Polaris 2010 Ranger RZR 800 EFI Manuals

Polaris 2010 Ranger RZR 800 EFI Manuals

Manuals and User Guides for Polaris 2010 Ranger RZR 800 EFI. We have 1 Polaris 2010 Ranger RZR 800 EFI manual available for free PDF download: Manual

Polaris 2010 Ranger RZR 800 EFI Manual

Polaris 2010 Ranger RZR 800 EFI Manual (352 pages)

Brand: Polaris | Category: Utility Vehicle | Size: 20.95 MB

Table of Contents

General Information Chapter

1
- Table of Contents
  1
- Chapter 1
  2
- Engine Designation Number
  2
- Engine Serial Number Location
  2
- Model Identification
  2
- Model Information
  2
- Vin Identification
  2
- Special Tools
  3
- Vehicle Information
  3
  - Publication Numbers
    3
  - Replacement Keys
    3
- 2009 General Specifications
  4
- 2010 General Specifications
  8
- Misc. Specifications and Charts
  12
  - Conversion Table
    12
  - Standard Torque Specifications
    13
  - Sae Tap / Drill Sizes
    14
  - Metric Tap / Drill Sizes
    14
  - Glossary of Terms
    15
Maintenance Chapter 2 Maintenance 2

17
- Break-In Period / Maintenance Chart Key
  19
- Chapter 2
  19
- Periodic Maintenance Chart
  19
- Pre-Ride - 25 Hour Maintenance Interval
  20
- 50 - 300 Hour Maintenance Interval
  21
- Component Inspection / Service Locations
  22
  - Front and Rear View
    22
  - Rh and Lh Side Views
    23
- Lubricants / Service Products
  24
- Maintenance References
  25
- General Vehicle Inspection and Maintenance
  26
- Fuel System and Air Intake
  27
- Engine
  32
- Transmission and Gearcases
  35
- Cooling System
  39
- Final Drive / Wheel and Tire
  41
  - Wheel, Hub, and Spindle Torque Table
    41
  - Wheel Removal / Installation
    41
  - Wheel Installation
    41
  - Tire Inspection
    42
  - Tire Pressure
    42
  - Drive Shaft Boot Inspection
    42
- Electrical and Ignition System
  43
  - Battery Maintenance
    43
  - Battery Removal / Installation
    43
  - Battery off Season Storage
    44
  - Battery Charging (Maintenance Free)
    44
  - Spark Plug Service
    44
  - Engine to Frame Ground
    45
- Steering
  45
  - Steering Wheel Freeplay
    45
  - Steering Inspection
    45
  - Steering Inspection / Tie Rod Ends and Hubs
    46
  - Toe Alignment Inspection
    46
  - Toe Adjustment
    47
- Suspension (Rzr)
  47
  - Spring Preload Adjustment
    47
  - Suspension (Rzr S)
    48
  - Spring Preload Adjustment
    48
  - Shock Compression Adjustment
    48
- Brake System
  49
- Maintenance Log
  50
Chapter 3 Engine

51
- Crankcase Exploded Views
  52
- Engine Specifications
  52
- Engine Fastener Torque Patterns
  57
- Torque Specifications
  58
- 800 EFI Engine Service Specifications
  59
- Special Tools
  61
- Engine Cooling System
  62
- General Engine Service
  65
  - Engine Lubrication Specifications
    65
  - Accessible Engine Components
    65
  - Oil Pressure Test
    65
  - Oil Flow Chart
    66
  - Engine Removal
    67
  - Engine / Transmission Separation
    73
- Engine Disassembly and Inspection
  74
  - Cylinder Head Assembly Exploded View
    74
  - Rocker Arms
    75
  - Push Rods
    75
  - Cylinder Head Removal
    75
  - Cylinder Head Inspection / Warp
    76
  - Valve Seal / Spring Service (on Engine)
    76
  - Cylinder Head Disassembly
    77
  - Valve Inspection
    78
  - Combustion Chamber
    79
  - Valve Seat Reconditioning
    79
  - Cylinder Head Reassembly
    81
  - Valve Sealing Test
    82
  - Cylinder Removal
    82
  - Valve Lifter Removal / Inspection
    82
  - Piston Removal
    83
  - Cylinder Inspection
    84
  - Cylinder Hone Selection and Honing Procedure
    85
  - Honing to Deglaze / Cleaning the Cylinder after Honing
    85
  - Piston-To-Cylinder Clearance
    86
  - Piston / Rod Inspection
    86
  - Piston Ring Installed Gap
    87
  - Starter Drive Bendix Removal / Inspection
    87
  - Flywheel / Stator Removal / Inspection
    88
  - Engine Crankcase Disassembly / Inspection
    88
  - Camshaft Inspection
    96
- Engine Reassembly
  97
  - Crankcase Reassembly
    97
  - Flywheel / Stator Installation
    106
  - Cylinder Head Reassembly
    106
  - Oil Pump Priming
    108
- Engine Installation
  109
  - Engine Assembly and Installation
    109
  - Engine Break-In Period
    110
- Troubleshooting
  111
  - Engine
    111
  - Cooling System
    112
Electronic Fuel Injection Chapter 4 Electronic Fuel Injection

113
- Chapter 4
  114
- General Information
  114
- Special Tools
  114
- Service Notes
  116
- Efi System Exploded View
  117
- Efi System Component Locations
  118
- Fuel Tank
  120
  - Fuel Lines - Quick Connect
    121
- Electronic Fuel Injection
  121
  - Initial Priming / Starting Procedure
    122
- Electronic Control Unit (Ecu)
  122
- Temperature and Barometric Air Pressure Sensor (T-Bap)
  123
- Crankshaft Position Sensor (Cps)
  124
  - Cps Test
    124
  - Cps Replacement
    125
- Fuel Injectors
  129
  - Fuel Injector Service
    129
- Fuel Pump
  132
  - Fuel Sender Test
    132
  - Fuel Pump Test
    133
  - Fuel Pump Replacement
    134
  - Fuel Tank Removal
    134
  - Fuel Tank Installation
    136
- Throttle Position Sensor (Tps)
  137
  - Tps Learn Function
    137
  - Tps Tester / Regulator
    137
  - Checking Tps Reading
    138
- Engine Coolant Temperature Sensor (Ect)
  140
- Ignition Coil
  141
  - Ignition Coil Tests
    141
  - Ignition Coil / Ht Lead Replacement
    141
- Diagnostic "Blink Codes
  142
  - Efi Troubleshooting
    143
- General Troubleshooting
  142
- Digital Wrench™ Operation
  144
Body / Steering / Suspension Chapter 5 Body / Steering / Suspension

153
- Special Tools
  154
- Torque Specifications
  154
- Cab Frame (Rzr)
  155
- Cab Frame (Rzr S)
  156
- Body Exploded Views
  157
- Dash Instruments / Controls (RZR / RZR S)
  157
- Dash Instruments / Controls (RZR S INT'L)
  158
- Chapter 5
  160
- Hood / Front Body Work
  160
- Floor / Rocker Panels
  162
- Rear Cargo Box / Fenders
  163
- Chassis / Main Frame
  164
- Body Component Removal
  165
  - Rear Bumper
    165
  - Hood and Front Body Work
    166
  - Rocker Panels, Console and Floor
    167
  - Rear Fender, Flair and Tie down Removal
    167
  - Cargo Box Assembly Removal
    167
- Exploded View (RZR / RZR S)
  168
- Steering Assembly
  168
- Exploded View (RZR S INT'L)
  169
  - Steering Wheel Removal
    170
- Wheel Hubs
  171
- Front A-Arms
  172
  - Removal / Replacement
    172
  - Exploded View
    173
- Ball Joint Service
  174
- Front Stabilizer Bar (Rzr / Rzr "S" Int'l)
  175
  - Exploded View
    176
- Rear A-Arms
  177
  - Removal
    177
  - Installation
    178
  - Exploded View
    179
- Rear Stabilizer Bar (Rzr)
  180
- Rear Stabilizer Bar (Rzr S)
  181
- Decal Replacement
  182
- Shocks / Springs (Rzr)
  182
  - Exploded View
    182
  - Fox™ Shock Exploded View (Rzr S)
    183
  - Fox™ Shock Service (Rzr S)
    184
  - Fox™ Podium X Shock Rebuild Information
    185
  - Fox™ Podium X Shock Disassembly
    186
  - Fox™ Podium X Shock Rebuild
    188
  - Fox™ Podium X Shock Reassembly
    189
Clutching Chapter 6 Clutching

193
- Chapter 6
  194
- Drive Clutch Operation
  194
- General Operation
  194
- Pvt System Overview
  194
- Special Tools and Supplies
  194
- Torque Specifications
  194
- Driven Clutch Operation
  195
- Maintenance / Inspection
  195
- Pvt Break-In (Drive Belt / Clutches)
  195
- Overheating / Diagnosis
  196
- Pvt System Service
  197
  - Pvt Sealing and Ducting Components
    197
  - Disassembly
    197
  - Assembly
    198
- Drive Belt
  199
  - Belt Removal
    199
  - Belt Inspection
    200
  - Belt Installation
    200
  - Pvt Break-In (Drive Belt / Clutches)
    200
- Drive Clutch Service
  201
  - Spring Specifications
    201
  - 2009 Shift Weights
    202
  - 2010 Shift Weights
    203
  - 2009 Non-Braking Exploded View (Rzr)
    204
  - 2009 Ebs Exploded View (Rzr S)
    204
  - 2010 Non-Braking Exploded View (Rzr / Rzr S)
    205
  - Clutch Disassembly
    205
  - Spider Removal
    206
  - Roller, Pin, and Thrust Washer Inspection
    207
  - Button to Tower Clearance Inspection
    207
  - Shift Weight Inspection
    207
  - Bearing Inspection
    208
  - Clutch Inspection
    208
  - Moveable Sheave Bushing Inspection
    209
  - Bushing Service
    210
  - Clutch Assembly
    212
- Driven Clutch Service (Early Build 2009 Rzr / All 2009 Rzr S Models)
  213
  - Clutch Disassembly
    213
  - Bushing Service
    215
  - Clutch Assembly
    217
  - Exploded View
    220
- Driven Clutch Service (Late Build 2009 Rzr / All 2010 Models)
  221
  - Exploded View
    221
  - Clutch Disassembly / Inspection
    221
  - Clutch Assembly
    223
- Troubleshooting
  224
Chapter 7 Final Drive

227
- Bearing Carrier Inspection / Removal
  228
- Front Bearing Carrier
  228
- Special Tools
  228
- Torque Specifications
  228
- Bearing Replacement
  229
- Bearing Carrier Installation
  230
- Front Drive Shaft
  232
  - Drive Shaft Removal
    232
  - Drive Shaft / CV Joint Handling Tips
    233
  - Outer CV Joint / Boot Replacement
    233
  - Inner Plunging Joint / Boot Replacement
    234
  - Drive Shaft Installation
    236
- Propshaft Service
  237
- Propshaft U-Joint Service
  238
- Front Gearcase / Centralized Hilliard
  240
  - Centralized Hilliard Exploded View
    240
  - All Wheel Drive Operation
    241
  - Awd Diagnosis
    242
  - Gearcase Assembly / Inspection
    245
  - Backlash Thrust Plate Adjustment
    247
  - Gearcase Installation
    248
- Rear Bearing Carrier
  249
  - Bearing Carrier Inspection / Removal
    249
  - Bearing Replacement
    250
  - Bearing Carrier Bushing Replacement
    250
  - Bearing Carrier Installation
    251
- Rear Drive Shaft
  252
  - Drive Shaft Removal
    252
  - Outer CV Joint / Boot Replacement
    253
  - Inner Plunging Joint / Boot Replacement
    256
  - Drive Shaft Exploded View
    258
  - Drive Shaft Installation
    258
- Rear Gearcase
  260
  - Gearcase Removal
    260
  - Rear Gearcase (Rzr "S" Int'l)
    260
  - Gearcase Disassembly
    261
  - Gearcase Assembly
    263
  - Gearcase Installation
    264
  - Gearcase Exploded View
    265
- Wheel Hubs
  278
  - Front Hub Exploded View
    278
  - Rear Hub Exploded View
    278
Transmission Chapter 8 Transmission

279
- Chapter 8
  280
- Installation
  280
- Removal
  280
- Shift Lever
  280
- Torque Values / Specifications
  280
- Shift Cable Inspection / Adjustment
  281
- Transmission Service
  282
- Troubleshooting
  296
  - Troubleshooting Checklist
    296
- 2009 Transmission Exploded View
  297
- 2010 Transmission Exploded View
  298
Brakes Chapter 9 Brakes

299
- Chapter 9
  300
- General Specifications
  300
- Special Tools
  300
- Torque Specifications
  300
- Brake Noise Troubleshooting
  301
- Brake System Service Notes
  301
- Brake System Exploded View
  302
- Hydraulic Brake System Operation
  302
- Brake Pedal Lever
  303
- Master Cylinder
  303
- Brake Bleeding / Fluid Change
  304
- Front Brake Pads
  305
  - Pad Assembly / Installation
    306
  - Brake Burnishing Procedure
    306
- Front Caliper Service
  307
  - Caliper Exploded View
    307
  - Caliper Removal
    307
  - Caliper Disassembly
    308
  - Caliper Installation
    310
- Front Brake Disc
  311
- Rear Brake Pad
  312
  - Pad Removal
    312
  - Brake Burnishing Procedure
    313
- Rear Caliper Service
  314
  - Caliper Exploded View
    314
  - Caliper Removal
    314
- Rear Brake Disc
  317
- Troubleshooting
  318
  - Brakes Squeal / Poor Brake Performance
    318
  - Pedal Vibration
    318
  - Caliper Overheats (Brakes Drag)
    318
  - Brakes Lock
    318
Electrical Chapter 10 Electrical

319
- Chapter 10
  321
- Electrical Service Notes
  321
- General Information
  321
- Special Tools
  321
- Switches / Controls
  321
  - Headlamp Switch
    321
  - Ignition Switch
    322
  - Turn Signal Switch (2010 Int'l Models)
    322
  - Brake Light Switch
    323
  - Awd / 2Wd Switch
    323
  - Awd / 2Wd / Turf Switch (Int'l Models)
    323
  - Differential Solenoid (Int'l Models)
    324
- Under-Dash Components
  321
- Instrument Cluster
  325
  - Rider Information Display
    325
  - Standard Display Modes
    326
  - Diagnostic Display Mode
    326
  - Viewing Diagnostic Codes
    328
- Instrument Cluster Troubleshooting Tests
  330
  - Test 1 - no All Wheel Drive
    330
  - Test 2 - no Display
    331
  - Test 3 - Vehicle Speed Sensor
    331
  - Test 4 - no Awd Hub Safety Limiter
    332
  - Test 5 - Fuel Gauge Display Not Working
    333
- All Wheel Drive Coil
  334
- Gear Position Indicator Switch
  334
- Speed Sensor
  334
- Head Lights
  335
  - Headlight Adjustment
    335
  - Headlamp Bulb Replacement
    335
- Tail / Brake Lights
  336
  - Bulb Replacement
    336
- Cooling System Schematic
  337
  - Cooling System Break-Out Diagram
    337
  - Coolant Temperature Sensor
    338
- Efi Diagnostics
  338
- Fuel Sender
  338
- Relays
  339
- Fuses / Circuit Breaker
  340
- Charging System
  341
  - Current Draw - Key off
    341
  - Charging System "Break Even" Test
    341
  - Charging System Alternator Tests
    342
  - Regulator / Rectifier Test
    343
  - Charging System Testing Flow Chart
    344
- Battery Service
  345
  - General Battery Information
    345
  - Battery Removal / Installation
    345
  - Charging Procedure (Maintenance Free)
    345
  - Maintenance Free Battery Testing
    345
  - Ocv - Open Circuit Voltage Test
    345
  - Load Test
    345
  - Off Season Storage
    345
- Starting System
  346
  - Troubleshooting
    346
  - Voltage Drop Test
    346
  - Starter Motor Removal / Disassembly
    346
  - Brush Inspection / Replacement
    347
  - Armature Testing
    348
  - Starter Reassembly / Installation
    348
  - Starter Drive
    349
  - Starter Solenoid Bench Test
    350
  - Starter Solenoid Operation
    350
  - Starter Exploded View
    351
- Starting System Testing Flow Chart
  352

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