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RANGER RZR S
Polaris RANGER RZR S Manuals
Manuals and User Guides for Polaris RANGER RZR S. We have
3
Polaris RANGER RZR S manuals available for free PDF download: Service Manual, Owner's Manual
Polaris RANGER RZR S Service Manual (418 pages)
Brand:
Polaris
| Category:
Offroad Vehicle
| Size: 39.29 MB
Table of Contents
General Information Chapter 1 1
6
Table of Contents
6
Chapter 1
7
Engine Designation Number
7
General Information
7
Model Identification
7
Model Information
7
Vehicle and Engine Serial Number Location
7
Vin Identification
7
Special Tools
8
Vehicle Information
8
Publication Numbers
8
Replacement Keys
8
General Specifications
9
Misc. Specifications and Charts
15
Conversion Table
15
Standard Torque Specifications
16
Sae Tap / Drill Sizes
17
Metric Tap / Drill Sizes
17
Glossary of Terms
18
Maintenance Chapter 2 Maintenance 2
20
Break-In Period / Maintenance Chart Key
22
Chapter 2
22
Periodic Maintenance Chart
22
Pre-Ride - 25 Hour Maintenance Interval
23
50 - 500 Hour Maintenance Interval
24
Maintenance Quick Reference
25
Maintenance Quick Reference, Continued
26
Grease Lubrication Points
27
Lubricants / Service Products
28
General Vehicle Inspection and Maintenance
29
Pre-Ride / Daily Inspection
29
Frame, Nuts, Bolts, and Fasteners
29
Shift Cable Inspection / Adjustment
29
Fuel System and Air Intake
30
Fuel Line / Fuel Pump / Fuel Filters / Vent Lines
30
Throttle Pedal Inspection
31
Throttle Freeplay Adjustment
31
Air Filter Service
32
Engine
34
Engine Oil Level
34
Engine Oil and Filter Service
35
Engine Breather Hose Inspection
36
Engine and Transmission Mounts
36
Compression and Leakdown Test
36
Exhaust - Spark Arrestor
36
Transmission and Gearcases
37
Transmission Lubrication
37
Front Gearcase Lubrication
39
Rear Gearcase Lubrication
40
Cooling System
41
Coolant Level Inspection
41
Coolant Strength / Type
41
Cooling System Pressure Test
42
Cooling System Hoses / Radiator
42
Coolant Drain / Radiator Removal
42
Wheel Installation
43
Final Drive / Wheel and Tire
43
Wheel and Hub Torque Table
43
Wheel Removal / Installation
43
Tire Inspection / Pressure
44
Drive Shaft Boot Inspection
44
Electrical and Ignition System
45
Battery Maintenance
45
Battery Removal
45
Battery Installation
46
Battery off Season Storage
46
Battery Charging (Maintenance Free)
46
Spark Plug Service
46
Engine to Frame Ground
47
Steering
47
Steering Inspection / Steering Wheel Freeplay
47
Tie Rod End / Wheel Hub Inspection
48
Wheel Toe Alignment Inspection
48
Wheel Toe Adjustment
49
Suspension (Fox™)
50
Shock Compression Adjustment
51
Suspension (Standard)
50
Spring Preload Adjustment
50
Suspension (Walker Evans™)
52
Spring Preload Adjustment
52
Shock Compression Adjustment
52
Brake System
53
Brake Fluid / Pad / Disc Inspection
53
Brake Hose and Fitting Inspection
53
Brake Fluid Inspection
53
Maintenance Log
54
Chapter 3 Engine
56
Crankcase
57
Engine Specifications
57
Oil Pump / Gears / Engine Cover
58
Stator Cover / Starter / Water Pump / Lubrication System
59
Cylinder / Cylinder Head / Piston
60
Engine Efi Sensors / Valve Cover / General Components
61
Engine Torque Specifications
62
800 EFI Engine Service Specifications
63
Special Tools
65
Engine Cooling System
66
Cooling System Specifications / Pressure Test / Cap Test
66
Cooling System Exploded View
67
Cooling System Bleeding Procedure
68
General Engine Service
69
Engine Lubrication Specifications
69
Accessible Engine Components / Oil Pressure Test
69
Oil Flow Chart
70
Engine Removal
71
Engine / Transmission Separation
78
Engine Disassembly and Inspection
79
Cylinder Head Assembly Exploded View
79
Rocker Arms / Push Rods
80
Cylinder Head Removal
80
Cylinder Head Inspection / Warp
81
Valve Seal / Spring Service (on Engine)
81
Cylinder Head Warp
81
Cylinder Head Disassembly
82
Valve Inspection
83
Combustion Chamber
84
Valve Seat Reconditioning
84
Cylinder Head Reassembly
86
Valve Sealing Test
87
Cylinder Removal
87
Valve Lifter Removal / Inspection
87
Piston Removal
88
Cylinder Inspection
89
Cylinder Hone Selection and Honing Procedure
90
Honing to Deglaze / Cleaning the Cylinder after Honing
90
Piston-To-Cylinder Clearance
91
Piston / Rod Inspection
91
Piston Ring Installed Gap
92
Starter Drive Bendix Removal / Inspection
92
Flywheel / Stator Removal / Inspection
93
Engine Crankcase Disassembly / Inspection
93
Camshaft Inspection
101
Engine Reassembly
102
Crankcase Reassembly
102
Flywheel / Stator Installation
111
Cylinder Head Reassembly
111
Oil Pump Priming
113
Engine Installation
114
Engine Assembly and Installation
114
Engine Break-In Period
115
Troubleshooting
116
Chapter 4 Electronic Fuel Injection
118
Electronic Fuel Injection
119
General Information
119
Special Tools
119
Service Notes
121
Efi System Exploded View
122
Efi System Component Locations
123
Fuel Tank
125
Fuel Lines - Quick Connect
126
Electronic Fuel Injection
126
Principal Components / Efi Operation Overview
126
Initial Priming / Starting Procedure
127
Electronic Control Unit (Ecu)
127
Temp / Manifold Absolute Pressure Sensor (T-Map)
128
Crankshaft Position Sensor (Cps)
129
Cps Test
129
Cps Replacement
130
Fuel Injectors
133
Fuel Injector Service
134
Fuel Injector Replacement
135
Fuel Pump
136
Fuel Sender Test
136
Fuel Pump Test
137
Fuel Pump Replacement
138
Fuel Tank Removal (Rzr / Rzr S)
141
Fuel Tank Removal (Rzr 4)
143
Fuel Tank Installation
145
Idle Air Control (Iac)
146
Throttle Position Sensor (Tps)
147
Tps Replacement
148
Camshaft Phase Sensor
150
Engine Coolant Temperature Sensor (Ect)
151
Overview, Test and Replacement
151
Ignition Coil
152
Efi Diagnostics
153
Instrument Cluster Trouble Code Display
153
Diagnostic Trouble Code Table
153
Efi Troubleshooting
156
Digital Wrench™ Operation
157
Digital Wrench™ Communication Errors
157
Digital Wrench™ - Diagnostic Connector
158
Digital Wrench™ Updates
159
Digital Wrench™ Feature Map
160
Engine Controller Reprogramming (Reflash)
161
Efi System Electrical Operation
165
Chapter 5 Body / Steering / Suspension
166
Special Tools
168
Torque Specifications
168
Cab Frame (Rzr / Rzr S)
169
Cab Frame (Rzr 4)
170
Body Exploded Views
171
Side Safety Nets
171
Dash Instruments / Controls / Glovebox
172
Hood / Front Body Work
173
Seat Assembly
175
Seat Belts / Mounting (Rzr / Rzr S)
175
Seat Belts / Mounting (Rzr 4)
176
Floor / Rocker Panels (Rzr / Rzr S)
177
Floor / Rocker Panels (Rzr 4)
178
Rear Cargo Box / Fenders (Rzr / Rzr S)
179
Rear Cargo Box / Fenders (Rzr 4)
180
Chassis / Main Frame (Rzr / Rzr S)
181
Chassis / Main Frame (Rzr 4)
182
Body Component Removal
183
Seats
183
Rear Service Panel (Rzr / Rzr S)
183
Rear Console Cover (Rzr 4)
183
Front Bumper
183
Rear Bumper
184
Hood and Front Body Work
184
Rear Fender, Flair and Tie down Removal
185
Cargo Box Assembly Removal
185
Rocker Panels, Console and Floor
186
Steering Assembly
187
Exploded View (Non-Eps Models)
187
Steering Wheel Removal (Non-Eps Models)
188
Steering Shaft Removal (Non-Eps Models)
188
Steering Shaft Bearing Replacement
189
Electronic Power Steering Assembly
190
Exploded View (Eps Models)
190
Upper Steering Shaft Removal (Eps Models)
191
Steering Wheel Removal (Eps Models)
192
Power Steering Unit Removal
192
Power Steering Unit Installation
194
Upper Steering Shaft Installation (Eps Models)
195
Front A-Arms
196
Removal / Replacement
196
Exploded View
197
Ball Joint Service
198
Removal
198
Installation
199
Front Stabilizer Bar (Rzr / Rzr S Int'l)
199
Sway Bar Linkage Removal
199
Stabilizer Bar Removal
199
Exploded View
200
Rear A-Arms
201
Removal
201
Installation
202
Exploded View
203
Rear Stabilizer Bar (Rzr)
204
Rear Stabilizer Bar (Rzr S / Rzr 4)
205
Decal Replacement
206
Shocks / Springs / Fasteners
206
Exploded View (Rzr / Rzr S)
206
Exploded View (Rzr S / Rzr S Int'l)
206
Exploded View (Rzr 4)
207
Fox™ Shock Exploded Views
208
Fox™ Podium X 'Piggyback' Shock (Rzr S)
208
Fox™ 2.0 'Piggyback' Shock (Rzr 4)
209
Fox™ Shock Service
210
General Service Information
210
Fox™ Shock Rebuild Information
212
Fox™ Shock Disassembly
213
Fox™ Shock Rebuild
215
Fox™ Shock Reassembly
216
Walker Evans™ Shock Exploded View
219
Walker Evans™ Compression Adjuster Reservoir Shock (Rzr L.e.)
219
Walker Evans™ Shock Service
220
Recommended Service Intervals
220
Walker Evans™ Shock Rebuild Information
221
Special Tools
221
Valve Shim Arrangement
221
Piston Orientation
221
Walker Evans™ Shock Disassembly
222
Walker Evans™ Shock Assembly
224
Clutching Chapter 6 Clutching
228
Chapter 6
229
Drive Clutch Operation
229
General Operation
229
Pvt System Overview
229
Special Tools and Supplies
229
Torque Specifications
229
Driven Clutch Operation
230
Maintenance / Inspection
230
Pvt Break-In (Drive Belt / Clutches)
230
Overheating / Diagnosis
231
Pvt System Service
232
Pvt Covers and Ducting Components
232
Pvt Disassembly
233
Pvt Assembly
234
Clutch Offset Procedure
235
Drive Belt
237
Pvt Break-In (Drive Belt / Clutches)
237
Drive Clutch Service
238
Spring Specifications
238
Shift Weights
239
Drive Clutch Exploded View
239
Clutch Disassembly
240
Spider Removal
240
Roller, Pin, and Thrust Washer Inspection
241
Button to Tower Clearance Inspection
242
Shift Weight Inspection
242
Bearing Inspection
242
Clutch Inspection
243
Moveable Sheave Bushing Inspection
244
Bushing Service
244
Clutch Assembly
246
Driven Clutch Service
248
Exploded View
248
Clutch Disassembly / Inspection
248
Clutch Assembly
250
Troubleshooting
251
Chapter 7 Final Drive
254
Bearing Carrier Inspection / Removal
255
Front Bearing Carrier
255
Special Tools
255
Torque Specifications
255
Bearing Replacement
256
Bearing Carrier Installation
257
Front Drive Shaft
259
Drive Shaft Removal
259
Drive Shaft / CV Joint Handling Tips
260
Outer CV Joint / Boot Replacement
260
Inner Plunging Joint / Boot Replacement
261
Drive Shaft Installation
263
Propshaft Service
264
Removal / Installation (Rzr / Rzr S)
264
Removal / Installation (Rzr 4)
265
Support Bearing Replacement (Rzr 4)
266
Propshaft U-Joint Service
267
Front Gearcase / Centralized Hilliard
269
Centralized Hilliard Exploded View
269
All Wheel Drive Operation
270
Awd Diagnosis
271
Gearcase Removal
272
Gearcase Assembly
275
Gearcase Installation
277
Rear Bearing Carrier
279
Bearing Carrier Inspection / Removal
279
Bearing Replacement
280
Bearing Carrier Bushing Replacement
280
Bearing Carrier Installation
281
Rear Drive Shaft
282
Drive Shaft Removal
282
Outer CV Joint / Boot Replacement
283
Inner Plunging Joint / Boot Replacement
286
Drive Shaft Exploded View
288
Rear Gearcase
290
Gearcase Removal
290
Gearcase Disassembly
291
Gearcase Assembly
293
Gearcase Installation
294
Gearcase Exploded View
295
Rear Gearcase (Rzr S Int'l)
296
General Operation
296
Gearcase Removal
297
Gearcase Disassembly
298
Differential Disassembly
302
Differential Assembly
303
Gearcase Assembly
304
Gearcase Installation
306
Gearcase Exploded View
307
Wheel Hubs
308
Transmission Chapter 8 Transmission
310
Shift Lever
311
Torque Values / Specifications
311
Chapter 8 Shift Cable Inspection / Adjustment
312
Transmission Service
313
Transmission Removal / Service Notes
313
Transfer Case Disassembly
313
Transfer Case Reassembly
316
Transmission Shift Housing Disassembly
318
Transmission Shift Housing Reassembly
322
Troubleshooting
327
Troubleshooting Checklist
327
Transmission Exploded View
328
Brakes Chapter 9 Brakes
330
Brake Noise Troubleshooting
332
Brake System Service Notes
332
Hydraulic Brake System Operation
333
Brake System Exploded View
334
Chapter 9
334
Rzr / Rzr S / Rzr S Int'l
334
Rzr 4
334
Brake Pedal Lever
335
Master Cylinder
335
Brake Bleeding / Fluid Change
336
Front Brake Pads
337
Pad Removal
337
Brake Burnishing Procedure
339
Front Caliper Service
340
Caliper Exploded View (Rzr / Rzr S / Rzr S Int'l)
340
Caliper Exploded View (Rzr 4)
340
Caliper Removal
341
Caliper Disassembly
342
Caliper Inspection
343
Caliper Assembly
344
Front Brake Disc
345
Disc Replacement
346
Rear Brake Pads
347
Pad Removal
347
Brake Burnishing Procedure
348
Rear Caliper Service
349
Caliper Exploded View
349
Caliper Removal
349
Caliper Assembly
351
Caliper Installation
352
Rear Brake Disc
352
Disc Inspection
352
Disc Replacement
353
Troubleshooting
353
Pedal Vibration
353
Brakes Lock
353
Chapter 10 Electrical
354
General Information
356
Switches / Controls
356
Electrical Service Notes
356
Brake Light Switch
356
Headlamp Switch
357
Ignition Key Switch
357
Ignition Key Switch (Int'l)
358
Awd / 2Wd Switch
358
Awd / 2Wd / Turf Switch (Int'l)
359
Turn Signal Switch (Int'l)
359
Hazard Switch (Int'l)
359
Transmission (Gear Position) Switch
360
Vehicle Speed Sensor
360
Rear Diff Solenoid (Int'l)
361
Instrument Cluster
362
Rider Information Display
363
Information Display Area
363
Diagnostic Mode
366
Instrument Cluster Pinouts
367
Instrument Cluster Installation
367
Instrument Cluster Removal
367
All Wheel Drive Coil
368
Head Lights
368
Headlight Adjustment
368
Headlamp Bulb Replacement
369
Tail / Brake Lights
370
Bulb Replacement
370
Cooling System
371
Cooling System Break-Out Diagram
371
Coolant Temperature Sensor
372
Efi Diagnostics
372
Fuel Sender
372
Fuse Box: Fuses / Relays / Circuit Breaker
373
Fuse Box Detail
374
Relay Operation
375
Charging System
377
Current Draw - Key off
377
Regulator / Rectifier
378
Charging System Testing Flow Chart
379
Battery Service
380
Battery Testing
381
Ocv - Open Circuit Voltage Test
381
Load Test
381
Battery Conductance Analyzer
382
Charging Procedure
382
Starting System
383
Voltage Drop Test
383
Starter Motor Removal / Disassembly
383
Brush Inspection / Replacement
384
Armature Testing
385
Starter Reassembly / Installation
385
Starter Drive
386
Starter Solenoid Bench Test
387
Starter Solenoid Operation
387
Starter Exploded View
388
Starting System Testing Flow Chart
389
Electronic Power Steering (Eps)
390
Eps Operation
390
Eps 8-Way Wire Harness Connector
390
Proper Eps System Diagnosing
390
Eps System Breakout
391
Eps Troubleshooting (Using Digital Wrench™)
394
Electrical System Breakouts
395
Awd
395
Vehicle Speed Sensor
395
Cooling Fan
396
Charging System
397
Chassis Power
398
Key-On Battery Power
399
Electronic Power Steering (Eps)
400
Engine Start (Starter Interlock)
401
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Polaris RANGER RZR S Owner's Manual (146 pages)
Brand:
Polaris
| Category:
Offroad Vehicle
| Size: 10.87 MB
Table of Contents
Table of Contents
7
Introduction
8
Vehicle Identification Numbers
10
Safety
11
Safety
12
Eye Protection
13
Age Restrictions
14
Operating Without Instruction
14
Safety Warnings
14
Using Alcohol or Drugs
14
Protective Apparel
15
Carrying a Passenger
16
Passengers in the Cargo Box
16
Jumps and Stunts
17
Turning Improperly
17
Descending Hills Improperly
18
Improper Hill Climbing
18
Crossing Hillsides
19
Improper Tire Maintenance
20
Operating through Water
21
Skidding or Sliding
21
Improper Cargo Loading
22
Operating a Damaged Vehicle
22
Exposure to Exhaust
23
Handling Gasoline
23
Hot Exhaust Systems
23
Age Warning
27
Passenger Safety Warning
28
Discretionary Warning
29
Component Locations
30
Seat Removal
33
Steering Wheel
34
Features and Controls
30
Passenger Hand Hold
34
Storage Compartments
35
Seat Belts
38
Seat Belt Inspection
39
Auxiliary Outlet
40
Ignition Switch
41
Light Switch
41
Gear Selector
42
Brake Pedal
43
Throttle Pedal
43
Engaging Awd
44
Instrument Cluster
45
Rider Information Center
46
Diagnostic Mode
49
Operation
52
Brake System Break-In
53
Safe Operation Practices
55
Starting the Engine
56
Stopping the Engine
56
Parking the Vehicle
57
Trail Etiquette
57
Driving with a Passenger
60
Driving on Slippery Surfaces
61
Driving Uphill
62
Driving Downhill
63
Driving through Water
64
Driving over Obstacles
65
Driving in Reverse
66
Parking on an Incline
67
Hauling Cargo
68
Belt Life
69
Towing Loads
69
Emission Control Systems
70
Maintenance
71
Severe Use Definition
71
Periodic Maintenance Chart
73
Lubrication Recommendations
76
Engine Oil
78
Oil Check
79
Oil and Filter Change
80
Rear Gearcase
87
Gearcase Specification Chart
88
Spark Plugs
89
Spark Plug Condition
90
Cooling System
91
Radiator and Cooling Fan
92
Coolant Level
93
Radiator Coolant Level
94
Pvt Drying
96
Air Filter
97
Filter Systems
97
Spark Arrestor
98
Throttle Freeplay
99
Throttle Freeplay Inspection
99
Throttle System
99
Throttle Freeplay Adjustment
100
Brake Fluid
102
Brake Inspection
103
Steering Wheel Inspection
103
Suspension Settings (Rzr S)
105
Tire Tread Depth
107
Wheel Removal
108
Wheel Installation
108
Headlight Lamp Replacement
109
Headlight Beam Adjustment
110
Vehicle Immersion
111
Brake Lights
111
Battery Removal
113
Battery Installation
114
Battery Storage
115
Cleaning and Storage
118
Washing the Vehicle
119
Polishing the Vehicle
119
Oil and Filter
121
Fluid Levels
121
Battery Maintenance
122
Removal from Storage
123
Transporting the Vehicle
123
Specifications
124
Specifications
125
Polaris Products
126
Troubleshooting
127
Declaration of Conformity
131
Limited Warranty
132
Warranty
132
Maintenance Log
139
Index
142
Index
143
Oil Change
144
Polaris RANGER RZR S Owner's Manual (148 pages)
Brand:
Polaris
| Category:
Offroad Vehicle
| Size: 3.84 MB
Table of Contents
Table of Contents
7
Introduction
8
Vehicle Identification Numbers
10
Safety
11
Safe Riding Gear
12
Safety Warnings
14
Protective Apparel
15
Operating on Pavement
17
Operating on Public Roads
17
Operating at Excessive Speeds
17
Improper Hill Climbing
18
Turning Improperly
18
Jumps and Stunts
18
Descending Hills Improperly
19
Crossing Hillsides
19
Stalling While Climbing a Hill
19
Improper Tire Maintenance
20
Operating in Unfamiliar Terrain
20
Operating on Slippery Terrain
20
Skidding or Sliding
21
Improper Cargo Loading
22
Operating a Damaged Vehicle
22
Handling Gasoline
23
Exposure to Exhaust
23
Hot Exhaust Systems
23
Age Warning
27
Features and Controls
32
Component Locations
33
Seat Removal
35
Steering Wheel
36
Fuel Cap
38
Seat Belt Inspection
39
Seat Belts
39
Auxiliary Outlet
40
Headlight Switch
41
Ignition Switch
41
Gear Selector
42
Brake Pedal
43
Throttle Pedal
43
Engaging Awd
44
Instrument Cluster
45
Mode Button
45
Indicator Lamps
46
Rider Information Center
47
Operation
54
Brake System Break-In
55
Safe Operation Practices
57
Starting the Engine
58
Stopping the Engine
58
Parking the Vehicle
59
Trail Etiquette
59
Driving with Passengers
62
Driving on Slippery Surfaces
63
Driving Uphill
64
Driving Downhill
65
Driving through Water
66
Driving over Obstacles
67
Driving in Reverse
68
Parking on an Incline
69
Hauling Cargo
70
Belt Life
71
Towing Loads
71
Crankcase Emission Control System
72
Emission Control Systems
72
Maintenance
73
Severe Use Definition
73
Maintenance Chart Key
74
Periodic Maintenance Chart
74
Lubrication Recommendations
78
Engine Oil
80
Oil Recommendations
80
Oil Check
81
Oil and Filter Change
82
Rear Gearcase
89
Spark Plugs
90
Spark Plug Condition
91
Cooling System
94
Radiator and Cooling Fan
95
Radiator Coolant Level
95
Coolant Level
96
Pvt Drying
98
Air Filter
99
Spark Arrester
100
Throttle Freeplay Inspection
101
Throttle System
101
Throttle Freeplay Adjustment
102
Brake Fluid
104
Brake Inspection
105
Steering Wheel Inspection
105
Suspension Settings
106
Tire Tread Depth
109
Wheel Installation
110
Wheel Removal
110
Headlight Lamp Replacement
111
Headlight High Beam Adjustment
112
Brake Lights
113
Vehicle Immersion
113
Battery Removal
115
Battery Installation
116
Battery Storage
117
Cleaning and Storage
120
Polishing the Vehicle
121
Washing the Vehicle
121
Storage Tips
123
Removal from Storage
125
Transporting the Vehicle
125
Specifications
126
POLARIS Products
130
Troubleshooting
131
Warranty
135
Maintenance Log
142
Index
144
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