Polaris 2009 Ranger RZR 800 EFI Manuals

Polaris 2009 Ranger RZR 800 EFI Manuals

Manuals and User Guides for Polaris 2009 Ranger RZR 800 EFI. We have 1 Polaris 2009 Ranger RZR 800 EFI 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: 19.17 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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