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Polaris 2011 RANGER RZR Service Manual

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2011 RANGER RZR / RZR S / RZR 4
SERVICE MANUAL
PN 9923142

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  Summary of Contents for Polaris 2011 RANGER RZR

  • Page 1 2011 RANGER RZR / RZR S / RZR 4 SERVICE MANUAL PN 9923142...
  • Page 2 Publication Printed September 2010 (PN 9923142) Rev 1 © Copyright 2010 Polaris Sales Inc. All information contained within this publication is based on the latest product information at the time of publication. Due to constant improvements in the design and quality of production components, some minor discrepancies may result between the actual vehicle and the information presented in this publication.
  • Page 3 Hilliard, Trademark of the Hilliard Corporation Warn, Trademark of Warn Industries FOX, Registered Trademark of FOX RACING SHOX RydeFX, Registered Trademark of ArvinMeritor Some Polaris factory publications can be downloaded from www.polarisindustries.com, purchased from www.purepolaris.com or by contacting the nearest Polaris dealer.
  • Page 4 GENERAL INFORMATION MAINTENANCE ENGINE ELECTRONIC FUEL INJECTION BODY / STEERING / SUSPENSION CLUTCHING FINAL DRIVE TRANSMISSION BRAKES ELECTRICAL...
  • Page 6: Table Of Contents

    GENERAL: 2011 RANGER RZR S / EPS INT’L....... . 1.6...
  • Page 7: General Information

    Vehicle and Engine Serial Number Location Whenever corresponding about a Polaris ORV, refer to the vehicle identification number (VIN) and the engine serial number. The VIN can be found stamped on a portion of the front left frame rail, close to the left front wheel (see Figure 1-1).
  • Page 8: Vehicle Information

    Special tools may be required while servicing this vehicle. Some of the tools listed or depicted are mandatory, while other tools maybe substituted with a similar tool, if available. Polaris recommends the use of Polaris Special Tools when servicing any Polaris product.
  • Page 9: General Specifications

    Capacity (Payload) and trailer tongue weight) Hitch Towing Capacity 1500 lbs. / 680 kg Hitch Tongue Capacity 150 lbs. / 68 kg 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 10 Fuses (Fuse/Relay Box) Lights / EFI / Accessory: 20 Amp EFI: 20 Amp Fuses (Power Fuse Holder) Chassis / EPS: 30 Amp 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 11 Capacity (Payload) and trailer tongue weight) Hitch Towing Capacity 1500 lbs. / 680 kg Hitch Tongue Capacity 150 lbs. / 68 kg 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 12 Lights / EFI / Accessory: 20 Amp (B) = Bushed Shift Weight EFI: 20 Amp Fuses (Power Fuse Holder) Chassis / EPS: 30 Amp 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 13 Capacity (Payload) and trailer tongue weight) Hitch Towing Capacity 1500 lbs. / 680 kg Hitch Tongue Capacity 150 lbs. / 68 kg 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 14 Fuses (Fuse/Relay Box) Lights / EFI / Accessory: 20 Amp EFI: 20 Amp Fuses (Power Fuse Holder) Chassis / EPS: 30 Amp 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 15: Misc. Specifications And Charts

    MISC. SPECIFICATIONS AND CHARTS Conversion Table °C to °F: (°C + 32) = °F °F to °C: (°F - 32) = °C 1.10 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 16: Standard Torque Specifications

    Always consult the exploded views or each manual section for torque values of fasteners before using standard torque. 1.11 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 17: Sae Tap / Drill Sizes

    GENERAL INFORMATION SAE Tap / Drill Sizes Decimal Equivalents Metric Tap / Drill Sizes 1.12 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 18: Glossary Of Terms

    CC: Cubic centimeters. Center Distance: Distance between center of crankshaft and center of driven clutch shaft. Chain Pitch: Distance between chain link pins (No. 35 = 3/8" or 1 cm). Polaris measures chain length in number of pitches. CI: Cubic inches.
  • Page 19 GENERAL INFORMATION NOTES 1.14 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 20 WHEEL TOE ADJUSTMENT ..........2.30 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual...
  • Page 21 MAINTENANCE LOG ........... 2.35 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual...
  • Page 22: Periodic Maintenance Chart

    Polaris dealer.  = SEVERE USE ITEM: See information provided above. E = Emission Control System Service (California). NOTE: Inspection may reveal the need for replacement parts. Always use genuine Polaris parts. WARNING  Improperly performing the procedures marked could result in component failure and lead to serious injury or death.
  • Page 23: Pre-Ride - 25 Hour Maintenance Interval

    Perform these procedures more often for vehicles subjected to severe use. E Emission Control System Service (California)  Have an authorized Polaris dealer perform these services. 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 24: 50 - 500 Hour Maintenance Interval

    Perform these procedures more often for vehicles subjected to severe use. E Emission Control System Service (California)  Have an authorized Polaris dealer perform these services. 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 25: Maintenance Quick Reference

    * More often under severe use, such as operated in water or under severe loads. 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 26: Maintenance Quick Reference, Continued

    * More often under severe use, such as operated in water or under severe loads. 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 27: Grease Lubrication Points

    A-arm Pivot Bushings Polaris Premium U-Joint Grease miles (800 km). thoroughly washing or Stabilizer Bar Bushings submerging the vehicle. 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 28: Lubricants / Service Products

    Premium U-Joint Lube (14 oz.) (10 Count) 2871329 Dielectric Grease (Nyogel™) Coolant 2871323 60/40 Coolant (Gallon) (6 Count) 2871534 60/40 Coolant (Quart) (12 Count) 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 29: General Vehicle Inspection And Maintenance

    • Excessive gear clash (noise) • Gear selector moving out of desired range 2.10 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 30: Fuel System And Air Intake

    Be sure vent lines are routed properly and secured with Replace fuel line every two years. cable ties. IMPORTANT: Ensure lines are not kinked or pinched. 2.11 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 31: Throttle Pedal Inspection

    Using a 12 mm open-end wrench, move the cable adjuster until 1/16” to 1/8” (1.5 - 3 mm) of freeplay is achieved at the throttle pedal. 2.12 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 32: Air Filter Service

    Inspect the air filter element and replace if necessary. Do not attempt to clean the air filter with anything other that low pressure compressed air. 2.13 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 33 Intake Seal Seal Breather Filter Fitting Breather Hose Boot Clip (3) Filter Ring Air Box Can Clamps Seal Air Filter 2.14 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 34: Engine

    Reinstall the dipstick and lock the lever. Stop engine and lift the lever lock. Remove dipstick and wipe dry with a clean cloth. 2.15 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 35: Engine Oil And Filter Service

    Allow oil to drain completely. dipstick. Replace the sealing washer on drain plug. 19. Dispose of used oil and oil filter properly. 2.16 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 36: Engine Breather Hose Inspection

    Cylinder Compression: 165-185 PSI Cylinder Leakdown Service Limit: 15% (Inspect for cause if test exceeds 15%) 2.17 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 37: Transmission And Gearcases

    Transfer Case - Lubricant Level Check: Position vehicle on a level surface. Remove the fill plug. Remove the level check plug. 2.18 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 38 Remove the drain plug and allow to drain completely. Clean and Reinstall the drain plug with a new O-ring. Torque to 30-45 in. lbs. (3-5 Nm). 2.19 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 39: Front Gearcase Lubrication

    Reinstall the fill plug; torque to 8-10 ft. lbs. (11-14 Nm). Check for leaks. Discard the used lubricant properly. 2.20 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 40: Rear Gearcase Lubrication

    Check for leaks. Discard used lubricant properly. Add the recommended lubricant as needed. Reinstall the fill plug and torque to 40-50 ft. lbs. (54-68 Nm). 2.21 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 41: Cooling System

    Polaris 60/40 Anti-Freeze / Coolant Remove the hood from the front cab. (PN 2871323) View the coolant level in the recovery bottle. 2.22 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 42: Cooling System Pressure Test

    Check radiator (A) air passages for restrictions or damage. Drain Here Allow coolant to completely drain. Flush radiator fins in this direction 2.23 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 43: Wheel Installation

    Attach the wheel nuts and finger tighten them. Carefully lower the vehicle to the ground. 2.24 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 44: Tire Inspection / Pressure

    1/8", (.3 cm) or less. Tire Tread Depth Replace tires when tread depth is worn to 1/8" (3 mm) or less. 2.25 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 45: Electrical And Ignition System

    Charge battery according to “Charging Procedure” provided in Chapter 10. Do not use the vehicle’s stator/alternator to charge a new battery. 2.26 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 46: Battery Installation

    CAUTION: Severe engine damage may occur if the protective gloves when removing the spark plugs. incorrect spark plug is used. 2.27 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 47: Engine To Frame Ground

    • Tie Rod Ends • Steering Shaft U-Joints • Steering Gearbox RZR 4 Ground Terminal U-Joints Tie Rod Tie Rod Gearbox 2.28 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 48: Tie Rod End / Wheel Hub Inspection

    (A) - (B) = 1/8 - 1/4" (.3 to .6 cm) nuts or loose front hub nut). • Refer to Chapter 7 “Final Drive” for front hub service procedures. 2.29 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 49: Wheel Toe Adjustment

    • Shorten or lengthen the tie rod until alignment is as required to achieve the proper toe setting as specified in “Wheel Toe Alignment”. 2.30 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 50: Suspension (Standard)

    Each notch of the adjustment will add 6% - 8% more Rear Shock preload to the spring over the primary position. 2.31 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 51: Shock Compression Adjustment

    Factory (RZR S) 8 clicks from closed Factory (RZR 4) 10 clicks from closed Shock Spanner Wrench Firmest 2 clicks from closed (PN 2870803) 2.32 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 52: Suspension (Walker Evans™)

    12 in. (30.5 cm) Setting Compression Damping Softest Full counter-clockwise position Factory 6 clicks from softest position Rear Shock Firmest Full clockwise position 2.33 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 53: Brake System

    Check brake system hoses and fittings for cracks, deterioration, abrasion, and leaks. Tighten any loose fittings and replace any worn or damaged parts. 2.34 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 54: Maintenance Log

    MAINTENANCE MAINTENANCE LOG Service Date Hours / Miles (km) Service Performed / Comments Dealer / Technician 2.35 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 55 MAINTENANCE NOTES 2.36 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 56 TROUBLESHOOTING........... 3.61 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual...
  • Page 57: Engine Specifications

    ENGINE ENGINE SPECIFICATIONS Crankcase Exploded Views 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 58: Oil Pump / Gears / Engine Cover

    ENGINE Oil Pump / Gears / Engine Cover Exploded View 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 59: Stator Cover / Starter / Water Pump / Lubrication System

    ENGINE Stator Cover / Starter / Water Pump / Lubrication System Exploded View 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 60: Cylinder / Cylinder Head / Piston

    ENGINE Cylinder / Cylinder Head / Piston Exploded View 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 61: Engine Efi Sensors / Valve Cover / General Components

    Engine EFI Sensors / Valve Cover / General Components Exploded View NOTE: See chapter 4 for more information on the EFI System 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 62: Engine Torque Specifications

    Water Pump Impeller Nut 8 mm 108 ± 3 (12 ± 0.35) NOTE: * See exploded views for notes or torque sequences. 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 63: 800 Efi Engine Service Specifications

    1.735" (46.069 mm) Valve Spring Intake - 1.4638" (37.18 mm) Valve Spring Overall Length - Installed Height Exhaust - 1.4736" (37.43 mm) 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 64 Side Clearance Connecting Rod Big End 0.0015" 0.0006" (0.038  0.015 mm) Radial Clearance Crankshaft Crankshaft Runout Limit 0.00236" (0.060 mm) 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 65: Special Tools

    CRANKSHAFT MAIN SEAL SAVER PA-45401 WATER PUMP SEAL SAVER  2870975 MITY VAC™ PRESSURE TEST TOOL PU-45778 OIL SYSTEM PRIMING TOOL 3.10 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 66: Engine Cooling System

    Cooling System Pressure Test Remove the hood from the front cab. 3.11 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 67: Cooling System Exploded View

    To Top Fitting on Filler Neck Coolant Flow Diagram Filler Neck Engine Water Pump Radiator Recovery Bottle Engine Cylinder Head Bypass Engine Thermostat Housing 3.12 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 68: Cooling System Bleeding Procedure

    The coolant may be hot and could cause severe injury or burns. 3.13 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 69: General Engine Service

    Oil Pressure at Idle: 6 psi Oil Pressure at 6000 RPM (Engine Hot): Minimum: 27 psi Standard: 31 psi Maximum: 35 psi 3.14 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 70: Oil Flow Chart

    The third oil path flows through a crankcase galley to the MAG side crankshaft journal and also to the front balance shaft journal and onto the crankcase sump. 3.15 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 71: Engine Removal

    Remove the driver’s seat (see Chapter 5). Disconnect (-) negative battery cable. Remove the passenger seat(s) and remove the rear service panel (see Chapter 5). 3.16 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 72 16. Remove the high tension leads from the spark plugs and disconnect the ignition coil harness. Harness Connection 3.17 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 73 The harnesses are different and can not be connected incorrectly (PTO - Gray; MAG - Black). 3.18 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 74 32. Disconnect the stator / alternator harness. Mark Upper Jam Nut Stator Connector Lower Jam Nut 3.19 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 75 This will prevent the lubricant from leaking out during removal. 3.20 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 76 NOTE: The use of an overhead or portable engine hoist is the only recommended method for removing and installing the engine / transmission / rear gearcase assembly. 3.21 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 77 49. Lift the front portion of the assembly out first to allow the engine valve cover to clear the vehicle frame. Standard RZR Shown Allow valve cover to clear frame 3.22 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 78: Engine / Transmission Separation

    Carefully separate the engine and perform the required service (see “Engine Disassembly and Inspection”). Remove only the (4) outer fasteners retaining the engine to the transmission bracket. 3.23 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 79: Engine Disassembly And Inspection

    Retainer Locks (keepers) Push Rods Spring Retainers Springs Valve Seals (2) Valve Spring Seats (2) Coolant Bleeder Cylinder Head Hydraulic Lifters 3.24 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 80: Rocker Arms / Push Rods

    Push rods can also be checked with a dial indicator or rolled across a flat surface to check for straightness. 3.25 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 81: Cylinder Head Inspection / Warp

    Remove spring retainer and spring. The valve seals are now serviceable. 3.26 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 82: Cylinder Head Disassembly

    Valve Spring Free Length = In. / mm. Valve Spring Free Length: Std: 1.735" (44.069 mm) 3.27 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 83: Valve Inspection

    Compare to specifications. individually. Measure valve stem in several places. Rotate the valve 90 degrees and measure for wear. 3.28 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 84: Combustion Chamber

    Abrasive stone seat reconditioning equipment can also be used. Keep all valves in order with their respective seat. 3.29 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 85 Clean all filings from the area with hot soapy water. Rinse and dry with compressed air. 3.30 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 86: Cylinder Head Reassembly

    NOTE: To prevent damage to the valve seals, do not compress the valve spring more than necessary to install the keepers. 3.31 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 87: Valve Sealing Test

    If replacing the lifters, the camshaft should also be replaced. 3.32 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 88: Piston Removal

    Do not scratch the ring lands. Repeat procedure for second ring. Remove the oil control ring. 3.33 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 89: Cylinder Inspection

    Cylinder Warp: .004" (0.1 mm) Max. Standard Bore Size Inspect cylinder for wear, scratches, or damage. (Both Cylinders): 3.1496" (80 mm) 3.34 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 90: Cylinder Hone Selection And Honing Procedure

    NOTE: Do not allow cylinder to heat up during honing. • After honing has been completed, inspect cylinder for thinning or peeling. 3.35 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 91: Piston-To-Cylinder Clearance

    See “800 EFI Engine Service Specifications” on page 3.8 Piston Pin Bore: See “800 EFI Engine Service Specifications” on page 3.8 3.36 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 92: Piston Ring Installed Gap

    IMPORTANT: A difference in end gap indicates cylinder taper. The cylinder should be measured for excessive taper and out of round. 3.37 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 93: Flywheel / Stator Removal / Inspection

    (A). CAUTION Do not thread the puller bolts into the flywheel more than 1/4, or stator coils may be damaged. 3.38 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 94 1/4, or stator coils may be damaged. Note the position of the gears in the photo. Camshaft Gear 2871043 Crank Gear Counterbalance Gear 3.39 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 95 • While holding both gears together, lightly work a small flathead screwdriver between the two gears. • Remove the top gear. The springs should stay in place. 3.40 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 96 Push the gears back together, using both hands and hold securely. Align Timing Marks PU-45497-1 3.41 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 97 2871043 PU-45497-2 NOTE: For ease installing Gear Alignment Tool (PU-45497-2), use a twisting motion when pushing down on the tool. 3.42 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 98 Measure the gap between the two rotor tips as shown below. The clearance should not exceed 0.006" (0.15 mm). Max Tip Clearance 0.006” (0.15 mm) 3.43 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 99 33. Place the shaft in a press to remove the bearing. Press Off Bearing 3.44 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 100 Loctite This will prevent any possible damage to the bolts or to the crankcase casting. 3.45 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 101: Camshaft Inspection

    41. Remove and inspect crankshaft main journal bearings for Exhaust (Std.): abnormal wear. It is recommended to replace the 1.342” (34.096 mm) bearings anytime the engine is disassembled. 3.46 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 102: Engine Reassembly

    NOTE: Replace the engine crankcase assembly if camshaft journal bores are damaged or worn excessively. 3.47 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 103 Apply Crankcase Sealant (PN 2871557) to the top gearcase halve. NOTE: Do not apply sealant to cam relief hole (E). 3.48 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 104 12 O'clock position. 2. Second Ring 1. Top Ring 3. Oil Ring Piston Pin Cirlcip in 12 O’clock position 3.49 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 105 Primer N (PN 2874275) to remove any debris. This will ensure proper sealing when installing bolts and new Loctite™. 3.50 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 106 “This Side Out". This indicates the side of the gear that faces outward or away from the case. 3.51 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 107 Counterbalance Gear and Camshaft Gear Bolt Torque: 22  2 ft. lbs. (30  3 Nm) 3.52 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 108 Main Seal Installer (PA-45483) to seat the crankshaft lips to verify they have not been rolled or damaged. seal into place. PU-45543 PU-45658 PA-45483 3.53 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 109 PA-45401 PA-45658 Gear/Stator Housing Bolt Torque: 96  3 in. lbs. (10.85  0.35 Nm) *Torque in proper sequence 3.54 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 110 NOTE: There are thrust washers on both sides of starter drive. Water Pump Impeller Nut Torque: 108  6 in. lbs. (6.8  0.68 Nm) 3.55 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 111: Flywheel / Stator Installation

    Install the flywheel, washer, nut, and key. Torque flywheel nut to specification. 65 ± 7 ft. lbs. (88 ± 9.50 Nm) 3.56 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 112 3) Torque to 35 4 ft. lbs. in sequence 4) Tighten all head bolts in sequence another 90 or (1/4 turn). 3.57 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 113: Oil Pump Priming

    Rocker Cover Bolt Torque: cause internal engine damage on initial start-up. 84  8 in. lbs. (9.5  0.9 Nm) 3.58 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 114: Engine Installation

    Check for any possible rubbing points of electrical wires. • Carefully set the engine assembly into the vehicle while installing the propshaft. 3.59 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 115: Engine Break-In Period

    • Checks fluid levels: engine oil, transmission lubricant, and rear gearcase lubricant. • Bleed cooling system as described in this Chapter under “Cooling System Bleeding Procedure.” 3.60 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 116: Troubleshooting

    • Engine oil dirty or contaminated Engine Runs But Will Not Idle • Restricted fuel supply • Low compression • Crankcase breather restricted 3.61 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 117 Ignition or kill switch circuit faulty • Faulty pump shaft oil seal (oil leak) Poor connections in ignition system Ignition timing incorrect Sheared flywheel key 3.62 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 118 EFI SYSTEM ELECTRICAL OPERATION ........4.48 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual...
  • Page 119: General Information

    PU-47471 (PU-47470, PU-47469, PU-47468) Digital Wrench™ PU-47470 PC Interface Cable Digital Wrench™ PU-47469 Vehicle Interface Cable Digital Wrench™ PU-47468 SmartLink Module 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 120 Polaris dealers through our tool supplier SPX at (1-800-328- 6657) or http://polaris.spx.com Adaptor shown is included with kit. PU-47469 PU-47468 PU-47470 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 121: Service Notes

    • Always unplug ECU from the wire harness before performing any welding on the unit. 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 122: Efi System Exploded View

    7. Fuel Rail 8. Engine Coolant Sensor (ECT) 9. Throttle Position Sensor (TPS) 10. Throttle Body 11. Ignition Coil 12. Spark Plugs 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 123: Efi System Component Locations

    (RZR 4). Fuel Pump Assembly T-MAP RZR / RZR S Shown 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 124 TPS. 11. Ignition Coil - Located behind the rear service panel just above the outer PVT cover. Throttle Body Ignition Coil 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 125: Fuel Tank

    Exploded View Fuel Flow Fuel Injectors Fuel Rail Fuel Tank Pressure Regulator Fuel Pump Assembly Fuel Filters Quick Connect Fuel Line 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 126: Fuel Lines - Quick Connect

    Snap the fuel line back over the nipple and slide the locking mechanism back into place. Verify the connector tabs snap chamber, ignited and burned. back into place. 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 127: Initial Priming / Starting Procedure

    This process repeats it self in rapid succession, limiting operation to the preset maximum. 4.10 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 128: Temp / Manifold Absolute Pressure Sensor (T-Map)

    Remove the retaining bolt and remove the sensor from the intake boot. Use a light coating of soapy water on the grommet to aid installation of the new sensor. 4.11 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 129: Crankshaft Position Sensor (Cps)

    Black to Ground: 0 - 0.5  10% for each passing tooth. The ECU calculates engine speed from the time interval between the consecutive pulses. 4.12 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 130: Cps Replacement

    Remove the (3) bolts retaining the front portion of the mounting bracket to the transmission. Retain the bolts, washers, and spacers for installation. 4.13 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 131 Reinstall mounting bracket and hand tighten the (7) bolts. Torque ALL mounting bracket bolts to specification. Mount Bracket Bolt Torque: 23-27 ft. lbs. (31-37 Nm) 4.14 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 132 Middle Rear Gearcase Bolt Bottom Transmission Bolt 4.15 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 133: Fuel Injectors

    The ECU gathers fuel injection timing information from the Crankshaft Position Sensor and Camshaft Phase Sensor to allow for sequential fuel injection. 4.16 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 134: Fuel Injector Service

    NOTE: Be sure to connect like colored fuel injector connectors for proper engine function (PTO = GRAY, MAG = BLACK). 4.17 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 135: Fuel Injector Replacement

    Lubricate O-rings lightly with oil to aid installation. Torque the fuel rail mounting screw to specification. Fuel Rail Mounting Screw 216 +/- 24 in. lbs. (24 Nm) 4.18 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 136: Fuel Pump

    When the key switch is turned to "ON", the ECU activates the fuel pump, which pressurizes the system for start-up. 4.19 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 137: Fuel Pump Test

    NOTE: If the pump still does not operate, replace the switch off and depress the valve button on the tester to fuel pump assembly. relieve the system pressure. 4.20 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 138: Fuel Pump Replacement

    Properly drain fuel into a suitable container. NOTE: Apply downward force on the fuel pump flange while removing the fuel pump PFA nut. 4.21 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 139 11. Use cleaning wipes provided to clean fuel tank surface and threads. Remove all debris, grease and oil. Allow surfaces to dry completely. 4.22 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 140 22. Test the fuel pump by turning on the key and listening for the pump to activate. Cycle the key several times to prime the system. 4.23 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 141: Fuel Tank Removal (Rzr / Rzr S)

    (see Chapter 5). Disconnect the fuel pump electrical harness. Disconnect Here Remove RH Rocker Panel 4.24 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 142 4.25 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 143: Fuel Tank Removal (Rzr 4)

    NOTE: Remove the fuel tank cap and carefully lift the rocker panel up over the fuel tank filler neck. Remove the rocker panel from the vehicle. 4.26 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 144 NOTE: A small amount of fuel may come out of the fuel line or tank. Properly drain fuel into a suitable container. 4.27 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 145: Fuel Tank Installation

    Check for leaks. 12. Finally, install the rear service panel along with the seats. 4.28 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 146: Idle Air Control (Iac)

    2 - 3 5 - 6 60  ± 2.4  60  ± 2.4  1 - 3 4 - 6 4.29 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 147: Throttle Position Sensor (Tps)

    If the stop screw is repositioned or adjusted, the throttle body assembly must be replaced. 4.30 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 148: Tps Replacement

    Remove the seats, rear service panel and the rear cargo box (see Chapter 5). Loosen the hose clamps retaining the throttle body. 4.31 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 149 Securely tighten the hose clamps. 10. Reinstall cargo box, rear service panel and seats (see Chapter 5). 4.32 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 150: Camshaft Phase Sensor

    50 ± 5 in. lbs. (5.65 ± .55 Nm) NOTE: Use Digital Wrench™ Diagnostic Software (dealer only) if you suspect this sensor is faulty. 4.33 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 151: Engine Coolant Temperature Sensor (Ect)

    17 ft. lbs. (23 Nm) Add the required amount of coolant and properly bleed the cooling system (see Chapter 3). ECT Sensor 4.34 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 152: Ignition Coil

    6.7k  ± 5% Install the new ignition coil and/or high tension lead(s). Ignition Coil Retaining Bolt Torque: 75 in. lbs. (8.5 Nm) 4.35 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 153: Efi Diagnostics

    Voltage Too High P0118 Voltage Too Low P0117 Engine Temperature Sensor (ECT) Temperature Too High P0217 Engine Overheat Shutdown P1217 4.36 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 154 Steering Over Current Shut Down Current Above Normal or Grounded 520221 C1050 Steering Excessive Current Error Current Above Normal or Grounded 520222 C1051 4.37 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 155 Idle Air Control Valve (IAC) Driver Circuit Short to B+ 520270 P1539 M17; IAC Stepper Pin 6 Driver Circuit Grounded P1538 4.38 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 156: Efi Troubleshooting

    • Fouled spark plug • Throttle stop screw set incorrectly (out of sync with • TPS setting incorrect ECU) • Injector failure 4.39 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 157: Digital Wrench™ Operation

    Trouble Codes (that is, any fault that will turn on the ‘Check Engine’ indicator). In addition, guided diagnostics are also available for many other electrical sub systems. 4.40 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 158: Digital Wrench™ - Diagnostic Connector

    In this case, a newer update (04-27-09) is available and should be downloaded before using Digital Wrench™ (see “Digital Wrench™ Updates”). IMPORTANT: Always operate with the latest update. 4.41 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 159: Digital Wrench™ Updates

    Version: 3.1 04/27/09 install if you have version 3.0 or older on your PC. NOTE: Versions and updates are subject to change. 4.42 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 160: Digital Wrench™ Feature Map

    ELECTRONIC FUEL INJECTION Digital Wrench™ Feature Map 4.43 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 161: Engine Controller Reprogramming (Reflash)

    Verify the most current update has been downloaded and loaded into Digital Wrench™. See “Digital Wrench™ Version and Update ID” on page 4.41. 4.44 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 162 Click the “Continue” icon to obtain a Request Code. Select the “Special Tests” icon. 4.45 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 163 11. Enter or paste (CTRL+V) the Request Code into the box. Enter the “Request Code” Enter the “Authorization Key” 4.46 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 164 16. Once the ECU reprogramming procedure is complete, click the ‘Finish’ button on the screen. Verify the reflash was a success by starting the vehicle. 4.47 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 165: Efi System Electrical Operation

    ELECTRONIC FUEL INJECTION EFI SYSTEM ELECTRICAL OPERATION Block Diagram 4.48 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 166 EXPLODED VIEW ........... . . 5.35 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual...
  • Page 167 WALKER EVANS™ SHOCK ASSEMBLY ........5.59 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual...
  • Page 168: Torque Specifications

    38 ft. lbs. (52 Nm) M10 Bolts Outer Frame Coupler RZR 4 Push Rivet 17 ft. lbs. (23 Nm) M8 Bolts 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 169: Cab Frame (Rzr / Rzr S)

    Attach side bars to cab frame using M6 screws and nuts on top and M8 screws and nuts on the bottom. Tighten to 8-10 ft. lbs. (10.8-13.5 Nm). To remove the cab frame, reverse the assembly procedure (steps 1-5). 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 170: Cab Frame (Rzr 4)

    Fasten (1/4-20 x 3/4) Torx-head screws into lower portion of side bars through bracket slot. Tighten tap screws to 6-8 ft. lbs. (8-11 Nm). To remove the cab frame, reverse the assembly procedure (steps 1-5). 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 171: Body Exploded Views

    BODY / STEERING / SUSPENSION BODY EXPLODED VIEWS Side Safety Nets 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 172: Dash Instruments / Controls / Glovebox

    C. AWD/2WD or AWD/2WD/TURF Switch D. 12 Volt Accessory Receptacle E. Key Switch F. Hazard Switch (INT’L) G. Switch; Turn, Lights, Horn (INT’L) 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 173: Hood / Front Body Work

    Front LH Fender Flair Front RH Fender Flair T27 Screws Push Rivets Front Bumper Push Rivet Winch Pocket Cover T27 Screws 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 174 Screw Screw Headlight Winch Pocket Cover Rear Bumper LH Tail Light RH Tail Light Screw Speed Screws Nuts Rear Bumper Screws 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 175: Seat Assembly

    40 ft. lbs. (54 Nm) Latch Plunger Rear Seat Base 40 ft. lbs. 40 ft. lbs. (54 Nm) (54 Nm) 5.10 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 176: Seat Belts / Mounting (Rzr 4)

    Bumpers Latch Plunger Front Seat Base 40 ft. lbs. (54 Nm) 3 Point Seat Belts 40 ft. lbs. (54 Nm) 5.11 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 177: Floor / Rocker Panels (Rzr / Rzr S)

    Push Rivets U-Type Upper Floor Nuts Torx Screws Plastic Dart Screws RH Rocker Front Support Bracket Self-Tapping Screws Lower Floor 5.12 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 178: Floor / Rocker Panels (Rzr 4)

    Front Support Bracket U-Type Nuts Self-Tapping Torx Screws Self-Tapping Screw RH Rocker Screw Front Support Bracket Upper Floor Self-Tapping Screws 5.13 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 179: Rear Cargo Box / Fenders (Rzr / Rzr S)

    Service Panel Push Bolts Rivets Sound Cover Foam Foil Heat Shield Rear RH Panel Divider Screws Push Rivet Cargo Box Supports 5.14 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 180: Rear Cargo Box / Fenders (Rzr 4)

    Screws Screws Bolts Torx Screws Rear RH Fender Flair Push Rivet Foil Rear RH Floor Heat Shield Cargo Box Supports 5.15 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 181: Chassis / Main Frame (Rzr / Rzr S)

    Main Frame 15 ft. lbs. 17 ft. lbs. (20 Nm) (23 Nm) Skid Plate Washer 6-8 ft. lbs. (8-11 Nm) 5.16 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 182: Chassis / Main Frame (Rzr 4)

    (52 Nm) Fuel Tank Skid Plate Front Frame Bracket Self-Tapping Washers Screws Front Skid Plate Coupler 6-8 ft. lbs. (8-11 Nm) 5.17 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 183: Body Component Removal

    Disconnect the front head lamp connectors and remove the front bumper from the vehicle. 5.18 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 184: Rear Bumper

    Push Rivets Tilt the hood back to disengage the front tabs and remove Torx the hood from the vehicle. Screws 5.19 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 185: Rear Fender, Flair And Tie Down Removal

    (RZR-S/RZR-4) and remove the fender flair. Disconnect Harness Tie-Down Airbox Torx Push Screws Rivet Fender Fender Push Standard RZR Flair Rivets Shown 5.20 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 186: Rocker Panels, Console And Floor

    11. Remove the rear floor from the vehicle. Remove the Torx screws retaining the rear portion of the floor and remove the lower floor from the vehicle. 5.21 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 187: Steering Assembly

    17 ft. lbs. 17 ft. lbs. (23 Nm) (23 Nm) 12-14 ft. lbs. (16-19 Nm) Tie Rod Cotter Pin Rod End 5.22 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 188: Steering Wheel Removal (Non-Eps Models)

    Remove the steering shaft, pivot tube and steering wheel from the vehicle as an assembly. Refer to steps 11-13 of the “Steering Shaft Bearing Replacement” procedure for installation. 5.23 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 189: Steering Shaft Bearing Replacement

    NOTE: Bearings will be seated in the pivot housing upon tightening the steering wheel nut in step 14. 5.24 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 190: Electronic Power Steering Assembly

    17 ft. lbs. 17 ft. lbs. (23 Nm) (23 Nm) 12-14 ft. lbs. (16-19 Nm) Rod End Tie Rod Cotter Pin 5.25 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 191: Upper Steering Shaft Removal (Eps Models)

    Remove the fastener retaining the upper portion of the steering wheel tilt shock to the pivot tube. Swing the shock down out of the way. Remove 5.26 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 192: Steering Wheel Removal (Eps Models)

    Power Steering Fault. Disconnect the (2) electrical harnesses from the power steering unit. Remove Place the assembly in a vise. 5.27 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 193 Remove Carefully remove the power steering unit and mount bracket from the vehicle as an assembly. 5.28 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 194: Power Steering Unit Installation

    Install the power steering unit and reassemble the vehicle (see “Power Steering Unit Installation” procedure). Lower Steering Shaft Pinch Bolt: 17 ft. lbs. (23 Nm) 5.29 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 195: Upper Steering Shaft Installation (Eps Models)

    NOTE: Be sure upper steering shaft hardware is Turn the key switch on and test EPS operation. positioned correctly (see “Exploded View’). 5.30 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 196: Front A-Arms

    (F) and remove the lower A-arm from the vehicle. 17. Examine A-arm bushings and pivot tube (see “Exploded Standard RZR Shown View”). Replace if worn. Discard hardware. 5.31 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 197: Exploded View

    A-arm Grease Zerk Grease Zerk Pinch Bushing Pinch Bolts Bolts Ball Joint CV Shield CV Shield Screws Ball Joint Screws 5.32 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 198: Ball Joint Service

    - Inside diameter cannot be any smaller than 1.375 in. (3.49 cm). - Driver must be at least 3 in. (7.62 cm) tall. 5.33 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 199: Installation

    Remove the (2) upper radiator retaining bolts. Repeat the ball joint service procedure for any additional A-arm ball joint replacements. 5.34 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 200: Exploded View

    RZR: 30 ft. lbs. (41 Nm) RZR S INT’L: 37 ft. lbs. (50 Nm) Mount Front Shock Bracket RZR S INT’L 5.35 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 201: Rear A-Arms

    Examine bushings and pivot tubes (see “Exploded View”). If not replacing the A-arm, thoroughly clean the a-arm and Replace if worn. Discard hardware. pivot tubes. 5.36 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 202: Installation

    Examine bushings and pivot tubes (see “Exploded View”). RZR S / RZR 4: 40 ft. lbs. (54 Nm) Replace if worn. Discard hardware. 5.37 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 203: Exploded View

    Lower Tube A-arm Bushings Bearing Pivot Carrier Tube Screws Lower Shield Pivot Fastener Tube Screws Bearing Carrier Lower Shield Fastener 5.38 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 204: Rear Stabilizer Bar (Rzr)

    (24 Nm) Bracket Remove the (4) fasteners retaining the stabilizer bar bracket to the frame. 17 ft. lbs. Bushing (23 Nm) 5.39 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 205: Rear Stabilizer Bar (Rzr S / Rzr 4)

    Bushings Bracket Remove 18 ft. lbs. (24 Nm) Linkage Remove the (4) fasteners retaining the stabilizer bar to the bracket. 5.40 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 206: Decal Replacement

    Retainer gap should be 180° from spring end 5.41 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 207: Exploded View (Rzr 4)

    Reverse the procedure to reinstall the shock. Torque new fasteners to specification (refer to exploded views). 5.42 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 208: Fox™ Shock Exploded Views

    Piston Asm, Floating (IFP) Damping Adjust Asm., Piston Valving Asm. Damping Adjust Asm., Concentric Adjuster Bearing Asm. Screw Asm. Bumper 5.43 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 209: Fox™ 2.0 'Piggyback' Shock (Rzr 4)

    2 or 3 Plate, Back-Up Bearing, Spherical Lock Nut Retaining Ring Reservoir Decal Piston Asm, Floating (IFP) Shock Oil (2870995) 5.44 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 210: Fox™ Shock Service

    0.700 x 0.010 0.620 x .093 Back-Up 0.875 x .100 Back-Up 1.125 x .093 Top-Out Piston Orifice: 2x 0.070 Piston Orifice: 0.098 5.45 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 211 0.900 x 0.015 1.570 x 0.128 Top-Out 0.800 x 0.015 Piston Orifice: 2x 0.070 1.125 x .093 Top-Out Piston Orifice: 0.081 5.46 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 212: Fox™ Shock Rebuild Information

    8. 1.834 TC Seal Kit 30. Cleaning Solvent 9. 5wt. Shock Fluid 31. Vise with soft jaws 32. Tape Measure 5.47 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 213: Fox™ Shock Disassembly

    11. When the shock is fully discharged, pull reservoir away from the FOX™ Safety Needle in a straight, smooth motion. 5.48 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 214 16. Clamp the body cap of the shock securely in vise with the open end of the body tube pointing up. 5.49 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 215: Fox™ Shock Rebuild

    This can scratch the surface of the seal groove which will compromise the performance and reliability of the shock absorber. Figure 10 5.50 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 216: Fox™ Shock Reassembly

    Lubricate the new IFP O-ring with an ample amount of assembly lube. 11. Using the IFP Depth Setting Tool, push the IFP into the reservoir until it stops. 5.51 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 217 This opens the valves on the damping piston. You will see the released air bubbles come to the surface of the oil. 5.52 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 218 200 psi (Fig. 19). suspension is performing correctly. 5.53 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 219: Walker Evans™ Shock Exploded View

    Nut, Crimp Wear Band, Piston Loop, Shaft Screw, Bleed Bearing O-Ring Piston O-Ring, Stud Screw Ball, Detent Stud, Clicker Spring, Detent 5.54 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 220: Walker Evans™ Shock Service

    .625 x .065 1.50 x .215 1.50 x .125 Piston Bleed Orifice: .052 Piston Bleed Orifice: .086 5.55 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 221: Walker Evans™ Shock Rebuild Information

    The face of the piston with the greater number of relief ports will always face the rebound valve stack = Relief Port Faces Rebound Stack Faces Compression Stack 5.56 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 222: Walker Evans™ Shock Disassembly

    Remove the valve cap from the end of the reservoir. Carefully depressurize the shock. 5.57 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 223 15. Inspect the piston wear band and replace if damaged or worn. PS-45908 11. Clean and inspect ALL parts and replace as needed. 5.58 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 224: Walker Evans™ Shock Assembly

    IMPORTANT: If unsure of the valve stack order, refer to “Shock Valving” under the “Shock Service Information” provided earlier in this section. 5.59 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 225 • Be sure to bottom out the piston in the reservoir body. • Allow time for the bubbles to dissipate. • Repeat the process until all the air has been removed. 5.60 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 226 24. Pour the residual shock oil out of the reservoir into a proper disposal container. 5.61 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 227 200 psi. suspension is performing correctly. Nitrogen Pressure: 200 psi (1379 kPa) 5.62 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 228 TROUBLESHOOTING........... 6.24 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual...
  • Page 229: Special Tools And Supplies

    At lower RPM, the drive belt rotates low in the drive clutch sheaves. As engine RPM increases, centrifugal force causes the drive belt to be forced upward on drive clutch sheaves. 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 230: Driven Clutch Operation

    (see Chapter 3 “Engine Break-In Period” for break-in example). Pull only light loads. Avoid aggressive acceleration and high speed operation during the break-in period. 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 231: Overheating / Diagnosis

    IMPORTANT: Using High gear for heavy loads, hilly terrain, or in wet, muddy conditions will increase the chance of drive belt burning. 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 232: Pvt System Service

    Boot Outlet Duct Cover Screws Clamp Clamps Bolt & Washer Inner Clutch Cover Retainer Outer Screws Outer Cover Seal Clutch Cover 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 233: Pvt Disassembly

    Remove the driven clutch retaining bolt and driven clutch. Remove driven clutch offset spacers from the transmission input shaft. Keep Spacers In Order (Note Thickness) Seat Base Retaining Bolt 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 234: Pvt Assembly

    Apply a light film 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). 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 235: Clutch Offset Procedure

    40 ft. lbs. (54 Nm). • .030" Offset Washer - PN 7556454 • .060" Offset Washer - PN 7556120 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 236 The belt should now be resting evenly between the drive clutch stationary and moveable sheaves. Inspect the outer clutch cover gasket. Replace if damaged. 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 237: Drive Belt

    Inspect belt for loose cords, missing cogs, cracks, abrasions, thin spots, or excessive wear. Compare belt measurements with a new drive belt. Replace if necessary. 6.10 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 238: Drive Clutch Service

    Red / White .200" 2.58" 7043372 Red / Blue .187" 2.56" 7043382 Red / Green .177" 2.63" 7043594 Black .177" 2.80" 6.11 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 239: Shift Weights

    Cover Bearing Bolt Spider Bearing Non-Braking Flat Spacer Bearing Washer Cover Button Screws Roller Button Washers Bolt Shift Washers Weight 6.12 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 240: Clutch Disassembly

    Spider Removal Tool: brass than Teflon is visible on (PN 2870341) the bushing. Refer to bushing replacement in this chapter. 6.13 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 241: Roller, Pin, And Thrust Washer Inspection

    Replace the cover bushing if more brass than Teflon is visible on the bushing. Refer to bushing replacement in this chapter. 6.14 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 242: Button To Tower Clearance Inspection

    The contact surface of the weight should be smooth and free of dents or gall marks. 6.15 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 243: Clutch Inspection

    Service Limit: .025” (.64 mm) Size of bearing may differ from what is shown 6.16 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 244: Moveable Sheave Bushing Inspection

     each bushing. Clean all residual Loctite from bushing bore prior to installing new bushing. 6.17 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 245 Remove sheave from puller. Install removal tool (Item A, B) into center of sheave with 10. Remove installation tool. “A side" toward sheave. 6.18 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 246: Clutch Assembly

    Turn clutch cover counterclockwise on puller rod until bushing is seated. Remove nut from puller rod. Take installation tool and clutch cover off rod. 6.19 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 247 Reinstall cover, aligning “X” mark with other marks. Torque cover bolts evenly to specification. Cover Screw Torque: 90 in. lbs. (10.4 Nm) 6.20 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 248: Driven Clutch Service

    Outer Spring Retainer NOTE: Spring is compression only and has no torsional wind. 6.21 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 249 Inspect for Abnormal Wear Moveable Sheave Bearing Inspection: Replace the clutch assembly if more brass than Teflon™ is visible on the bearing. 6.22 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 250: Clutch Assembly

    Carefully install the snap ring. Compress the outer retainer and install the snap ring. Snap Ring 6.23 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 251: Troubleshooting

    Belt burnt, thin spots -Dragging brake -Inspect brake system. -Fast, effective use of throttle for efficient engagement. -Slow, easy clutch engagement 6.24 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 252 -Replace belt. Refer to belt burnt troubleshooting and Engagement instruct operator. erratic or stabby -Drive clutch bushings stick -Inspect and repair clutches. 6.25 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 253 CLUTCHING NOTES 6.26 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 254 WHEEL HUBS ............7.55 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual...
  • Page 255: Special Tools

    27 ft. lbs. (37 Nm) Castle Nut Cone Washers Cotter Pin Remove the fastener retaining the steering tie rod end to the front bearing carrier. 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 256: Bearing Replacement

    12. Replace bearing if moisture, dirt, corrosion, or roughness is evident. 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 257: Bearing Carrier Installation

    Install the upper and lower ball joint ends into the front bearing carrier. Cone Washers Wheel Install brake caliper mounting bolts and torque to specification. RZR / RZR S Shown 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 258 Torque the tie rod end fastener to specification and install a new cotter pin. Tie Rod End Fastener: 42.5 ft. lbs. (58 Nm) 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 259: Front Drive Shaft

    CAUTION: Do not hang the caliper by the brake line. Use wire to hang caliper to prevent damage to the brake line. Remove the front wheel hub assembly. 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 260: Drive Shaft / Cv Joint Handling Tips

    NOTE: If using a brass drift, be sure to tap on the Outer CV Joint Capacity: 80g inner race of the joint only. 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 261: Inner Plunging Joint / Boot Replacement

    11. Install a NEW circlip on the end of the shaft. 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 262 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 263: Drive Shaft Installation

    Install washers with domed side out. Cone Washers Wheel RZR / RZR S Shown Install the upper ball joint end into the front bearing carrier. 7.10 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 264: Propshaft Service

    NOTE: You may have to loosen the front gearcase directions. mounting bolts to allow for propshaft removal. 7.11 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 265: Removal / Installation (Rzr 4)

    Remove the retaining screw and the gear selector handle. Slide the front portion of the propshaft back and away from the front gearcase to remove it. 7.12 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 266: Support Bearing Replacement (Rzr 4)

    Support Bearing Fasteners: 16-18 ft. lbs. (22-24 Nm) 14. When installing the front portion of the propshaft, use a NEW roll pin. 7.13 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 267: Propshaft U-Joint Service

    10. Install the front portion of the propshaft onto the front grease and install a NEW roll pin. 11. Reinstall the center console, selector handle and front seats. 7.14 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 268 If the joint is stiff or binding, tap the yoke lightly to center the joint until it pivots freely. 7.15 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 269: Front Gearcase / Centralized Hilliard

    Gearcase Housing Fill Plug Clutch Housing (Ring Gear) Drain Plug, Magnetic Roll Cage Retaining Ring, External Hub / Race Assembly 7.16 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 270: All Wheel Drive Operation

    Centers Roll Cage and Rollers in Ring Gear Output Hubs Ring Gear Torsion Roll Cage Spring & Rollers 7.17 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 271: Awd Diagnosis

    See the following illustrations: Check for wear bands Armature Plate 7.18 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 272: Gearcase Removal

    Remove the (4) bolts securing the front gearcase to frame. Remove Vent Line Disconnect Harness Gearcase image is for reference only. Remove 4 Bolts 7.19 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 273 Remove and inspect the armature plate. Refer to “AWD Diagnosis” for detailed inspection process. Remove as an assembly Armature Plate 7.20 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 274 13. Inspect clutch housing ring gear (C) for a consistent wear pattern. Inspect the ring gear for chipped, broken, or missing teeth. Inspect 7.21 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 275: Gearcase Assembly

    Check each for excessive wear or damage. Carefully install the rollers into the roll cage assembly while installing the assembly into the clutch housing. 7.22 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 276 10. Carefully install the ring gear and roll cage assembly into the gearcase housing. Align during installation 7.23 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 277: Gearcase Installation

    30 ft. lbs. (41 Nm) Cover Plate Screws: 7-11 ft. lbs. (10-15 Nm) Front Gearcase Mounting Bolts: 30 ft. lbs. (41 Nm) 7.24 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 278 Chapter 2 for fluid fill and change information. Polaris Demand Drive Plus (PN 2877922) Front Housing Capacity 6.75 fl. oz. (200 ml) 7.25 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 279: Rear Bearing Carrier

    Remove Rotate bearing by hand and check for smooth rotation. Visually inspect bearing for moisture, dirt, or corrosion. 7.26 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 280: Bearing Replacement

    Inspect the bearing carrier housing for scratches, wear or Control Arm Pivot Tube damage. Replace rear bearing carrier if damaged. Bushing 7.27 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 281: Bearing Carrier Installation

    RZR: 38 ft. lbs. (52 Nm) RZR S / RZR 4: 40 ft. lbs. (54 Nm) Apply grease to drive shaft axle splines. 7.28 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 282: Rear Drive Shaft

    Wear eye protection when removing bearings and seals. Remove the (4) wheel nuts and remove the rear wheel. 7.29 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 283: Outer Cv Joint / Boot Replacement

    Brass Drift Shown Inspect the axle splines and CV boots for any damage. IMPORTANT: Tap on inner race only! 7.30 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 284 7.31 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 285 Axle Boot Clamp Tool: PU-48951 CV Boot Clamp Pliers: 8700226 Axle Boot Clamp Tool: PU-48951 CV Boot Clamp Pliers: 8700226 7.32 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 286: Inner Plunging Joint / Boot Replacement

    IMPORTANT: Tap on inner race only! 7.33 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 287 16. Pull on the joint to test that the circlip is seated and that the joint is securely fastened to the shaft. CV Boot Clamp Pliers: 8700226 7.34 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 288: Drive Shaft Exploded View

    Boot Kit Grease Pack Large Clamp Spring Ring CV Joint Slide the rear drive shaft into the rear bearing carrier. 7.35 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 289 Steel Wheels: 27 ft. lbs. (37 Nm) Aluminum Wheels: 30 ft. lbs. + 90° (1/4 turn) 18 ft. lbs. 24 (Nm) 7.36 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 290: Rear Gearcase

    (see photo). Remove Remove Suspension Plate Remove Remove the (4) fasteners and remove the rear mount from the rear gearcase. Remove 7.37 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 291: Gearcase Disassembly

    Remove the remaining cover screws from the rear gearcase. Remove the ring gear/axle spool assembly. The bearings are a slip-fit and will slide off the axel spool. 7.38 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 292 NOTE: In the event damage to the gears, pinion bearings or housing requires replacement, the entire assembly must be replaced. 7.39 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 293: Gearcase Assembly

    O-ring in the gearcase cover. WARNING Wear the appropriate safety equipment while installing bearing races to reduce the risk of injury. 7.40 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 294: Gearcase Installation

    Drain Plug - 30-45 in. lbs. (3-5 Nm) Cover Screws: Fill Plug - 40 ft. lbs. (54 Nm) 23-27 ft. lbs. (31-37 Nm) 7.41 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 295: Gearcase Exploded View

    Screw, Flange Head Assembly, Rear Housing, RH Screw Dowel Assembly, Tapered Roller Bearing Plug, Drain w/O-Ring Shim Plug, Fill w/O-Ring 7.42 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 296: Rear Gearcase (Rzr S Int'l)

    Shift Yoke plunger extends Clutch Gear to disengage the clutch gear and unlock the differential. Differential - Lock 7.43 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 297: Gearcase Removal

    Remove the (2) rear gearcase mount bracket fasteners and mount bolt and remove bracket from vehicle. Unlocked Axle Shaft Axle Shaft 7.44 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 298: Gearcase Disassembly

    Remove the vent line and lift the rear gearcase upward and on its side to remove it from the vehicle. 7.45 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 299 Inspect the bearing for smoothness and wear. Remove the shim(s) from the differential assembly. Be sure to keep the shims together for reassembly. 7.46 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 300 11. Remove the pinion shaft seal using a seal puller or other suitable method. 7.47 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 301 OEM tooling in order to properly reassemble. If there is any damage to the pinion gear, bearings or case, the gearcase assembly must be replaced. 7.48 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 302: Differential Disassembly

    With the roll pin removed, slide the cross pin out and Remove the upper differential gear. remove the remaining differential gears. 7.49 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 303: Differential Assembly

    Install the ring gear and torque the retaining bolts to Install the lower differential gear and thrust washer. specification. Ring Gear Bolts: 70-80 ft. lbs. (95-108 Nm) 7.50 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 304: Gearcase Assembly

    Install new seals into the gearcase housing and gearcase cover using a standard seal installer or other suitable method. Install a new O-ring in the gearcase cover. 7.51 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 305 13. If previously removed, install the differential solenoid. Torque the solenoid to 30-40 ft. lbs. (41-54 Nm). 30-40 ft. lbs. (41-54 Nm) 7.52 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 306: Gearcase Installation

    Drain / Fill Plug: Drain Plug - 30-45 in. lbs. (3-5 Nm) Fill Plug - 40 ft. lbs. (54 Nm) 7.53 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 307: Gearcase Exploded View

    Thrust Washer, Side Gear Cover Asm., Rear Case, Diff Half Screw Pin, Diff, Cross Seal, Oil Pin, Spring Screw, Flanged 7.54 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 308: Wheel Hubs

    Brake Disc Studs Castle Nut 80 ft. lbs. Wheel Nuts (108 Nm) 27 ft. lbs. (37 Nm) Rear Rim (Steel) 7.55 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 309 FINAL DRIVE NOTES 7.56 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 310 TRANSMISSION EXPLODED VIEW........8.19 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual...
  • Page 311: Torque Values / Specifications

    (shifter, cable, console, shift knob). Tighten the shift cable nut to specification. Shift Cable Nut Torque: 130-155 in. lbs. (14.7-17.5 Nm) 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 312: Shift Cable Inspection / Adjustment

    If adjustment is required, loosen the lower jam nut and pull the cable out of the mount to move the upper jam nut. Upper Jam Nut Lower Jam Nut 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 313: Transmission Service

    Remove the screws from the transfer case cover and remove the cover (note position of the longest screw #4). Transfer Case Transmission Gearcase Drain Plug Drain Plug 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 314 12. Output shaft bearing cup is a slip-fit. Remove, note and record the number and thickness of shims and set aside. Note the alignment dowels (circled) in the cover for installation. 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 315 14. Remove the upper snap ring from the top side of the 21T main pinion gear and remove the gear. 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 316: Transfer Case Reassembly

    Install the front output pinion shaft assembly. NOTE: Bearing is pressed onto the shaft Output Pinion Shaft Bracket Screws: 23-27 ft. lbs. (31-37 Nm) 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 317 2871557 Apply Sealant PN 2871557 To Case Mating Surfaces Mount Bracket Fasteners: 23-27 ft. lbs. (31-37 Nm) 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 318: Transmission Shift Housing Disassembly

    Remove the reverse clutch gear assembly from the housing. Note the orientation of the needle bearing. Inspect these components and replace if needed. 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 319 NOTE: The reverse idler shaft is a non-serviceable item and should not be pressed out of the housing. 8.10 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 320 18. Remove the sliding shoes from the clutch yoke. 8.11 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 321 Inspect the gears for damage and/or wear. Replace the shaft if required. 21. Remove the set screw retaining the pivot pin. 8.12 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 322: Transmission Shift Housing Reassembly

    Assemble the input shaft with new ball bearings (if required). NOTE: Install new bearings and seals by pressing on the outer edge only. 8.13 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 323 Install the clutch shaft into the transmission housing. Install the sliding shoes onto the clutch yoke. Install the pivot pin set screw and torque to specification. 8.14 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 324 Detent Sleeve Assembly: 40-45 ft. lbs. (54-61 Nm) Outer Detent Screws: 23-27 ft. lbs. (31-37 Nm) 8.15 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 325 16. Install the park flange and torque the (5) screws to specification. Park Flange Screws: 130-155 in. lbs. (15-18 Nm) 8.16 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 326 23. Proceed with transfer case reassembly. See “Transfer Case Reassembly” on page 8.7 Shift Housing Screws: 23-27 ft. lbs. (31-37 Nm) 8.17 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 327: Troubleshooting

    (rounding), damage. Inspect all bearings, circlips, thrust washers and shafts for wear. 8.18 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 328: Transmission Exploded View

    TRANSMISSION TRANSMISSION EXPLODED VIEW Shift Housing / Transfer Case Exploded View 8.19 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 329 TRANSMISSION NOTES 8.20 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 330 TROUBLESHOOTING........... 9.24 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual...
  • Page 331 Front Brake Disc to Hub Bolts Rear Brake Disc to Hub Bolts Brake Switch 12-15 16-20 Master Cylinder to Frame Brake Pedal Mounting Bracket to Frame 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 332: Brake System Service Notes

    Noise is from other source (axle, hub, disc or wheel) sources. Inspect and repair as necessary Wrong pad for conditions Change to a softer or harder pad 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 333: Hydraulic Brake System Operation

    Never overfill the reservoir! Do not fill the reservoir beyond the MAX LEVEL line! When servicing Polaris brake systems use only Polaris DOT 4 Brake Fluid (PN 2872189). WARNING: Once a bottle is opened, use what is necessary and discard the rest in accordance with local laws.
  • Page 334: Brake System Exploded View

    Brake Line 47 in. lbs. (5.3 Nm) 15 ft. lbs. All Flare Style Fittings: (20 Nm) 12-15 ft. lbs. (16-20 Nm) 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 335: Master Cylinder

    .090” (2.28 mm) CAUTION Brake fluid will damage finished surfaces. Do not allow brake fluid to come in contact with finished surfaces. 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 336: Brake Bleeding / Fluid Change

    Attach a clean, clear hose to fitting and place the other end in a clean container. Be sure the hose fits tightly on fitting. 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 337: Front Brake Pads

    Remove excess fluid from reservoir as required. 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 338 Shown Service Limit: .180” (4.6 mm) 31-34 ft. lbs. (42-46 Nm) Front Caliper Mount Bolt Torque: 31-34 ft. lbs. (42-46 Nm) 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 339: Brake Burnishing Procedure

    Repeat this procedure 10 times. Do not make more than 3 stops per 1 mile (1.6 km). 9.10 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 340: Front Caliper Service

    C. Caliper Assy. D. Boots E. Square O-rings F. Pistons G. Caliper Mount H. Brake Pads I. Brake Scraper J. Bolts 9.11 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 341: Caliper Removal

    RZR 4 Shown Remove Brake Line Remove RZR / RZR S Remove Brake Line RZR 4 9.12 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 342: Caliper Disassembly

    Use a commercially available caliper piston pliers to extract the pistons from the caliper. Clean Components RZR 4 NOTE: Be sure to clean seal grooves in caliper body. 9.13 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 343: Caliper Inspection

    Inspect piston for nicks, scratches, pitting or wear. Measure piston diameter and replace if damaged or worn beyond service limit. 9.14 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 344: Caliper Assembly

    Install the brake line onto the caliper taking care not to RZR 4 allow any debris to enter the caliper. Install the caliper and torque the mounting bolts to specification. 9.15 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 345: Front Brake Disc

    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 limit. Measure Thickness Front Disc 9.16 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 346: Disc Replacement

    Clean the wheel hub mating surface and install new disc on wheel hub. Install new bolts and torque to 18 ft. lbs. (24 Nm). 18 ft. lbs. (24 Nm) 9.17 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 347: Rear Brake Pads

    NOTE: When removing caliper, be careful not to damage brake line. Support caliper so as not to kink or bend brake line. 9.18 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 348: Brake Burnishing Procedure

    Repeat this procedure 10 times. Do not make more than 3 stops per 1 mile (1.6 km). 9.19 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 349: Rear Caliper Service

    Place a container below the caliper to catch the brake fluid when removing the line. Remove brake line from caliper. Remove Brake Line 9.20 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 350 Clean the caliper body, piston, and retaining bracket with brake cleaner or alcohol. NOTE: Be sure to clean seal grooves in caliper body. Clean Components 9.21 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 351: Caliper Assembly

    Install the brake pads. Clean the disc and pads with brake parts cleaner or denatured alcohol to remove any dirt, oil or grease. 9.22 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 352: Caliper Installation

    Aluminum Wheels: 30 ft. lbs. + 90° (1/4 turn) NOTE: If new pads are installed, refer to “REAR BRAKE PADS - Brake Burnishing Procedure”. 9.23 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 353: Disc Replacement

    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. 9.24 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 354 CHARGING PROCEDURE..........10.29 10.1 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 355 ENGINE START (STARTER INTERLOCK) ....... . . 10.48 10.2 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 356: General Information

    • For resistance readings, isolate the component to be switch terminals. Re-test and replace switch if necessary. tested. Disconnect it from the wiring harness or power supply. 10.3 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 357: Headlamp Switch

    1 and 2; 4 and 5. NOTE: Pins 7 and 8 provide power and ground to light the switch lamp. 10.4 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 358: Ignition Key Switch (Int'l)

    • Turn the ignition key to START. There should be continuity between pins A and B; C and D; E and F. 10.5 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 359: Awd / 2Wd / Turf Switch (Int'l)

    1 and 2. • Move the switch to NONE / OFF. There should be no continuity between the switch legs. 10.6 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 360: Transmission (Gear Position) Switch

    Gear Position when measured at terminals A and B 620  HIGH 300  160  75  24  PARK 10.7 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 361: Rear Diff Solenoid (Int'l)

    CAUTION Do not power the solenoid with 12 Volts for more than 1 second, or damage may occur to solenoid. 10.8 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 362: Instrument Cluster

    Do not use alcohol to clean the instrument cluster. Do not allow insect sprays to contact the lens. Immediately clean off any gasoline that splashes on the instrument cluster. 10.9 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 363: Rider Information Display

    TURF position (INT’L Models Only). 12. Neutral Gear Indicator - LED icon illuminates when gear selector is in the neutral (N) position. 10.10 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 364 “OFF” is displayed. Engine temperature can be displayed in Fahrenheit or Celsius. Refer to “Units of Measurement” to change the format. 10.11 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 365 Press and hold the MODE button to save the setting and advance to the next display option. Repeat the procedure to change remaining display settings. 10.12 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 366: Diagnostic Mode

    • The third number (located bottom right) can be 1 to 2 digits in length. This number equates to the fault mode (FMI). 10.13 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 367: Instrument Cluster Pinouts

    Apply pressure on the bezel while pressing down on the instrument cluster. 10.14 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 368: All Wheel Drive Coil

    80% of all electrical issues are caused by bad/failed connections and grounds. 10.15 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 369: Headlamp Bulb Replacement

    (INT’L Only) also located in the headlamp housing. procedure in this section. NOTE: Make sure the tabs on the bulb locate properly in the housing. 10.16 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 370: Tail / Brake Lights

    Turn Signal Light Test the tail light, brake light and turn signal (INT’L Only) to verify it is working properly. 10.17 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 371: Cooling System

    ELECTRICAL COOLING SYSTEM Cooling System Break-Out Diagram 10.18 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 372: Coolant Temperature Sensor

    If none of the conditions exist, the fuel sender assembly is faulty. malfunctions the radiator fan will default to 'ON'. Replace the fuel pump assembly (see Chapter 4). 10.19 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 373: Fuse Box: Fuses / Relays / Circuit Breaker

    EFI system, drive system and electronic power steering. A separate 20-amp circuit breaker protects the fan motor circuit. 10.20 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 374: Fuse Box Detail

    ELECTRICAL Fuse Box Detail 10.21 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 375: Relay Operation

    Orange Red / White operation. constant battery voltage. Provides 12 Vdc power for EFI system Red / Dark Blue circuits. 10.22 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 376 Relay coil ground. Relay switched power to operate the Rear Diff Solenoid. Ground to energize the Rear Diff Blue Solenoid. 10.23 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 377: Charging System

    0.19 ± 15% Battery Charge Coil Y1 to Y3 0.19 ± 15% Battery Charge Coil Y2 to Y3 0.19 ± 15% 10.24 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 378: Regulator / Rectifier

    AC Voltage (VAC) Reading 1300 18 VAC ± 25 % 3000 42 VAC ± 25 % 5000 64 VAC ± 25 % 10.25 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 379: Charging System Testing Flow Chart

    10.26 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 380: Battery Service

    Refer to OCV table (see “OCV - Open Circuit Voltage Test”). Charge the battery as recommended (see “Charging Procedure”). 10.27 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 381: Battery Testing

    13.0 V 75% Charged 12.8 V 50% Charged 12.5 V 25% Charged 12.0 V 0% Charged 11.5 V or less 10.28 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 382: Battery Conductance Analyzer

    NOTE: Follow the charger instructions supplied by the manufacture regarding the order or connections, switch positions and when to connect the charger to an outlet. 10.29 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 383: Starting System

    Remove the starter from the engine. Remove the two bolts, washers, and sealing O-Rings. Inspect O-Rings and replace if damaged. 10.30 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 384: Brush Inspection / Replacement

    5/16” (8 mm) or less. The brushes must slide freely in their holders. Brush Length Limit 5/16” (8 mm) 10.31 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 385: Armature Testing

    Using a digital multitester, measure the resistance between each of the commutator segments. The reading should be 0.3 ohms or less. 10.32 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 386: Starter Drive

    (12 Nm). Then torque the top bolt to the same alignment pins and the back flange of the anti kick-out specification. shoes. 10.33 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 387: Starter Solenoid Bench Test

    • Once the pull-in coil is energized, the solenoid provides a current path for 12V power to reach the starter motor. 10.34 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 388: Starter Exploded View

    6. Brush Complete 16. Flange Bolt 7. O-Ring* 17. Thrust Washer 8. Thrust Washer 18. Flange Bushing 9. Shaft Complete 10.35 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 389: Starting System Testing Flow Chart

    If all of these indicate a good condition, yet the starter still fails to turn, the starter must be removed for static testing and inspection. 10.36 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 390: Electronic Power Steering (Eps)

    ATV and RANGER product lines. NOTE: See Chapter 5 “Body/Steering/Suspension” for power steering unit removal and installation procedures. 10.37 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 391: Eps System Breakout

    ELECTRICAL EPS System Breakout 10.38 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 392 ELECTRICAL EPS Troubleshooting (Power Steering Non-Functional with MIL ON) 10.39 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 393 ELECTRICAL EPS Troubleshooting (Power Steering Non-Functional with MIL OFF) 10.40 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 394: Eps Troubleshooting (Using Digital Wrench™)

    ELECTRICAL EPS Troubleshooting (Using Digital Wrench™) 10.41 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 395: Electrical System Breakouts

    ELECTRICAL ELECTRICAL SYSTEM BREAKOUTS Vehicle Speed Sensor 10.42 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 396: Cooling Fan

    ELECTRICAL Cooling Fan 10.43 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 397: Charging System

    ELECTRICAL Charging System 10.44 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 398: Chassis Power

    ELECTRICAL Chassis Power 10.45 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 399: Key-On Battery Power

    ELECTRICAL Key-On Battery Power 10.46 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 400: Electronic Power Steering (Eps)

    ELECTRICAL Electronic Power Steering (EPS) 10.47 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 401: Engine Start (Starter Interlock)

    ELECTRICAL Engine Start (Starter Interlock) 10.48 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc.
  • Page 402 Chassis (RZR / RZR S) ......5.16 Chassis (RZR 4) ....... 5.17 Air Filter Service .
  • Page 403 EFI System, Component Locations ....4.6 Engine, Flywheel Removal ..... . 3.39 EFI System, Electrical Layout .
  • Page 404 Fuel Pump Test ....... . 4.20 Fuel Sender Test ......4.19 10.19 Nets, Side .
  • Page 405 Rear Gearcase, Assembly (RZR S INT’L) ...7.51 Special Tools, Final Drive ......7.2 Rear Gearcase, Diff Assembly (RZR S INT’L) .
  • Page 406 Suspension, Spring Preload Adjustment (FOX) ..2.31 VIN Identification ....... 1.2 Suspension, Spring Preload Adjustment (Standard) .
  • Page 407 IX.6...
  • Page 408 RANGER RZR RANGER RZR S RANGER RZR 4 PN 9923142 Printed in USA...
  • Page 409 2011 RANGER RZR / RZR S...
  • Page 410 2011 RANGER RZR / RZR S...
  • Page 411 2011 RANGER RZR EPS...
  • Page 412 2011 RANGER RZR EPS...
  • Page 413 2011 RANGER RZR 4...
  • Page 414 2011 RANGER RZR 4...
  • Page 415 2011 RANGER RZR 4 EPS...
  • Page 416 2011 RANGER RZR 4 EPS...
  • Page 417 2011 RANGER RZR S INT’L...
  • Page 418 2011 RANGER RZR S INT’L...