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RANGER RZR 2011
Polaris RANGER RZR 2011 Manuals
Manuals and User Guides for Polaris RANGER RZR 2011. We have
1
Polaris RANGER RZR 2011 manual available for free PDF download: Service Manual
Polaris RANGER RZR 2011 Service Manual (418 pages)
Brand:
Polaris
| Category:
Offroad Vehicle
| Size: 39.29 MB
Table of Contents
6
General Information Chapter 1 1
6
Table of Contents
7
Chapter 1
7
General Information
7
Model Information
7
Model Identification
7
Engine Designation Number
7
Vin Identification
7
Vehicle and Engine Serial Number Location
8
Special Tools
8
Vehicle Information
8
Publication Numbers
8
Replacement Keys
9
General Specifications
15
Misc. Specifications and Charts
15
Conversion Table
16
Standard Torque Specifications
17
Sae Tap / Drill Sizes
17
Metric Tap / Drill Sizes
18
Glossary of Terms
20
Maintenance Chapter 2 Maintenance 2
22
Chapter 2
22
Periodic Maintenance Chart
22
Break-In Period / Maintenance Chart Key
23
Pre-Ride - 25 Hour Maintenance Interval
24
50 - 500 Hour Maintenance Interval
25
Maintenance Quick Reference
26
Maintenance Quick Reference, Continued
27
Grease Lubrication Points
28
Lubricants / Service Products
29
General Vehicle Inspection and Maintenance
29
Pre-Ride / Daily Inspection
29
Frame, Nuts, Bolts, and Fasteners
29
Shift Cable Inspection / Adjustment
30
Fuel System and Air Intake
30
Fuel Line / Fuel Pump / Fuel Filters / Vent Lines
31
Throttle Pedal Inspection
31
Throttle Freeplay Adjustment
32
Air Filter Service
34
Engine
34
Engine Oil Level
35
Engine Oil and Filter Service
36
Engine Breather Hose Inspection
36
Engine and Transmission Mounts
36
Compression and Leakdown Test
36
Exhaust - Spark Arrestor
37
Transmission and Gearcases
37
Transmission Lubrication
39
Front Gearcase Lubrication
40
Rear Gearcase Lubrication
41
Cooling System
41
Coolant Level Inspection
41
Coolant Strength / Type
42
Cooling System Pressure Test
42
Cooling System Hoses / Radiator
42
Coolant Drain / Radiator Removal
43
Wheel Installation
43
Final Drive / Wheel and Tire
43
Wheel and Hub Torque Table
43
Wheel Removal / Installation
44
Tire Inspection / Pressure
44
Drive Shaft Boot Inspection
45
Electrical and Ignition System
45
Battery Maintenance
45
Battery Removal
46
Battery Installation
46
Battery Off Season Storage
46
Battery Charging (Maintenance Free)
46
Spark Plug Service
47
Engine to Frame Ground
47
Steering
47
Steering Inspection / Steering Wheel Freeplay
48
Tie Rod End / Wheel Hub Inspection
48
Wheel Toe Alignment Inspection
49
Wheel Toe Adjustment
50
Suspension (Fox™)
51
Shock Compression Adjustment
50
Suspension (Standard)
50
Spring Preload Adjustment
52
Suspension (Walker Evans™)
52
Spring Preload Adjustment
52
Shock Compression Adjustment
53
Brake System
53
Brake Fluid / Pad / Disc Inspection
53
Brake Hose and Fitting Inspection
53
Brake Fluid Inspection
54
Maintenance Log
56
Chapter 3 Engine
57
Engine Specifications
57
Crankcase
58
Oil Pump / Gears / Engine Cover
59
Stator Cover / Starter / Water Pump / Lubrication System
60
Cylinder / Cylinder Head / Piston
61
Engine Efi Sensors / Valve Cover / General Components
62
Engine Torque Specifications
63
800 EFI Engine Service Specifications
65
Special Tools
66
Engine Cooling System
66
Cooling System Specifications / Pressure Test / Cap Test
67
Cooling System Exploded View
68
Cooling System Bleeding Procedure
69
General Engine Service
69
Engine Lubrication Specifications
69
Accessible Engine Components / Oil Pressure Test
70
Oil Flow Chart
71
Engine Removal
78
Engine / Transmission Separation
79
Engine Disassembly and Inspection
79
Cylinder Head Assembly Exploded View
80
Rocker Arms / Push Rods
80
Cylinder Head Removal
81
Cylinder Head Inspection / Warp
81
Valve Seal / Spring Service (On Engine)
81
Cylinder Head Warp
82
Cylinder Head Disassembly
83
Valve Inspection
84
Combustion Chamber
84
Valve Seat Reconditioning
86
Cylinder Head Reassembly
87
Valve Sealing Test
87
Cylinder Removal
87
Valve Lifter Removal / Inspection
88
Piston Removal
89
Cylinder Inspection
90
Cylinder Hone Selection and Honing Procedure
90
Honing to Deglaze / Cleaning the Cylinder After Honing
91
Piston-To-Cylinder Clearance
91
Piston / Rod Inspection
92
Piston Ring Installed Gap
92
Starter Drive Bendix Removal / Inspection
93
Flywheel / Stator Removal / Inspection
93
Engine Crankcase Disassembly / Inspection
101
Camshaft Inspection
102
Engine Reassembly
102
Crankcase Reassembly
111
Flywheel / Stator Installation
111
Cylinder Head Reassembly
113
Oil Pump Priming
114
Engine Installation
114
Engine Assembly and Installation
115
Engine Break-In Period
116
Troubleshooting
118
Chapter 4 Electronic Fuel Injection
119
Electronic Fuel Injection
119
General Information
119
Special Tools
121
Service Notes
122
Efi System Exploded View
123
Efi System Component Locations
125
Fuel Tank
126
Fuel Lines - Quick Connect
126
Electronic Fuel Injection
126
Principal Components / Efi Operation Overview
127
Initial Priming / Starting Procedure
127
Electronic Control Unit (Ecu)
128
Temp / Manifold Absolute Pressure Sensor (T-Map)
129
Crankshaft Position Sensor (Cps)
129
Cps Test
130
Cps Replacement
133
Fuel Injectors
134
Fuel Injector Service
135
Fuel Injector Replacement
136
Fuel Pump
136
Fuel Sender Test
137
Fuel Pump Test
138
Fuel Pump Replacement
141
Fuel Tank Removal (Rzr / Rzr S)
143
Fuel Tank Removal (Rzr 4)
145
Fuel Tank Installation
146
Idle Air Control (Iac)
147
Throttle Position Sensor (Tps)
148
Tps Replacement
150
Camshaft Phase Sensor
151
Engine Coolant Temperature Sensor (Ect)
151
Overview, Test and Replacement
152
Ignition Coil
153
Efi Diagnostics
153
Instrument Cluster Trouble Code Display
153
Diagnostic Trouble Code Table
156
Efi Troubleshooting
157
Digital Wrench™ Operation
157
Digital Wrench™ Communication Errors
158
Digital Wrench™ - Diagnostic Connector
159
Digital Wrench™ Updates
160
Digital Wrench™ Feature Map
161
Engine Controller Reprogramming (Reflash)
165
Efi System Electrical Operation
166
Chapter 5 Body / Steering / Suspension
168
Special Tools
168
Torque Specifications
169
Cab Frame (Rzr / Rzr S)
170
Cab Frame (Rzr 4)
171
Body Exploded Views
171
Side Safety Nets
172
Dash Instruments / Controls / Glovebox
173
Hood / Front Body Work
175
Seat Assembly
175
Seat Belts / Mounting (Rzr / Rzr S)
176
Seat Belts / Mounting (Rzr 4)
177
Floor / Rocker Panels (Rzr / Rzr S)
178
Floor / Rocker Panels (Rzr 4)
179
Rear Cargo Box / Fenders (Rzr / Rzr S)
180
Rear Cargo Box / Fenders (Rzr 4)
181
Chassis / Main Frame (Rzr / Rzr S)
182
Chassis / Main Frame (Rzr 4)
183
Body Component Removal
183
Seats
183
Rear Service Panel (Rzr / Rzr S)
183
Rear Console Cover (Rzr 4)
183
Front Bumper
184
Rear Bumper
184
Hood and Front Body Work
185
Rear Fender, Flair and Tie Down Removal
185
Cargo Box Assembly Removal
186
Rocker Panels, Console and Floor
187
Steering Assembly
187
Exploded View (Non-Eps Models)
188
Steering Wheel Removal (Non-Eps Models)
188
Steering Shaft Removal (Non-Eps Models)
189
Steering Shaft Bearing Replacement
190
Electronic Power Steering Assembly
190
Exploded View (Eps Models)
191
Upper Steering Shaft Removal (Eps Models)
192
Steering Wheel Removal (Eps Models)
192
Power Steering Unit Removal
194
Power Steering Unit Installation
195
Upper Steering Shaft Installation (Eps Models)
196
Front A-Arms
196
Removal / Replacement
197
Exploded View
198
Ball Joint Service
198
Removal
199
Installation
199
Front Stabilizer Bar (Rzr / Rzr S Int'l)
199
Sway Bar Linkage Removal
199
Stabilizer Bar Removal
200
Exploded View
201
Rear A-Arms
201
Removal
202
Installation
203
Exploded View
204
Rear Stabilizer Bar (Rzr)
205
Rear Stabilizer Bar (Rzr S / Rzr 4)
206
Decal Replacement
206
Shocks / Springs / Fasteners
206
Exploded View (Rzr / Rzr S)
206
Exploded View (Rzr S / Rzr S Int'l)
207
Exploded View (Rzr 4)
208
Fox™ Shock Exploded Views
208
Fox™ Podium X 'Piggyback' Shock (Rzr S)
209
Fox™ 2.0 'Piggyback' Shock (Rzr 4)
210
Fox™ Shock Service
210
General Service Information
212
Fox™ Shock Rebuild Information
213
Fox™ Shock Disassembly
215
Fox™ Shock Rebuild
216
Fox™ Shock Reassembly
219
Walker Evans™ Shock Exploded View
219
Walker Evans™ Compression Adjuster Reservoir Shock (Rzr L.e.)
220
Walker Evans™ Shock Service
220
Recommended Service Intervals
221
Walker Evans™ Shock Rebuild Information
221
Special Tools
221
Valve Shim Arrangement
221
Piston Orientation
222
Walker Evans™ Shock Disassembly
224
Walker Evans™ Shock Assembly
228
Clutching Chapter 6 Clutching
229
Chapter 6
229
Pvt System Overview
229
General Operation
229
Drive Clutch Operation
230
Driven Clutch Operation
230
Pvt Break-In (Drive Belt / Clutches)
230
Maintenance / Inspection
231
Overheating / Diagnosis
229
Special Tools and Supplies
229
Torque Specifications
232
Pvt System Service
232
Pvt Covers and Ducting Components
233
Pvt Disassembly
234
Pvt Assembly
235
Clutch Offset Procedure
237
Drive Belt
237
Pvt Break-In (Drive Belt / Clutches)
238
Drive Clutch Service
238
Spring Specifications
239
Shift Weights
239
Drive Clutch Exploded View
240
Clutch Disassembly
240
Spider Removal
241
Roller, Pin, and Thrust Washer Inspection
242
Button to Tower Clearance Inspection
242
Shift Weight Inspection
242
Bearing Inspection
243
Clutch Inspection
244
Moveable Sheave Bushing Inspection
244
Bushing Service
246
Clutch Assembly
248
Driven Clutch Service
248
Exploded View
248
Clutch Disassembly / Inspection
250
Clutch Assembly
251
Troubleshooting
254
Chapter 7 Final Drive
255
Front Bearing Carrier
255
Bearing Carrier Inspection / Removal
256
Bearing Replacement
257
Bearing Carrier Installation
255
Special Tools
255
Torque Specifications
259
Front Drive Shaft
259
Drive Shaft Removal
260
Drive Shaft / CV Joint Handling Tips
260
Outer CV Joint / Boot Replacement
261
Inner Plunging Joint / Boot Replacement
263
Drive Shaft Installation
264
Propshaft Service
264
Removal / Installation (Rzr / Rzr S)
265
Removal / Installation (Rzr 4)
266
Support Bearing Replacement (Rzr 4)
267
Propshaft U-Joint Service
269
Front Gearcase / Centralized Hilliard
269
Centralized Hilliard Exploded View
270
All Wheel Drive Operation
271
Awd Diagnosis
272
Gearcase Removal
275
Gearcase Assembly
277
Gearcase Installation
279
Rear Bearing Carrier
279
Bearing Carrier Inspection / Removal
280
Bearing Replacement
280
Bearing Carrier Bushing Replacement
281
Bearing Carrier Installation
282
Rear Drive Shaft
282
Drive Shaft Removal
283
Outer CV Joint / Boot Replacement
286
Inner Plunging Joint / Boot Replacement
288
Drive Shaft Exploded View
290
Rear Gearcase
290
Gearcase Removal
291
Gearcase Disassembly
293
Gearcase Assembly
294
Gearcase Installation
295
Gearcase Exploded View
296
Rear Gearcase (Rzr S Int'l)
296
General Operation
297
Gearcase Removal
298
Gearcase Disassembly
302
Differential Disassembly
303
Differential Assembly
304
Gearcase Assembly
306
Gearcase Installation
307
Gearcase Exploded View
308
Wheel Hubs
310
Transmission Chapter 8 Transmission
311
Chapter 8
311
Shift Lever
312
Shift Cable Inspection / Adjustment
311
Torque Values / Specifications
313
Transmission Service
313
Transmission Removal / Service Notes
313
Transfer Case Disassembly
316
Transfer Case Reassembly
318
Transmission Shift Housing Disassembly
322
Transmission Shift Housing Reassembly
327
Troubleshooting
327
Troubleshooting Checklist
328
Transmission Exploded View
330
Brakes Chapter 9 Brakes
332
Chapter 9
332
Brake Noise Troubleshooting
332
Brake System Service Notes
333
Hydraulic Brake System Operation
334
Brake System Exploded View
334
Rzr / Rzr S / Rzr S Int'l
334
Rzr 4
335
Brake Pedal Lever
335
Master Cylinder
336
Brake Bleeding / Fluid Change
337
Front Brake Pads
337
Pad Removal
339
Brake Burnishing Procedure
340
Front Caliper Service
340
Caliper Exploded View (Rzr / Rzr S / Rzr S Int'l)
340
Caliper Exploded View (Rzr 4)
341
Caliper Removal
342
Caliper Disassembly
343
Caliper Inspection
344
Caliper Assembly
345
Front Brake Disc
346
Disc Replacement
347
Rear Brake Pads
347
Pad Removal
348
Brake Burnishing Procedure
349
Rear Caliper Service
349
Caliper Exploded View
349
Caliper Removal
351
Caliper Assembly
352
Caliper Installation
352
Rear Brake Disc
352
Disc Inspection
353
Disc Replacement
353
Troubleshooting
353
Pedal Vibration
353
Brakes Lock
354
Chapter 10 Electrical
356
General Information
356
Under-Dash Components
356
Switches / Controls
356
Electrical Service Notes
356
Brake Light Switch
357
Headlamp Switch
357
Ignition Key Switch
358
Ignition Key Switch (Int'l)
358
Awd / 2Wd Switch
359
Awd / 2Wd / Turf Switch (Int'l)
359
Turn Signal Switch (Int'l)
359
Hazard Switch (Int'l)
360
Transmission (Gear Position) Switch
360
Vehicle Speed Sensor
361
Rear Diff Solenoid (Int'l)
362
Instrument Cluster
363
Rider Information Display
363
Information Display Area
366
Diagnostic Mode
367
Instrument Cluster Pinouts
367
Instrument Cluster Installation
367
Instrument Cluster Removal
368
All Wheel Drive Coil
368
Head Lights
368
Headlight Adjustment
369
Headlamp Bulb Replacement
370
Tail / Brake Lights
370
Bulb Replacement
371
Cooling System
371
Cooling System Break-Out Diagram
372
Coolant Temperature Sensor
372
Efi Diagnostics
372
Fuel Sender
373
Fuse Box: Fuses / Relays / Circuit Breaker
374
Fuse Box Detail
375
Relay Operation
377
Charging System
377
Current Draw - Key Off
378
Regulator / Rectifier
379
Charging System Testing Flow Chart
380
Battery Service
381
Battery Testing
381
Ocv - Open Circuit Voltage Test
381
Load Test
382
Battery Conductance Analyzer
382
Charging Procedure
383
Starting System
383
Voltage Drop Test
383
Starter Motor Removal / Disassembly
384
Brush Inspection / Replacement
385
Armature Testing
385
Starter Reassembly / Installation
386
Starter Drive
387
Starter Solenoid Bench Test
387
Starter Solenoid Operation
388
Starter Exploded View
389
Starting System Testing Flow Chart
390
Electronic Power Steering (Eps)
390
Eps Operation
390
Eps 8-Way Wire Harness Connector
390
Proper Eps System Diagnosing
391
Eps System Breakout
394
Eps Troubleshooting (Using Digital Wrench™)
395
Electrical System Breakouts
395
Awd
395
Vehicle Speed Sensor
396
Cooling Fan
397
Charging System
398
Chassis Power
399
Key-On Battery Power
400
Electronic Power Steering (Eps)
401
Engine Start (Starter Interlock)
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