Engine Installation; Engine Assembly And Installation - Polaris 2009 Ranger RZR 800 EFI Manual

1. After the engine is completely assembled and ready for
installation, the engine must be properly primed with
Polaris PS-4 PLUS 2W-50 Synthetic Oil (PN 2876244).
Fill the oil filter three-quarters full with Polaris PS-4 PLUS
2W-50 Synthetic Oil (PN 2876244). Let the oil soak into
the filter for 8-10 minutes. Install the filter onto the engine.
2. Remove primer plug from the engine. Install Oil System
Priming Adapter (PU-45778) into the oil plug hole. Push
3-5 oz. (approx.) of Polaris PS-4 PLUS 2W-50 engine oil
into the adapter or until resistance is felt. Remove the
adapter. Apply sealant to the plug threads. Install the plug
and torque to specification.
PU-45778
Primer Plug Torque
18 ± 2 ft.lbs. (24.4 ± 2.71 Nm)
Fill 3/4 full
with PS-4 PLUS
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ENGINE INSTALLATION

Engine Assembly and Installation

Use the following procedure to reinstall the engine assembly.
Assemble 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 eliminate any gaps
that may be present in the mounting areas.
3. Torque fasteners to specification using a 2 part sequence.
• Torque fasteners to half of the specified torque value
• Then torque fasteners to the full specified torque value
40 ft. lbs.
(54 Nm)
Engine / Transmission Mounting Fasteners
(2) Lower 3/8" Nuts: 40 ft. lbs. (54 Nm)
(4) Outer M8 Bolts: 28 ft. lbs. (38 Nm)
Install the inner clutch cover, drive clutch, and driven clutch.
Torque to specification (see Chapter 6).
• Clean clutch sheaves thoroughly and inspect inlet and
outlet ducts for proper routing and sealing.
To install engine assembly, reverse the "Engine Removal"
procedure detailed earlier in this Chapter.
• Properly route all electrical harnesses for engine
assembly installation. Check for any possible rubbing
points of electrical wires.
ENGINE
28 ft. lbs.
(38 Nm)
Plate is shown detached
from transmission for clarity
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3.59
3