transmission 2 Connect the wires from the S...

Page 449: ...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 Relay allowing it to...

Page 450: ...witch is functional and that a minimum of 11 volts is present at the hub coil Verify the AWD hub coil is functional Test the AWD hub coil using an ohm meter See specifications below AWD Hub Coil Resis...

Page 451: ...atures 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 Certain products in...

Page 452: ...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 upon start up onc...

Page 453: ...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 interval hours When the s...

Page 454: ...ent flashes Release 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...

Page 455: ...lowing procedure to display diagnostic trouble codes that were activated during current ignition cycle causing the MIL to illuminate Diagnostic trouble codes will remain stored in the gauge even if MI...

Page 456: ...ss connector from the back side of the instrument cluster 2 Push instrument cluster out from back side of the dash while securely holding the dash and rubber mount NOTE Do not remove the rubber mount...

Page 457: ...beam to the desired position by loosening the adjustment screw A and moving the lamp to the appropriate height 6 Adjust the beam to desired position Repeat the procedure to adjust the other headlight...

Page 458: ...ulb if previously removed 4 Adjust headlights using the Headlight Adjustment procedure in this section HEAD LIGHTS LED Headlight Adjustment The headlight beams are adjustable 1 Place the vehicle on a...

Page 459: ...n severe injury or death Headlamp Replacement IMPORTANT If an LED headlamp has fogging or moisture inside disconnect the wire harness from the headlamp s for a few days to allow the moisture to clear...

Page 460: ...usly removed 6 Connect headlamp electrical connector to the headlamp assembly NOTE The headlights are different and electrical connectors cannot be interchanged 7 Perform the Headlight Adjustment proc...

Page 461: ...FI DIAGNOSTICS EFI Component Testing All EFI component information and diagnostic testing procedures are located in Chapter 4 Refer to Chapter 4 Electronic Fuel Injection System EFI when diagnosing an...

Page 462: ...sensor harness disconnected but will not turn on when the engine is hot check the coolant temperature sensor and connector terminals Coolant Temperature Sensor The coolant temperature sensor can be te...

Page 463: ...ring and components such as the instrument cluster ECU EFI system main harness lights accessories and power steering The relays assist with component operation like the cooling fan fuel pump EFI syste...

Page 465: ...tected 12 Vdc constant battery voltage Dark Green Yellow ECU ground input to enable relay Red White 20 Amp fuse protected 12 Vdc constant battery voltage Red Dark Blue Provides 12 Vdc power for EFI sy...

Page 466: ...or disconnect the battery cable or ammeter with the engine running Damage will occur to electrical components Connect an ammeter in series with the negative battery cable Check for current draw with...

Page 467: ...performed using a multi meter to determine the condition of the stator alternator TEST 1 Resistance Value of Each Stator Leg 1 Measure the resistance value of each of the three stator legs Y1 to Y2 Y1...

Page 468: ...C voltage varies significantly from the specified value the stator may need to be replaced RPM Reading AC Voltage VAC Reading 1300 22 VAC 25 3000 49 VAC 25 5000 80 VAC 25 Regulator Rectifier The Regul...

Page 469: ...yright 2013 Polaris Sales Inc Charging System Testing Flow Chart Whenever charging system problems are suspected proceed with the following system check after verifying that all wires are in good cond...

Page 470: ...emicals known to the State of California to cause cancer and birth defects or other reproductive harm WASH HANDS AFTER HANDLING WARNING Battery electrolyte is poisonous It contains acid Serious burns...

Page 471: ...he plates reducing the efficiency and service life of the battery Use a volt ohm meter to test battery voltage Battery PN 4011496 OPEN CIRCUIT VOLTAGE State of Charge Maintenance Free 100 13 0 V 75 Ch...

Page 472: ...overheated battery could explode causing severe injury or death Always watch charging times carefully Stop charging if the battery becomes very warm to the touch Allow it to cool before resuming charg...

Page 473: ...meter when testing connections should not exceed 0 1 VDC per connection or component To perform the test place the meter on DC volts and place the meter leads across the connection to be tested Refer...

Page 474: ...aximum of 5 seconds With the solenoid energized resistance should read about 0 0 5 between terminals A and B If resistance measurement is out of specification replace the starter solenoid Starter Sole...

Page 476: ...ration NOTE To conserve battery power the EPS unit will shut down 5 minutes after the engine has stopped if the key remains in the ON position At this point the EPS Malfunction Indicator Light will il...

Page 481: ...t Breaker 10 25 Clutch Offset Procedure 6 11 Combustion Chamber 3 33 Communication Problems Digital Wrench 4 48 Compression Test 2 17 Console and Floor Panel Removal RZR RZR S 5 24 Console and Floor P...

Page 482: ...l 3 44 Engine Gears Installation 3 55 Engine Oil Pressure Test 3 17 Engine Oil Pump Removal 3 44 Engine Piston Installation 3 55 Engine Piston Removal Inspection 3 37 Engine Piston Ring Installed Gap...

Page 483: ...3 69 Oil Pump Disassembly 3 44 Oil Pump Reassembly 3 44 Oil Pump Removal 3 44 P Periodic Maintenance Chart 2 3 Piston Ring Installed Gap 3 42 Piston to Cylinder Clearance 3 40 Piston to Rod Inspectio...

Page 484: ...park Plug Service 2 29 Special Tool Cam Gear Installation Kit 3 44 Special Tools 1 5 Special Tools Body Steering Suspension 5 4 Special Tools Brakes 9 4 Special Tools Clutching 6 3 Special Tools EFI 4...

Page 485: ...Steering Suspension 5 4 Torque Specifications Brakes 9 4 Torque Specifications Clutching 6 3 Torque Specifications Final Drive 7 3 Torque Specifications Transmission 8 2 Torque Specifications Wheel a...

Page 487: ...2013 2014 RANGER RZR 800...

Page 488: ...2013 2014 RANGER RZR 800...

Page 489: ...2013 2014 RANGER RZR 800 EPS...

Page 490: ...2013 2014 RANGER RZR 800 EPS...

Page 491: ...2013 2014 RANGER RZR S 800...

Page 492: ...2013 2014 RANGER RZR S 800...

Page 493: ...2013 2014 RANGER RZR S 800 INT L...

Page 494: ...2013 2014 RANGER RZR S 800 INT L...

Page 495: ...2013 2014 RANGER RZR 4 800...

Page 496: ...2013 2014 RANGER RZR 4 800...

Page 497: ...2013 2014 RANGER RZR 4 800 EPS...

Page 498: ...2013 2014 RANGER RZR 4 800 EPS...

Page 499: ...2013 2014 RANGER RZR RZR S RZR 4 CARGO BOX...

Page 500: ...2013 2014 RANGER RZR S 800 INT L CARGO BOX...

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