Polaris Ranger RZR 800 Utility Vehicle Manuals

Manuals and User Guides for Polaris Ranger RZR 800 Utility Vehicle. We have 2 Polaris Ranger RZR 800 Utility Vehicle manuals available for free PDF download: Manual, Owner's Manual

Polaris Ranger RZR 800 Manual

Polaris Ranger RZR 800 Manual (406 pages)

Brand: Polaris | Category: Utility Vehicle | Size: 77 MB

Table of Contents

General Information Chapter

1
- Table of Contents
  1
- Chapter 1
  2
- Engine Designation Number
  2
- Model Identification
  2
- Model Information
  2
- Vehicle and Engine Serial Number Location
  2
- Vin Identification
  2
- Special Tools
  3
- Vehicle Information
  3
  - Publication Numbers
    3
  - Replacement Keys
    3
- General Specifications
  4
- Misc. Specifications and Charts
  10
  - Conversion Table
    10
  - Standard Torque Specifications
    11
  - Sae Tap / Drill Sizes
    12
  - Metric Tap / Drill Sizes
    12
  - Glossary of Terms
    13
Maintenance Chapter 2 Maintenance 2

15
- Break-In Period / Maintenance Chart Key
  17
- Chapter 2
  17
- Periodic Maintenance Chart
  17
- Pre-Ride - 25 Hour Maintenance Interval
  18
- 50 - 500 Hour Maintenance Interval
  19
- Maintenance Quick Reference
  20
- Maintenance Quick Reference, Continued
  21
- Grease Lubrication Points
  22
- Lubricants / Service Products
  23
- General Vehicle Inspection and Maintenance
  24
- Fuel System and Air Intake
  25
- Engine
  29
- Transmission and Gearcases
  32
- Cooling System
  36
- Final Drive / Wheel and Tire
  38
  - Wheel and Hub Torque Table
    38
  - Wheel Removal / Installation
    38
  - Wheel Installation
    38
  - Tire Inspection / Pressure
    39
  - Drive Shaft Boot Inspection
    39
- Electrical and Ignition System
  40
  - Battery Maintenance
    40
  - Battery Removal
    40
  - Battery Installation
    41
  - Battery off Season Storage
    41
  - Battery Charging (Maintenance Free)
    41
  - Spark Plug Service
    41
  - Engine to Frame Ground
    42
- Steering
  42
- Suspension (Fox™)
  45
  - Shock Compression Adjustment
    46
- Suspension (Standard)
  45
  - Spring Preload Adjustment
    45
- Suspension (Walker Evans™)
  47
  - Spring Preload Adjustment
    47
  - Shock Compression Adjustment
    47
- Brake System
  48
  - Brake Fluid / Pad / Disc Inspection
    48
  - Brake Hose and Fitting Inspection
    48
- Maintenance Log
  49
Engine Chapter 3 Engine

51
- Chapter 3
  52
- Crankcase
  52
- Engine Specifications
  52
- Oil Pump / Gears / Engine Cover
  53
- Stator Cover / Starter / Water Pump / Lubrication System
  54
- Cylinder / Cylinder Head / Piston
  55
- Engine Efi Sensors / Valve Cover / General Components
  56
- Engine Torque Specifications
  57
- 800 EFI Engine Service Specifications
  58
- Special Tools
  60
- Engine Cooling System
  61
- General Engine Service
  64
- Engine Disassembly and Inspection
  74
- Engine Reassembly
  97
  - Crankcase Reassembly
    97
  - Flywheel / Stator Installation
    106
  - Cylinder Head Reassembly
    106
  - Oil Pump Priming
    108
- Engine Installation
  109
  - Engine Assembly and Installation
    109
  - Engine Break-In Period
    110
- Troubleshooting
  111
Electronic Fuel Injection Chapter 4 Electronic Fuel Injection

113
- Chapter 4
  114
- Electronic Fuel Injection Chapter
  114
- General Information
  114
- Special Tools
  114
- Service Notes
  116
- Efi System Exploded View
  117
- Efi System Component Locations
  118
- Fuel Tank
  120
  - Fuel Lines - Quick Connect
    121
- Electronic Fuel Injection
  121
  - Principal Components / Efi Operation Overview
    121
  - Initial Priming / Starting Procedure
    122
- Electronic Control Unit (Ecu)
  122
- Temp / Manifold Absolute Pressure Sensor (T-Map)
  123
- Crankshaft Position Sensor (Cps)
  124
  - Cps Test
    124
  - Cps Replacement
    125
- Fuel Injectors
  128
  - Fuel Injector Replacement
    130
- Fuel Pump
  131
  - Fuel Sender Test
    131
  - Fuel Pump Test
    132
  - Fuel Pump Replacement
    133
  - Fuel Tank Removal (Rzr / Rzr S)
    136
  - Fuel Tank Removal (Rzr 4)
    138
  - Fuel Tank Installation
    140
- Idle Air Control (Iac)
  141
- Throttle Position Sensor (Tps)
  142
  - Tps Replacement
    143
- Camshaft Phase Sensor
  145
- Engine Coolant Temperature Sensor (Ect)
  146
- Ignition Coil
  147
- Efi Diagnostics
  148
  - Instrument Cluster Trouble Code Display
    148
  - Efi Troubleshooting
    151
- Digital Wrench™ Operation
  152
- Efi System Electrical Operation
  160
Body / Steering / Suspension Chapter 5 Body / Steering / Suspension

161
- Special Tools
  163
- Torque Specifications
  163
- Cab Frame (Rzr / Rzr S)
  164
- Cab Frame (Rzr 4)
  165
- Body Exploded Views
  166
- Chapter 5
  166
- Side Safety Nets
  166
- Dash Instruments / Controls / Glovebox
  167
- Hood / Front Body Work
  168
- Front / Rear Bumper
  169
- Seat Assembly
  170
- Seat Belts / Mounting (Rzr / Rzr S)
  170
- Seat Belts / Mounting (Rzr 4)
  171
- Floor / Rocker Panels (Rzr / Rzr S)
  172
- Floor / Rocker Panels (Rzr 4)
  173
- Rear Cargo Box / Fenders (Rzr / Rzr S)
  174
- Rear Cargo Box / Fenders (Rzr 4)
  175
- Chassis / Main Frame (Rzr / Rzr S)
  176
- Chassis / Main Frame (Rzr 4)
  177
- Body Component Removal
  178
  - Seats
    178
  - Rear Service Panel (Rzr / Rzr S)
    178
  - Rear Console Cover (Rzr 4)
    178
  - Front Bumper
    178
  - Rear Bumper
    179
  - Hood and Front Body Work
    179
  - Rear Fender, Flair and Tie down Removal
    180
  - Cargo Box Assembly Removal
    180
  - Rocker Panels, Console and Floor
    181
- Steering Assembly
  182
- Electronic Power Steering Assembly
  185
- Front A-Arms
  191
  - Removal / Replacement
    191
  - Exploded View
    192
- Ball Joint Service
  193
  - Removal
    193
  - Installation
    194
- Front Stabilizer Bar (Rzr / Rzr S Int'l)
  194
  - Sway Bar Linkage Removal
    194
  - Stabilizer Bar Removal
    194
  - Exploded View
    195
- Rear A-Arms
  196
  - Removal
    196
  - Installation
    197
  - Exploded View
    198
- Rear Stabilizer Bar (Rzr)
  199
- Rear Stabilizer Bar (Rzr S / Rzr 4)
  200
- Decal Replacement
  201
- Shocks / Springs / Fasteners
  201
  - Exploded View (Rzr / Rzr S)
    201
  - Exploded View (Rzr S / Rzr S Int'l)
    201
  - Exploded View (Rzr 4)
    202
- Fox™ Shock Exploded Views
  203
  - Fox™ Podium X 'Piggyback' Shock (Rzr S)
    203
  - Fox™ 2.0 'Piggyback' Shock (Rzr 4)
    204
- Fox™ Shock Service
  205
  - General Service Information
    205
  - Fox™ Shock Rebuild Information
    207
  - Fox™ Shock Disassembly
    208
  - Fox™ Shock Rebuild
    210
  - Fox™ Shock Reassembly
    211
- Walker Evans™ Shock Exploded View
  214
  - Walker Evans™ Compression Adjuster Reservoir Shock (Rzr L.e.)
    214
- Walker Evans™ Shock Service
  215
  - Recommended Service Intervals
    215
  - Walker Evans™ Shock Rebuild Information
    216
  - Special Tools
    216
  - Valve Shim Arrangement
    216
  - Piston Orientation
    216
  - Walker Evans™ Shock Disassembly
    217
  - Walker Evans™ Shock Assembly
    219
Clutching Chapter 6 Clutching

223
- Chapter 6
  224
- Drive Clutch Operation
  224
- General Operation
  224
- Pvt System Overview
  224
- Special Tools and Supplies
  224
- Torque Specifications
  224
- Driven Clutch Operation
  225
- Maintenance / Inspection
  225
- Pvt Break-In (Drive Belt / Clutches)
  225
- Overheating / Diagnosis
  226
- Pvt System Service
  227
  - Pvt Covers and Ducting Components
    227
  - Pvt Disassembly
    228
  - Pvt Assembly
    229
  - Clutch Offset Procedure
    230
- Drive Belt
  232
  - Pvt Break-In (Drive Belt / Clutches)
    232
- Drive Clutch Service
  233
  - Spring Specifications
    233
  - Shift Weights
    234
  - Drive Clutch Exploded View
    234
  - Clutch Disassembly
    235
  - Spider Removal
    235
  - Roller, Pin, and Thrust Washer Inspection
    236
  - Button to Tower Clearance Inspection
    237
  - Shift Weight Inspection
    237
  - Bearing Inspection
    237
  - Clutch Inspection
    238
  - Moveable Sheave Bushing Inspection
    239
  - Bushing Service
    239
  - Clutch Assembly
    241
- Driven Clutch Service
  243
  - Exploded View
    243
  - Clutch Disassembly / Inspection
    243
  - Clutch Assembly
    245
- Troubleshooting
  246
Final Drive Chapter 7 Final Drive

249
- Bearing Carrier Inspection / Removal
  250
- Chapter 7
  250
- Front Bearing Carrier
  250
- Special Tools
  250
- Torque Specifications
  250
- Bearing Replacement
  251
- Bearing Carrier Installation
  252
- Front Drive Shaft
  254
  - Drive Shaft Removal
    254
  - Drive Shaft / CV Joint Handling Tips
    255
  - Outer CV Joint / Boot Replacement
    255
  - Inner Plunging Joint / Boot Replacement
    256
  - Drive Shaft Installation
    258
- Propshaft Service
  259
- Propshaft U-Joint Service
  262
- Front Gearcase / Centralized Hilliard
  264
  - Centralized Hilliard Exploded View
    264
  - All Wheel Drive Operation
    265
  - Awd Diagnosis
    266
  - Gearcase Assembly
    270
  - Gearcase Installation
    272
- Rear Bearing Carrier
  274
  - Bearing Carrier Inspection / Removal
    274
  - Bearing Replacement
    275
  - Bearing Carrier Bushing Replacement
    275
  - Bearing Carrier Installation
    276
- Rear Drive Shaft
  277
- Rear Gearcase
  285
  - Gearcase Removal
    285
  - Gearcase Disassembly
    286
  - Gearcase Assembly
    288
  - Gearcase Installation
    289
  - Gearcase Exploded View
    290
- Rear Gearcase (Rzr S Int'l)
  291
  - General Operation
    291
  - Gearcase Removal
    292
  - Gearcase Disassembly
    293
  - Differential Disassembly
    297
  - Differential Assembly
    298
  - Gearcase Assembly
    299
  - Gearcase Installation
    301
  - Gearcase Exploded View
    302
- Wheel Hubs
  303
Transmission Chapter 8 Transmission

305
- Shift Lever
  306
- Torque Values / Specifications
  306
- Chapter 8 Shift Cable Inspection / Adjustment
  307
- Transmission Service
  308
- Troubleshooting
  322
- Transmission Exploded View
  323
Brakes Chapter 9 Brakes

325
- Brake Noise Troubleshooting
  327
- Brake System Service Notes
  327
- Hydraulic Brake System Operation
  328
- Brake System Exploded View
  329
- Chapter 9
  329
- Rzr / Rzr S / Rzr S Int'l
  329
- Rzr 4
  329
- Brake Pedal Lever
  330
- Master Cylinder
  330
- Brake Bleeding / Fluid Change
  331
- Front Brake Pads
  332
  - Pad Removal
    332
  - Brake Burnishing Procedure
    334
- Front Caliper Service
  335
  - Caliper Exploded View (Rzr / Rzr S / Rzr S Int'l)
    335
  - Caliper Exploded View (Rzr 4)
    335
  - Caliper Removal
    336
  - Caliper Disassembly
    337
  - Caliper Inspection
    338
- Front Brake Disc
  340
  - Disc Replacement
    341
- Rear Brake Pads
  342
  - Pad Removal
    342
  - Brake Burnishing Procedure
    343
- Rear Caliper Service
  344
  - Caliper Exploded View
    344
  - Caliper Removal
    344
  - Caliper Assembly
    346
  - Caliper Installation
    347
- Rear Brake Disc
  347
  - Disc Inspection
    347
  - Disc Replacement
    348
- Troubleshooting
  348
Electrical Chapter 10 Electrical

349
- Chapter 10 Under-Dash Components
  351
- General Information
  351
- Switches / Controls
  351
  - Brake Light Switch
    351
  - Headlamp Switch
    352
  - Ignition Key Switch
    352
  - Ignition Key Switch (Int'l)
    353
  - Awd / 2Wd Switch
    353
  - Awd / 2Wd / Turf Switch (Int'l)
    354
  - Turn Signal Switch (Int'l)
    354
  - Hazard Switch (Int'l)
    354
  - Transmission (Gear Position) Switch
    355
- Vehicle Speed Sensor
  355
- Rear Diff Solenoid (Int'l)
  356
- Instrument Cluster
  357
  - Rider Information Display
    358
  - Information Display Area
    358
  - Diagnostic Mode
    361
- All Wheel Drive Coil
  363
- Head Lights
  363
  - Headlight Adjustment
    363
  - Headlamp Bulb Replacement
    364
- Tail / Brake Lights
  365
  - Bulb Replacement
    365
- Cooling System
  366
  - Cooling System Break-Out Diagram
    366
  - Coolant Temperature Sensor
    367
- Efi Diagnostics
  367
- Fuel Sender
  367
- Fuse Box: Fuses / Relays / Circuit Breaker
  368
  - Fuse Box Detail
    369
  - Relay Operation
    370
- Charging System
  372
  - Current Draw - Key off
    372
  - Regulator / Rectifier
    373
  - Charging System Testing Flow Chart
    374
- Battery Service
  375
  - Battery Testing
    376
  - Ocv - Open Circuit Voltage Test
    376
  - Load Test
    376
  - Battery Conductance Analyzer
    377
  - Charging Procedure
    377
- Starting System
  378
  - Troubleshooting
    378
  - Voltage Drop Test
    378
  - Starter Motor Removal / Disassembly
    378
  - Brush Inspection / Replacement
    379
  - Armature Testing
    380
  - Starter Reassembly / Installation
    380
  - Starter Drive
    381
  - Starter Solenoid Bench Test
    382
  - Starter Solenoid Operation
    382
  - Starter Exploded View
    383
- Starting System Testing Flow Chart
  384
- Electronic Power Steering (Eps)
  385
  - Eps Operation
    385
  - Eps 8-Way Wire Harness Connector
    385
  - Proper Eps System Diagnosing
    385
  - Eps System Breakout
    386
  - Eps Troubleshooting (Using Digital Wrench™)
    389
- Electrical System Breakouts
  390
  - Awd
    390
  - Vehicle Speed Sensor
    390
  - Cooling Fan
    391
  - Charging System
    392
  - Chassis Power
    393
  - Key-On Battery Power
    394
  - Electronic Power Steering (Eps)
    395
  - Engine Start (Starter Interlock)
    396

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Polaris Ranger RZR 800 Owner's Manual

Polaris Ranger RZR 800 Owner's Manual (157 pages)

Brand: Polaris | Category: Offroad Vehicle | Size: 3 MB

Table of Contents

Table of Contents
5
Introduction
6
- Vehicle Identification Numbers
  8
Safety
9
- Safe Riding Gear
  10
- Safety Warnings
  16
- Protective Apparel
  17
- Operating on Pavement
  19
- Operating on Public Roads
  19
- Operating at Excessive Speeds
  19
- Descending Hills Improperly
  20
- Improper Hill Climbing
  20
- Jumps and Stunts
  20
- Turning Improperly
  20
- Crossing Hillsides
  21
- Stalling While Climbing a Hill
  21
- Operating in Unfamiliar Terrain
  21
- Skidding or Sliding
  22
- Operating a Damaged Vehicle
  23
- Improper Cargo Loading
  24
- Exposure to Exhaust
  25
- Hot Exhaust Systems
  25
- Equipment Modifications
  26
Features and Controls
27
- Component Locations
  28
- Seat Removal
  29
- Steering Wheel
  30
  - Fuel Cap
    32
  - Seat Belt Inspection
    33
- Seat Belts
  33
  - Auxiliary Outlet
    34
  - Headlight Switch
    35
  - Ignition Switch
    35
  - Gear Selector
    36
  - Brake Pedal
    37
- Throttle Pedal
  37
  - All Wheel Drive System
    38
  - Engaging Awd
    38
  - Instrument Cluster
    39
  - Indicator Lamps
    40
- Rider Information Center
  41
- Clock Mode
  44
- Engine Error Codes
  47
Operation
48
- Brake System Break-In
  49
- Safe Operation Practices
  51
- Starting the Engine
  52
- Stopping the Engine
  52
- Parking the Vehicle
  53
- Trail Etiquette
  53
  - Driving with Passengers
    56
  - Driving on Slippery Surfaces
    57
  - Driving Uphill
    58
  - Driving Downhill
    59
  - Driving through Water
    60
  - Driving over Obstacles
    61
  - Driving in Reverse
    62
- Parking on an Incline
  63
  - Hauling Cargo
    64
  - Belt Life
    65
- Towing Loads
  66
Winch Guide
67
- Winch Safety Precautions
  68
- Winch Operation
  70
- Winch Cable Care
  75
- Winch Maintenance and Service Safety
  77
- Crankcase Emission Control System
  78
Emission Control Systems
78
Maintenance
79
- Severe Use Definition
  79
- Maintenance Chart Key
  80
- Periodic Maintenance Chart
  80
  - Lubrication Recommendations
    84
  - Engine Oil
    86
  - Engine Oil Check
    87
  - Oil Check
    87
  - Oil and Filter Change
    88
- Rear Gearcase
  95
- Gearcase Specification Chart
  96
- Spark Plugs
  96
- Spark Plug Condition
  97
  - Fuses
    99
  - Cooling System
    100
  - Radiator and Cooling Fan
    101
- Radiator Coolant Level
  101
- Coolant Level
  102
- Pvt Drying
  104
- Air Filter
  105
- Spark Arrester
  106
- Throttle Freeplay
  107
- Throttle Freeplay Inspection
  107
- Throttle System
  107
- Throttle Freeplay Adjustment
  108
  - Brake Fluid
    110
  - Brake Inspection
    111
- Steering Wheel Inspection
  112
- Suspension Settings
  113
- Tire Tread Depth
  117
- Wheel Installation
  118
- Wheel Removal
  118
- Brake Lights
  121
- Vehicle Immersion
  121
  - Battery Removal
    123
  - Battery Installation
    124
  - Battery Storage
    125
  - Cleaning and Storage
    128
- Polishing the Vehicle
  129
- Washing the Vehicle
  129
  - Storage Tips
    131
  - Removal from Storage
    133
- Transporting the Vehicle
  133
Specifications
134
POLARIS Products
138
Troubleshooting
139
Warranty
143
Maintenance Log
150
Index
152
- Gearcase Oil
  153
- Fluid Change
  153

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