Polaris 2009 Ranger RZR 800 EFI Sport UTV Manuals

Polaris 2009 Ranger RZR 800 EFI Sport UTV Manuals

Manuals and User Guides for Polaris 2009 Ranger RZR 800 EFI Sport UTV. We have 1 Polaris 2009 Ranger RZR 800 EFI Sport UTV manual available for free PDF download: Manual

Polaris 2009 Ranger RZR 800 EFI Manual

Polaris 2009 Ranger RZR 800 EFI Manual (332 pages)

Brand: Polaris | Category: Utility Vehicle | Size: 19 MB

Table of Contents

General Information Chapter

1
- Table of Contents
  1
- Chapter 1
  2
- Engine Designation Number
  2
- Engine Serial Number Location
  2
- Model Identification
  2
- Model Information
  2
- Vin Identification
  2
- Unit Serial Number (Vin) Location
  3
- Special Tools
  4
- Vehicle Information
  4
  - Publication Numbers
    4
  - Paint Codes
    4
  - Replacement Keys
    4
- General Specifications
  5
- Misc. Specifications and Charts
  8
  - Conversion Table
    8
  - Standard Torque Specifications
    9
  - Sae Tap / Drill Sizes
    10
  - Metric Tap / Drill Sizes
    10
  - Glossary of Terms
    11
Maintenance Chapter 2 Maintenance 2

13
- Break-In Period
  15
- Chapter 2
  15
- Maintenance Chart Key
  15
- Periodic Maintenance Chart
  15
- Periodic Maintenance Overview
  15
- Pre-Ride - 25 Hour Maintenance Interval
  16
- 50 - 300 Hour Maintenance Interval
  17
- Component Inspection / Service Locations
  18
  - Front and Rear View
    18
  - Rh and Lh Side Views
    19
- Lubricants / Service Products
  20
- Maintenance References
  21
- General Vehicle Inspection and Maintenance
  22
- Fuel System and Air Intake
  23
  - Fuel System
    23
  - Fuel Line
    23
  - Fuel Pump / Fuel Filters
    23
  - Vent Lines
    23
  - Throttle Pedal Inspection
    24
  - Throttle Freeplay Adjustment
    24
  - Throttle Cable Replacement
    24
  - Air Filter Service
    26
- Engine
  28
- Transmission and Gearcases
  31
- Cooling System
  35
  - Cooling System Overview
    35
  - Coolant Level Inspection
    35
  - Coolant Strength / Type
    35
  - Cooling System Pressure Test
    36
  - Cooling System Hoses
    36
  - Radiator
    36
  - Coolant Drain / Radiator Removal
    36
- Final Drive / Wheel and Tire
  37
  - Wheel, Hub, and Spindle Torque Table
    37
  - Wheel Removal
    37
  - Wheel Installation
    37
  - Tire Inspection
    38
  - Tire Pressure
    38
  - Drive Shaft Boot Inspection
    38
- Electrical and Ignition System
  39
  - Battery Maintenance
    39
  - Battery Removal
    39
  - Battery Installation
    39
  - Battery off Season Storage
    40
  - Battery Charging (Sealed Battery)
    40
  - Spark Plug Service
    40
  - Engine to Frame Ground
    41
- Steering
  41
  - Steering Inspection
    41
  - Steering Wheel Freeplay
    41
  - Steering Inspection / Tie Rod Ends and Hubs
    42
  - Toe Alignment Inspection
    42
  - Toe Adjustment
    43
- Suspension (Rzr)
  43
  - Spring Preload Adjustment
    43
  - Suspension (Rzr "S")
    44
  - Spring Preload Adjustment
    44
  - Shock Compression Adjustment
    44
- Brake System
  45
  - Brake Fluid Inspection
    45
  - Brake Pad / Disc Inspection
    45
  - Brake Hose and Fitting Inspection
    45
  - Maintenance Log
    46
Engine

47
- Chapter 3
  48
- Crankcase Exploded Views
  48
- Engine Specifications
  48
- Engine Fastener Torque Patterns
  53
- Torque Specifications
  54
- 800 EFI Engine Service Specifications
  55
- Special Tools
  57
- Engine Cooling System
  58
- General Engine Service
  61
  - Engine Lubrication Specifications
    61
  - Accessible Engine Components
    61
  - Oil Pressure Test
    61
  - Oil Flow Chart
    62
  - Engine Removal
    63
  - Engine / Transmission Separation
    69
- Engine Disassembly and Inspection
  70
- Engine Reassembly
  93
  - Crankcase Reassembly
    93
  - Flywheel / Stator Installation
    102
  - Cylinder Head Reassembly
    102
  - Oil Pump Priming
    104
- Engine Installation
  105
  - Engine Assembly and Installation
    105
  - Engine Break-In Period
    106
- Troubleshooting
  107
  - Engine
    107
  - Cooling System
    108
Electronic Fuel Injection Chapter 4 Electronic Fuel Injection

109
- Chapter 4
  110
- General Information
  110
- Special Tools
  110
- Service Notes
  112
- Efi System Exploded View
  113
- Efi System Component Locations
  114
- Fuel Tank
  116
  - Fuel Lines - Quick Connect
    117
- Electronic Fuel Injection
  117
  - Principal Components / Efi Operation Overview
    117
  - Initial Priming / Starting Procedure
    118
- Electronic Control Unit (Ecu)
  118
  - Ecu Service / Replacement
    119
- Temperature and Barometric Air Pressure Sensor (T-Bap)
  119
- Crankshaft Position Sensor (Cps)
  120
  - Cps Test
    120
  - Cps Replacement
    121
- Fuel Injectors
  125
  - Fuel Injector Service
    125
  - Fuel Injector Test / Replacement
    126
- Fuel Pump
  128
  - Fuel Sender Test
    128
  - Fuel Pump Test
    128
  - Fuel Tank / Fuel Pump Replacement
    130
- Throttle Position Sensor (Tps)
  132
  - Tps Tester / Regulator
    132
  - Checking Tps Reading
    133
  - Tps Adjustment / Replacement
    134
- Engine Coolant Temperature Sensor (Ect)
  135
  - Ect Sensor Test / Replacement
    135
- Ignition Coil
  136
  - Ignition Coil Tests
    136
  - Ignition Coil / Ht Lead Replacement
    136
- Diagnostic "Blink Codes
  137
  - Efi Troubleshooting
    138
- General Troubleshooting
  137
- Efi System Breakout Diagrams
  139
Body / Steering / Suspension Chapter 5 Body / Steering / Suspension

145
- Special Tools
  146
- Torque Specifications
  146
- Cab Frame (Rzr)
  147
- Cab Frame (Rzr "S")
  148
- Body Exploded Views
  149
- Chapter 5
  149
- Dash Instruments / Controls
  149
- Hood / Front Body Work
  151
- Floor / Rocker Panels
  153
- Rear Cargo Box / Fenders
  154
- Chassis / Main Frame
  155
- Body Component Removal
  156
  - Rear Bumper
    156
  - Hood and Front Body Work
    157
  - Rocker Panels, Console and Floor
    158
  - Rear Fender, Flair and Tie down Removal
    158
  - Cargo Box Assembly Removal
    158
- Steering Assembly
  159
- Wheel Hubs
  161
- Front A-Arms
  162
  - Removal / Replacement
    162
  - Exploded Views
    163
- Ball Joint Service
  164
  - Removal
    164
  - Installation
    165
- Front Stabilizer Bar (Rzr)
  165
  - Sway Bar Linkage Removal
    165
  - Stabilizer Bar Removal
    165
  - Exploded View
    166
- Rear A-Arms
  167
  - Removal
    167
  - Installation
    168
  - Exploded Views
    169
- Rear Stabilizer Bar (Rzr)
  170
- Rear Stabilizer Bar (Rzr "S")
  171
- Decal Replacement
  172
- Shocks / Springs (Rzr)
  172
- Fox™ Shock Exploded View (Rzr "S")
  173
  - Fox™ Podium X 'Piggyback' Shock
    173
  - Fox™ Shock Service (Rzr "S")
    174
  - General Service Information
    174
  - Front Shock Service Information
    174
  - Rear Shock Service Information
    174
  - Fox™ Podium X Shock Rebuild Information
    175
  - Fox™ Podium X Shock Disassembly
    176
  - Fox™ Podium X Shock Rebuild
    178
  - Fox™ Podium X Shock Reassembly
    179
Clutching Chapter 6 Clutching

183
- Chapter 6 Pvt System Fastener Torques
  184
- Pvt System Overview
  184
  - General Operation
    184
  - Drive Clutch Operation
    184
  - Driven Clutch Operation
    185
  - Pvt Break-In (Drive Belt / Clutches)
    185
  - Maintenance / Inspection
    185
  - Overheating / Diagnosis
    186
- Special Tools and Supplies
  184
- Torque Specifications
  184
- Pvt System Service
  187
  - Pvt Sealing and Ducting Components
    187
  - Disassembly
    187
  - Assembly
    188
- Drive Belt
  189
  - Belt Removal
    189
  - Belt Inspection
    190
  - Belt Installation
    190
  - Pvt Break-In (Drive Belt / Clutches)
    190
- Drive Clutch Service
  191
  - Spring Specifications
    191
  - Shift Weights
    192
  - Non-Braking Exploded View (Rzr)
    193
  - Ebs Exploded View (Rzr "S")
    193
  - Clutch Disassembly
    194
  - Spider Removal
    194
  - Roller, Pin, and Thrust Washer Inspection
    195
  - Button to Tower Clearance Inspection
    196
  - Shift Weight Inspection
    196
  - Bearing Inspection
    196
  - Clutch Inspection
    197
  - Moveable Sheave Bushing Inspection
    198
  - Bushing Service
    198
  - Clutch Assembly
    200
- Driven Clutch Service
  201
  - Clutch Disassembly
    201
  - Bushing Service
    204
  - Clutch Assembly
    205
  - Exploded View
    209
- Driven Clutch Service (Late Build Rzr)
  210
  - Exploded View
    210
  - Clutch Disassembly / Inspection
    210
  - Clutch Assembly
    212
- Troubleshooting
  213
Final Drive Chapter 7 Final Drive

215
- Chapter 7 Wheel, Hub, and Spindle Torque Table
  216
- Front Bearing Carrier
  216
  - Bearing Carrier Inspection / Removal
    216
  - Bearing Replacement
    217
  - Bearing Carrier Installation
    218
- Special Tools
  216
- Torque Specifications
  216
- Front Drive Shaft
  220
  - Drive Shaft Removal
    220
  - Drive Shaft / CV Joint Handling Tips
    221
  - Outer CV Joint / Boot Replacement
    221
  - Inner Plunging Joint / Boot Replacement
    222
  - Drive Shaft Installation
    224
- Propshaft Service
  225
  - Removal / Installation
    225
- Propshaft U-Joint Service
  226
  - Disassembly
    226
  - Assembly
    226
  - Awd Diagnosis
    230
  - Gearcase Removal
    231
  - Gearcase Disassembly / Inspection
    231
  - Gearcase Assembly / Inspection
    233
  - Backlash Thrust Plate Adjustment
    235
  - Gearcase Installation
    236
- Rear Bearing Carrier
  237
  - Bearing Carrier Inspection / Removal
    237
  - Bearing Replacement
    238
  - Bearing Carrier Bushing Replacement
    238
  - Bearing Carrier Installation
    239
- Rear Drive Shaft
  240
  - Removal
    240
  - Outer CV Joint / Boot Replacement
    241
  - Inner Plunging Joint / Boot Replacement
    244
  - Drive Shaft Exploded View
    246
  - Installation
    246
- Rear Gearcase
  248
  - Gearcase Removal
    248
  - Gearcase Disassembly
    249
  - Gearcase Assembly
    251
  - Gearcase Installation
    252
  - Gearcase Exploded View
    253
- Wheel Hubs
  254
  - Front Hub Exploded View
    254
  - Rear Hub Exploded View
    254
Transmission Chapter 8 Transmission

255
- Chapter 8
  256
- Installation
  256
- Removal
  256
- Shift Lever
  256
- Torques / Specifications
  256
- Shift Cable Inspection / Adjustment
  257
- Transmission Service
  258
- Troubleshooting
  273
  - Troubleshooting Checklist
    273
- Transmission Exploded Views
  274
  - Shift Housing / Transfer Case Exploded View
    274
Brakes Chapter 9 Brakes

275
- Chapter 9
  276
- General Specifications
  276
- Special Tools
  276
- Torque Specifications
  276
- Brake Noise Troubleshooting
  277
- Brake System Service Notes
  277
- Brake System Exploded View
  278
- Hydraulic Brake System Operation
  278
- Brake Pedal Lever
  279
  - Pedal Removal
    279
  - Pedal Installation
    279
- Master Cylinder
  279
  - Removal
    279
  - Installation
    279
- Brake Bleeding / Fluid Change
  280
- Front Brake Pads
  281
  - Pad Removal
    281
  - Pad Inspection
    281
  - Pad Assembly / Installation
    282
  - Brake Burnishing Procedure
    282
- Front Caliper Service
  283
  - Caliper Exploded View
    283
  - Caliper Removal
    283
  - Caliper Disassembly
    284
  - Caliper Inspection
    285
  - Caliper Assembly
    285
  - Caliper Installation
    286
- Front Brake Disc
  287
  - Disc Inspection
    287
  - Disc Replacement
    287
- Rear Brake Pad
  288
  - Pad Removal
    288
  - Pad Inspection
    289
  - Pad Assembly / Installation
    289
  - Brake Burnishing Procedure
    289
- Rear Caliper Service
  290
  - Caliper Exploded View
    290
  - Caliper Removal
    290
  - Caliper Disassembly
    291
  - Caliper Inspection
    291
  - Caliper Assembly
    292
  - Caliper Installation
    292
- Rear Brake Disc
  293
  - Disc Inspection
    293
  - Disc Replacement
    293
- Troubleshooting
  294
  - Brakes Squeal / Poor Brake Performance
    294
  - Pedal Vibration
    294
  - Caliper Overheats (Brakes Drag)
    294
  - Brakes Lock
    294
Electrical Chapter 10 Electrical

295
- Chapter 10
  297
- Electrical Service Notes
  297
- General Information
  297
- Special Tools
  297
- Under-Dash Components
  297
- Switches / Controls
  298
  - Headlamp Switch
    298
  - Awd Switch
    298
  - Brake Light Switch
    298
- Instrument Cluster
  299
  - Overview
    299
  - Rider Information Display
    299
  - Standard Display Modes
    300
  - Diagnostic Display Mode
    300
  - Viewing Diagnostic Codes
    302
  - Instrument Cluster Removal
    303
  - Instrument Cluster Installation
    303
- Instrument Cluster Troubleshooting Tests
  304
- All Wheel Drive Coil
  308
- Gear Position Indicator Switch
  308
- Speed Sensor
  308
- Head Lights
  309
  - Headlight Adjustment
    309
  - Headlamp Bulb Replacement
    309
  - Headlamp Housing Removal
    310
  - Headlamp Housing Installation
    310
- Tail / Brake Lights
  310
  - Bulb Replacement
    310
- Cooling System Schematic
  311
- Efi Diagnostics
  312
- Fuel Sender
  312
- Fuse Box Layout
  313
- Relays
  313
- Fuses / Circuit Breaker
  314
- Charging System
  315
  - Current Draw - Key off
    315
  - Charging System "Break Even" Test
    315
  - Charging System Alternator Tests
    316
  - Charging System Testing Flow Chart
    317
- Battery Service
  318
  - General Battery Information
    318
  - Battery Removal / Installation
    318
  - Charging Procedure (Maintenance Free)
    318
  - Maintenance Free Battery Testing
    318
  - Ocv - Open Circuit Voltage Test
    318
  - Load Test
    318
  - Off Season Storage
    318
- Starting System
  319
  - Troubleshooting
    319
  - Voltage Drop Test
    319
  - Starter Motor Removal / Disassembly
    319
  - Brush Inspection / Replacement
    320
  - Armature Testing
    321
  - Starter Reassembly / Installation
    321
  - Starter Drive
    322
  - Starter Solenoid Bench Test
    323
  - Starter Solenoid Operation
    323
  - Starter Exploded View
    324
- Starting System Testing Flow Chart
  325
- Electrical Breakout Diagrams
  326
  - 12V Key-On Power Circuit
    326
  - Starting System Circuit
    326
  - Instrument Cluster Circuit
    327
  - Transmission Switch Circuit
    327
  - Wheel Speed Sensor Circuit
    328
  - Awd Circuit
    328
  - Fuel Gauge Display Circuit
    329
  - Cooling Fan Circuit
    329
  - Charging System Circuit
    330

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