Polaris Ranger RZR SW Manuals

Manuals and User Guides for Polaris Ranger RZR SW. We have 1 Polaris Ranger RZR SW manual available for free PDF download: Service Manual

Polaris Ranger RZR SW Service Manual

Polaris Ranger RZR SW Service Manual (346 pages)

Brand: Polaris | Category: Utility Vehicle | Size: 71.2 MB

Table of Contents

General Information Chapter 1 1

5
- Table of Contents
  5
- Chapter 1
  6
- Engine Designation Number
  6
- Model Identification
  6
- Model Information
  6
- Vehicle and Engine Serial Number Location
  6
- Vin Identification
  6
- Special Tools
  7
- Vehicle Information
  7
  - Publication Numbers
    7
- General Specifications
  8
  - Model: 2011 Ranger Rzr Sw
    8
- Misc. Specifications and Charts
  10
  - Conversion Table
    10
  - Standard Torque Specifications
    11
  - Sae Tap / Drill Sizes
    12
  - Metric Tap / Drill Sizes
    12
  - Glossary of Terms
    13
Maintenance Chapter 2 Maintenance

15
- Break-In Period
  17
- Chapter 2
  17
- Maintenance Chart Key
  17
- Periodic Maintenance Chart
  17
- Pre-Ride - 25 Hour Maintenance Interval
  18
- 50 - 300 Hour Maintenance Interval
  19
- Maintenance Quick Reference
  20
- Maintenance Quick Reference, Continued
  21
- Grease Lubrication Points
  22
- Lubricants / Service Products
  23
- General Vehicle Inspection and Maintenance
  24
- Fuel System and Air Intake
  25
  - Fuel System
    25
  - Fuel Line
    25
  - Fuel Pump / Fuel Filters
    25
  - Vent Lines
    25
  - Throttle Pedal Inspection
    26
  - Throttle Freeplay Adjustment
    26
  - Air Filter Service
    27
- Engine
  29
- Transmission and Gearcases
  32
- Cooling System
  36
  - Cooling System Overview
    36
  - Coolant Level Inspection
    36
  - Coolant Strength / Type
    36
  - Cooling System Pressure Test
    37
  - Cooling System Hoses
    37
  - Radiator
    37
  - Coolant Drain / Radiator Removal
    37
- Final Drive / Wheel and Tire
  38
  - Wheel and Hub Torque Table
    38
  - Wheel Removal
    38
  - Wheel Installation
    38
  - Tire Inspection
    39
  - Tire Pressure
    39
  - Drive Shaft Boot Inspection
    39
- Electrical and Ignition System
  40
  - Battery Maintenance
    40
  - Battery Removal
    40
  - Battery Installation
    40
  - Battery off Season Storage
    41
  - Battery Charging (Maintenance Free)
    41
  - Spark Plug Service
    41
  - Engine to Frame Ground
    41
- Steering
  42
  - Steering Inspection
    42
  - Steering Wheel Freeplay
    42
  - Tie Rod End / Wheel Hub Inspection
    42
  - Wheel Toe Alignment Inspection
    43
  - Wheel Toe Adjustment
    43
- Suspension (Fox™)
  44
  - Spring Preload Adjustment
    44
  - Shock Compression Adjustment
    45
- Brake System
  46
- Maintenance Log
  47
Chapter 3 Engine

49
- Crankcase Exploded Views
  50
- Engine Specifications
  50
- Engine Fastener Torque Patterns
  55
- Torque Specifications
  56
- 800 EFI Engine Service Specifications
  57
- Special Tools
  59
- Engine Cooling System
  60
- General Engine Service
  63
  - Engine Lubrication Specifications
    63
  - Accessible Engine Components
    63
  - Oil Pressure Test
    63
  - Oil Flow Chart
    64
  - Engine Removal
    65
  - Engine / Transmission Separation
    72
- Engine Disassembly and Inspection
  73
- Engine Reassembly
  96
  - Crankcase Reassembly
    96
  - Flywheel / Stator Installation
    105
  - Cylinder Head Reassembly
    105
  - Oil Pump Priming
    107
- Engine Installation
  108
  - Engine Assembly and Installation
    108
  - Engine Break-In Period
    109
- Troubleshooting
  110
  - Engine
    110
  - Cooling System
    111
Chapter 4 Electronic Fuel Injection

113
- General Information
  114
- Special Tools
  114
- Service Notes
  116
- Efi System Exploded View
  117
- Efi System Component Locations
  118
- Fuel Tank
  121
  - Fuel Lines - Quick Connect
    122
- Electronic Fuel Injection
  122
  - Principal Components / Efi Operation Overview
    122
  - Initial Priming / Starting Procedure
    123
- Electronic Control Unit (Ecu)
  123
  - Ecu Service / Replacement
    124
- Temp / Manifold Absolute Pressure Sensor (T-Map)
  124
- Crankshaft Position Sensor (Cps)
  125
  - Cps Test
    125
  - Cps Replacement
    126
- Fuel Injectors
  129
  - Fuel Injector Service / Test
    130
  - Fuel Injector Replacement
    131
- Fuel Pump
  132
  - Fuel Sender Test
    132
  - Fuel Pump Test
    133
  - Fuel Pump Replacement
    134
  - Fuel Tank Removal
    137
  - Fuel Tank Installation
    139
- Idle Air Control (Iac)
  139
  - Iac Test
    139
  - Iac Replacement
    140
- Throttle Position Sensor (Tps)
  140
  - Tps Resistance Tests
    141
  - Tps Tester / Regulator
    141
  - Tps Replacement
    142
- Camshaft Phase Sensor
  144
  - Cam Phase Sensor Test / Replacement
    144
- Engine Coolant Temperature Sensor (Ect)
  145
  - Ect Sensor Test / Replacement
    145
- Ignition Coil
  146
  - Ignition Coil / Ht Lead Replacement / Tests
    146
- Efi Diagnostics
  147
  - Instrument Cluster Trouble Code Display
    147
  - Efi Troubleshooting
    150
- Digital Wrench™ Operation
  151
Body / Steering / Suspension Chapter 5 Body / Steering / Suspension

159
- Special Tools
  160
- Torque Specifications
  160
- Cab Frame
  161
- Body Exploded Views
  162
- Chapter 5
  162
- Hood / Front Body Work
  162
- Front Bumper
  163
- Rear Bumper
  163
- Seat Assembly
  164
- Seat Belts / Mounting
  164
- Floor / Rocker Panels
  165
- Rear Cargo Box / Fenders
  166
- Chassis / Main Frame
  167
- Body Component Removal
  168
  - Seats
    168
  - Rear Service Panel
    168
  - Front Bumper
    168
  - Rear Bumper
    168
  - Hood and Front Body Work
    169
  - Rear Fender, Flair and Tie down Removal
    170
  - Cargo Box Assembly Removal
    170
  - Rocker Panels, Console and Floor
    171
- Steering Assembly
  172
  - Exploded View
    172
  - Steering Wheel Removal
    173
  - Steering Shaft Removal
    173
  - Steering Shaft Bearing Replacement
    173
- Front A-Arms
  174
  - Removal / Replacement
    174
  - Exploded View
    175
- Ball Joint Service
  176
  - Removal
    176
  - Installation
    177
- Rear A-Arms
  177
  - Removal
    177
  - Installation
    179
  - Exploded View
    179
- Rear Stabilizer Bar
  180
  - Removal / Installation
    180
- Decal Replacement
  181
- Shocks / Springs / Fasteners
  182
  - Exploded View
    182
  - Shock Removal / Installation
    182
  - Shock Replacement
    182
- Fox™ Shock Exploded Views
  183
- Fox™ Shock Service
  184
Clutching Chapter 6 Clutching

193
- Chapter 6
  194
- Drive Clutch Operation
  194
- Engine
  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 Covers and Ducting Components
    197
  - Pvt Disassembly
    197
  - Clutching
    197
  - Pvt Assembly
    198
  - Clutch Offset Procedure
    199
  - Transmission
    199
  - Brakes
    200
- Drive Belt
  201
  - Belt Removal
    201
  - Belt Inspection
    201
  - Belt Installation
    201
  - Pvt Break-In (Drive Belt / Clutches)
    201
- Drive Clutch Service
  202
  - Spring Specifications
    202
  - Shift Weights
    203
  - Non-Braking Exploded View (All Models)
    203
  - Clutch Disassembly
    204
  - Spider Removal
    204
  - Roller, Pin, and Thrust Washer Inspection
    205
  - Button to Tower Clearance Inspection
    206
  - Shift Weight Inspection
    206
  - Bearing Inspection
    206
  - Clutch Inspection
    207
  - Moveable Sheave Bushing Inspection
    208
  - Bushing Service
    208
  - Clutch Assembly
    210
- Driven Clutch Service
  212
  - Exploded View
    212
  - Clutch Disassembly / Inspection
    212
  - Clutch Assembly
    214
- Troubleshooting
  215
Chapter 7 Final Drive

217
- Bearing Carrier Inspection / Removal
  218
- Front Bearing Carrier
  218
- Special Tools
  218
- Torque Specifications
  218
- Bearing Replacement
  219
- Bearing Carrier Installation
  220
- Front Drive Shaft
  221
  - Drive Shaft Removal
    221
  - Drive Shaft / CV Joint Handling Tips
    222
  - Outer CV Joint / Boot Replacement
    222
  - Inner Plunging Joint / Boot Replacement
    224
  - Drive Shaft Installation
    225
- Propshaft Service
  227
  - Removal / Installation
    227
- Propshaft U-Joint Service
  228
  - Disassembly
    228
  - Assembly
    228
- Front Gearcase / Centralized Hilliard
  230
  - Centralized Hilliard Exploded View
    230
  - All Wheel Drive Operation
    231
  - Awd Diagnosis
    232
  - Electrical
    232
  - Gearcase Removal
    233
  - Gearcase Disassembly / Inspection
    233
  - Gearcase Assembly / Inspection
    236
  - Gearcase Installation
    238
- Rear Bearing Carrier
  239
  - Bearing Carrier Inspection / Removal
    239
  - Bearing Replacement
    240
  - Bearing Carrier Bushing Replacement
    241
  - Bearing Carrier Installation
    241
- Rear Drive Shaft
  243
  - Drive Shaft Removal
    243
  - Outer CV Joint / Boot Replacement
    244
  - Inner Plunging Joint / Boot Replacement
    246
  - Drive Shaft Exploded View
    249
  - Drive Shaft Installation
    249
- Rear Gearcase
  251
  - General Operation
    251
  - Gearcase Removal
    252
  - Gearcase Disassembly
    253
  - Differential Disassembly
    257
  - Differential Assembly
    258
  - Gearcase Assembly
    259
  - Gearcase Installation
    261
  - Gearcase Exploded View
    262
- Wheel Hubs
  263
  - Front Hub Exploded View
    263
  - Rear Hub Exploded View
    263
Transmission Chapter 8 Transmission

265
- Chapter 8
  266
- Installation
  266
- Removal
  266
- Shift Lever
  266
- Torque Values / Specifications
  266
- Shift Cable Inspection / Adjustment
  267
- Transmission Service
  268
- Troubleshooting
  282
  - Troubleshooting Checklist
    282
- Transmission Exploded View
  283
  - Shift Housing / Transfer Case Exploded View
    283
Brakes Chapter 9 Brakes

285
- Brake Noise Troubleshooting
  287
- Brake System Service Notes
  287
- Hydraulic Brake System Operation
  288
- Brake System Exploded View
  289
- Brake Pedal Lever
  290
  - Pedal Removal
    290
  - Pedal Installation
    290
- Chapter 9
  290
- Installation
  290
- Master Cylinder
  290
- Removal
  290
- Brake Bleeding / Fluid Change
  291
- Front Brake Pads
  292
  - Pad Removal
    292
  - Pad Inspection
    292
  - Pad Assembly / Installation
    293
  - Brake Burnishing Procedure
    293
- Front Caliper Service
  294
  - Caliper Exploded View
    294
  - Caliper Removal
    294
  - Caliper Disassembly
    295
  - Caliper Inspection
    296
  - Caliper Assembly
    296
  - Caliper Installation
    297
- Front Brake Disc
  298
  - Disc Runout
    298
  - Disc Inspection
    298
  - Disc Replacement
    298
- Rear Brake Pads
  299
  - Pad Removal
    299
  - Pad Inspection
    300
  - Pad Assembly / Installation
    300
  - Brake Burnishing Procedure
    301
- Rear Caliper Service
  302
  - Caliper Exploded View
    302
  - Caliper Removal
    302
  - Caliper Disassembly
    303
  - Caliper Inspection
    303
  - Caliper Assembly
    304
  - Caliper Installation
    304
- Rear Brake Disc
  305
  - Disc Inspection
    305
  - Disc Replacement
    305
- Troubleshooting
  306
  - Brakes Squeal / Poor Brake Performance
    306
  - Pedal Vibration
    306
  - Caliper Overheats (Brakes Drag)
    306
  - Brakes Lock
    306
Electrical Chapter 10 Electrical

307
- Chapter 10
  309
- Electrical Service Notes
  309
- General Information
  309
- Special Tools
  309
- Switches / Controls
  309
  - Brake Light Switch
    309
  - Headlamp Switch
    310
  - Ignition Key Switch
    310
  - Awd / 2Wd / Turf Switch
    311
  - Blackout Switch
    311
  - I.R. Light Switch
    312
  - Winch Switch
    312
  - Transmission (Gear Position) Switch
    313
- Under-Dash Components
  309
- Vehicle Speed Sensor
  313
  - Speed Sensor Location
    313
  - Speed Sensor Testing
    313
- Rear Differential Solenoid
  314
  - Differential Solenoid Overview
    314
  - Differential Solenoid Circuit Operation
    314
- Instrument Cluster
  315
  - Overview
    315
  - Rider Information Display
    316
  - Information Display Area
    316
  - Diagnostic Mode
    319
  - Instrument Cluster Pinouts
    320
  - Instrument Cluster Removal
    320
  - Instrument Cluster Installation
    320
- All Wheel Drive Coil
  321
  - Operation Overview
    321
  - Diagnosing System Failures
    321
- Head Lights
  321
  - Headlight Adjustment
    321
  - Headlamp Bulb Replacement
    322
  - Headlamp Housing Removal
    322
  - Headlamp Housing Installation
    322
- Tail / Brake Lights
  323
  - Bulb Replacement
    323
- Cooling System Schematic
  324
- Efi Diagnostics
  325
  - Efi Component Testing
    325
- Fuel Sender
  325
  - Testing
    325
  - Electronic Fuel Injection
    325
- Fuse Box: Fuses / Relays / Circuit Breaker
  326
  - Overview / Operation
    326
  - Relay Operation
    327
- Charging System
  328
  - Current Draw - Key off
    328
  - Charging System "Break Even" Test
    328
  - Charging System Alternator Tests
    329
  - Regulator / Rectifier Test
    330
  - Charging System Testing Flow Chart
    331
- Battery Service
  332
  - Battery Specifications
    332
  - General Battery Information
    332
  - Battery Removal / Installation
    332
  - Battery off Season Storage
    332
  - Battery Testing
    332
  - Ocv - Open Circuit Voltage Test
    333
  - Load Test
    333
  - Battery Conductance Analyzer
    333
  - Charging Procedure
    334
- Starting System
  334
  - Troubleshooting
    334
  - Voltage Drop Test
    335
  - Starter Motor Removal / Disassembly
    335
  - Brush Inspection / Replacement
    335
  - Armature Testing
    336
  - Starter Reassembly / Installation
    337
  - Starter Solenoid Bench Test
    338
  - Starter Solenoid Operation
    338
  - Starter Exploded View
    339
- Starting System Testing Flow Chart
  340
  - Body / Steering / Suspension
    343

Advertisement

Advertisement

Related Products

Polaris Categories

Offroad Vehicle Swimming Pool Vacuum Utility Vehicle Automobile Accessories Snowmobiles

More Polaris Manuals