User Manuals: Polaris RZR 800 2014 Off-road Vehicle

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Polaris RZR 800 2014 Manual

Polaris RZR 800 2014 Manual (500 pages)

Brand: Polaris | Category: Offroad Vehicle | Size: 82 MB

Table of Contents

Chapter 1 1 General Information

7
- Table of Contents
  7
- Engine Designation Number
  8
- Model Number Designation
  8
- Vehicle Identification
  8
- Vehicle Identification Number (Vin) Designation
  8
- Vehicle and Engine Serial Number Locations
  9
- Vehicle Information
  10
  - Publication Numbers
    10
  - Replacement Keys
    10
  - Special Tools
    11
- General Specifications
  12
- Misc. Specifications and Charts
  21
  - Conversion Table
    21
  - Standard Bolt Torque Specification
    22
  - Metric Bolt Torque Specification
    22
  - Sae Tap / Drill Sizes
    23
  - Metric Tap / Drill Sizes
    23
  - Decimal Equivalents
    24
Chapter 2 Maintenance

25
- Break-In Period
  27
- Maintenance Chart Key
  27
- Periodic Maintenance Chart
  27
- Periodic Maintenance Overview
  27
- Pre-Ride - 50 Hour Maintenance Interval
  28
- 100 - 300 Hour Maintenance Interval
  29
- Maintenance Quick Reference
  30
- Maintenance Quick Reference, Continued
  31
- Grease Lubrication Points
  32
- Lubricants / Service Products
  33
  - Polaris Lubricants, Maintenance and Service Products
    33
- General Vehicle Inspection and Maintenance
  34
- Fuel System and Air Intake
  35
  - Fuel System
    35
  - Fuel Line
    35
  - Fuel Pump / Fuel Filters
    35
  - Vent Lines
    36
  - Throttle Pedal Inspection
    36
  - Throttle Freeplay Adjustment
    36
  - Air Filter Service
    37
- Engine
  39
- Transmission and Gearcases
  43
- Cooling System
  48
  - Cooling System Overview
    48
  - Coolant Level Inspection
    48
  - Coolant Strength / Type
    48
  - Cooling System Pressure Test
    49
  - Cooling System Hoses
    49
  - Radiator
    49
  - Coolant Drain
    49
- Final Drive / Wheel and Tire
  50
  - Wheel and Hub Torque Table
    50
  - Wheel Removal
    50
  - Wheel Installation
    50
  - Tire Inspection
    51
  - Tire Pressure
    51
  - Drive Shaft Boot Inspection
    52
- Electrical and Ignition System
  52
  - Battery Maintenance
    52
  - Battery Removal
    53
  - Battery Installation
    53
  - Battery off Season Storage
    53
  - Battery Charging (Maintenance Free)
    53
  - Spark Plug Service
    53
  - Engine to Frame Ground
    55
- Steering
  55
  - Steering Inspection
    55
  - Steering Wheel Freeplay
    55
  - Tie Rod End / Wheel Hub Inspection
    56
  - Wheel Toe Alignment Inspection
    57
  - Wheel Toe Adjustment
    57
- Suspension (Standard)
  58
  - Spring Preload Adjustment
    58
- Suspension (Fox™)
  59
  - Spring Preload Adjustment
    59
  - Shock Compression Adjustment
    60
- Brake System
  60
Chapter 3 Engine

63
- Crankcase Exploded Views
  65
- Engine Specifications
  65
- Oil Pump / Gears / Engine Cover Exploded View
  66
- Stator Cover / Starter / Water Pump / Lubrication System Exploded View
  67
- Cylinder / Cylinder Head / Piston Exploded View
  68
- Engine Efi Sensors / Valve Cover / General Components Exploded View
  69
- Engine Torque Specifications
  70
- 800 EFI Engine Service Specifications
  71
- Special Tools
  73
- Engine Cooling System
  74
  - Cooling System Pressure Test
    74
  - Pressure Cap Test
    74
  - Cooling System Exploded View
    75
  - Radiator Removal
    76
  - Cooling System Bleeding Procedure
    77
- General Engine Service
  79
  - Engine Lubrication Specifications
    79
  - Oil Pressure Test
    79
  - Accessible Engine Components
    79
  - Oil Flow Chart
    80
  - Engine Removal
    81
  - Engine / Transmission Separation
    89
- Engine Disassembly and Inspection
  90
  - Cylinder Head Assembly Exploded View
    90
  - Rocker Arms
    91
  - Push Rods
    91
  - Cylinder Head Removal
    91
  - Cylinder Head Inspection
    92
  - Cylinder Head Warp
    92
  - Valve Seal / Spring Service (on Engine)
    92
  - Cylinder Head Disassembly
    93
  - Valve Inspection
    94
  - Combustion Chamber
    95
  - Valve Seat Reconditioning
    95
  - Cylinder Head Reassembly
    98
  - Valve Sealing Test
    98
  - Cylinder Removal
    98
  - Valve Lifter Removal / Inspection
    99
  - Piston Removal
    99
  - Cylinder Inspection
    100
  - Cylinder Hone Selection and Honing Procedure
    102
  - Honing to Deglaze
    102
  - Cleaning the Cylinder after Honing
    102
  - Piston-To-Cylinder Clearance
    102
  - Piston / Rod Inspection
    103
  - Piston Ring Installed Gap
    104
  - Starter Drive Bendix Removal / Inspection
    104
  - Flywheel / Stator Removal / Inspection
    105
  - Engine Crankcase Disassembly / Inspection
    106
  - Camshaft Inspection
    115
- Engine Reassembly
  117
  - Crankcase Reassembly
    117
  - Flywheel / Stator Installation
    127
  - Cylinder Head Reassembly
    128
  - Oil Pump Priming
    131
- Engine Installation
  132
  - Engine Assembly and Installation
    132
  - Engine Break-In Period
    133
- Troubleshooting
  134
  - Engine
    134
  - Cooling System
    135
Chapter 4 Electronic Fuel Injection

137
- General Information
  139
- Special Tools
  139
- Service Notes
  141
- Efi System Exploded View
  142
- Efi System Component Locations
  143
- Fuel Tank
  146
  - Exploded View
    146
  - Fuel Line Removal / Installation
    147
- Electronic Fuel Injection
  148
  - Principal Components
    148
  - Efi Operation Overview
    148
  - Initial Priming / Starting Procedure
    148
- Electronic Control Unit (Ecu)
  149
  - Operation Overview
    149
  - Ecu Service
    149
  - Ecu Replacement
    149
- Pressure Sensor (T-Map)
  150
  - Operation Overview
    150
  - T-Map Sensor Test
    150
  - T-Map Sensor Replacement
    150
- Crankshaft Position Sensor (Cps)
  151
  - Operation Overview
    151
  - Cps Test
    151
  - Cps Replacement
    152
- Fuel Injectors
  156
  - Operation Overview
    156
  - Fuel Injector Service
    156
  - Fuel Injector Test
    157
  - Fuel Injector Replacement
    157
- Fuel Pump
  159
  - Operation Overview
    159
  - Fuel Sender Test
    159
  - Fuel Pump Test
    160
  - Fuel Pump Replacement
    161
  - Fuel Tank Removal (Rzr / Rzr
    164
  - Fuel Tank Removal (Rzr 4)
    167
  - Fuel Tank Installation
    170
- Idle Air Control (Iac)
  170
  - Operation Overview
    170
  - Iac Test
    170
  - Iac Replacement
    171
- Throttle Position Sensor (Tps)
  171
  - Tps Resistance Tests
    172
  - Tps Tester / Regulator
    172
  - Tps Replacement
    173
- Camshaft Phase Sensor
  175
  - Operation Overview
    175
  - Cam Phase Sensor Test
    175
  - Cam Phase Sensor Replacement
    175
- Engine Coolant Temperature Sensor (Ect)
  176
  - Operation Overview
    176
  - Ect Sensor Test
    176
  - Ect Sensor Replacement
    176
- Ignition Coil
  177
  - Operation Overview
    177
  - Ignition Coil / Ht Lead Replacement
    177
  - Ignition Coil Tests
    177
- Efi Diagnostics
  178
  - Instrument Cluster Trouble Code Display
    178
  - Efi Troubleshooting
    182
- Digital Wrench® Operation
  183
  - Digital Wrench® Diagnostic Software Overview
    183
  - Special Tools
    183
  - Diagnostic Software Version
    183
  - Ecu Replacement
    183
  - Guided Diagnostic Available
    183
  - Digital Wrench® Communication Errors
    184
  - Digital Wrench® - Diagnostic Connector
    184
  - Digital Wrench® Serial Number Location
    184
  - Digital Wrench® Version and Update
    184
  - Digital Wrench® Updates
    185
  - Digital Wrench® Feature Map
    186
  - Engine Controller Reprogramming (Reflash)
    187
Chapter 5 Body / Steering / Suspension

191
- Special Tools
  194
- Torque Specifications
  194
- Cab Frame (Rzr / Rzr S)
  195
  - Assembly / Removal
    195
- Cab Frame (Rzr 4)
  197
  - Assembly / Removal
    197
- Body Exploded Views
  199
  - Side Safety Nets
    199
  - Dash Instruments / Controls / Glovebox
    200
  - Hood / Front Body Work
    201
  - Front Bumper
    202
  - Rear Bumper
    202
  - Seat Assembly
    203
  - Seat Belts / Mounting (Rzr / Rzr
    203
  - Seat Belts / Mounting (Rzr 4)
    204
  - Floor / Rocker Panels (Rzr / Rzr
    205
  - Floor / Rocker Panels (Rzr 4)
    206
  - Rear Cargo Box / Fenders (Rzr / Rzr
    207
  - Rear Cargo Box / Fenders (Rzr 4)
    208
  - Chassis / Main Frame (Rzr / Rzr
    209
  - Chassis / Main Frame (Rzr 4)
    210
- Body Component Removal
  211
  - Seats
    211
  - Rear Service Panel (Rzr / Rzr
    211
  - Rear Console Cover (Rzr 4)
    211
  - Front Bumper
    211
  - Rear Bumper
    212
  - Hood and Front Body Work
    212
  - Rear Fender, Flair and Tie down Removal
    213
  - Cargo Box Assembly Removal
    213
  - Rocker Panels, Console and Floor
    214
- Steering Assembly
  215
- Electronic Power Steering Assembly
  218
- Front A-Arms
  224
  - Removal / Replacement
    224
  - Exploded View (Rzr)
    226
  - Exploded View (Rzr S / Rzr 4)
    226
- Ball Joint Service
  227
  - Service Preparation
    227
  - Ball Joint Removal
    227
  - Ball Joint Installation
    228
- Front Stabilizer Bar (Rzr / Rzr S Int
  229
  - Stabilizer Bar Linkage Removal
    229
  - Stabilizer Bar Removal
    229
  - Exploded View
    231
- Rear A-Arms
  232
  - Removal
    232
  - Installation
    233
  - Exploded View (Rzr)
    234
  - Exploded View (Rzr S / Rzr 4)
    235
- Rear Stabilizer Bar (Rzr)
  235
  - Removal / Installation
    236
- Rear Stabilizer Bar (Rzr S / Rzr 4)
  236
- Decal Replacement
  238
- Shocks / Springs / Fasteners
  238
  - Exploded View (Rzr / Rzr
    238
  - Exploded View (Rzr S / Rzr S Int
    238
  - Shock Removal / Installation
    239
  - Shock Replacement
    239
- Fox™ Podium Piggyback Shock Service
  240
- Fox™ Podium Top Fill Shock Service
  252
- Walker Evans™ Shock Exploded Views
  262
  - Walker Evans™ 2.0" Shock
    262
- Walker Evans™ Shock Service
  263
  - General Service Information
    263
  - Rear Shock Service Information
    264
  - Walker Evans™ Shock Rebuild Information
    265
  - Special Tools
    265
  - Valve Shim Arrangement
    265
  - Piston Orientation
    265
  - Walker Evans™ Shock Disassembly
    266
  - Walker Evans™ Shock Assembly
    268
Chapter 6 Clutching

275
- Special Tools and Supplies
  277
- Torque Specifications
  277
- High Altitude Clutch Charts
  278
  - Rzr / Rzr S / Rzr 4
    278
  - Rzr Eps (Ebs Model)
    278
- Pvt System Overview
  278
  - General Operation
    278
  - Drive Clutch Operation
    278
  - Driven Clutch Operation
    279
  - Pvt Break-In (Drive Belt / Clutches)
    279
  - Maintenance / Inspection
    279
  - Overheating / Diagnosis
    280
- Pvt System Service
  281
  - Pvt Covers and Ducting Components
    281
  - Pvt Disassembly
    282
  - Pvt Assembly
    283
  - Clutch Offset Procedure
    285
- Drive Belt (Non-Ebs)
  287
  - Belt Removal
    287
  - Belt Inspection
    287
  - Belt Installation
    287
- Drive Belt (Ebs)
  288
  - Belt Removal
    288
  - Belt Inspection
    288
  - Belt Installation
    288
- Drive Clutch Service
  289
  - Exploded View
    289
  - Shift Weights
    289
  - Clutch Disassembly
    290
  - Bearing Inspection
    290
  - Drive Clutch Spring Inspection
    291
  - Shift Weight Inspection
    291
  - Button to Tower Clearance Inspection
    292
  - Spider Removal
    292
  - Roller, Pin, and Thrust Washer Inspection
    293
  - Clutch Inspection
    293
  - Moveable Sheave Bushing Inspection
    295
  - Bushing Service
    295
  - Clutch Assembly
    297
- Driven Clutch Service (Non-Ebs)
  299
  - Exploded View
    299
  - Clutch Disassembly / Inspection
    299
  - Clutch Assembly
    301
- Driven Clutch Service (Ebs)
  302
  - Clutch Disassembly
    302
  - Bushing Service
    305
  - Clutch Assembly
    306
  - Exploded View
    310
- Troubleshooting
  311
Chapter 7 Final Drive

313
- Special Tools
  315
- Torque Specifications
  315
- Front Bearing Carrier
  316
  - Bearing Carrier Inspection / Removal
    316
  - Bearing Replacement
    317
  - Bearing Carrier Installation
    318
- Front Drive Shaft
  320
  - Drive Shaft Removal
    320
  - Drive Shaft / CV Joint Handling Tips
    321
  - Outer CV Joint / Boot Replacement
    321
  - Inner Plunging Joint / Boot Replacement
    322
  - Drive Shaft Installation
    324
- Propshaft Service
  326
  - Removal / Installation (Rzr 4)
    327
  - Support Bearing Replacement (Rzr 4)
    329
- Propshaft U-Joint Service
  330
  - Disassembly
    330
  - Assembly
    330
- Front Gearcase / Centralized Hilliard
  332
  - Centralized Hilliard Exploded View
    332
  - All Wheel Drive Operation
    333
  - Awd Diagnosis
    334
  - Gearcase Removal
    335
  - Gearcase Disassembly / Inspection
    336
  - Gearcase Assembly
    339
  - Gearcase Installation
    342
- Rear Bearing Carrier
  343
  - Bearing Carrier Inspection / Removal
    343
  - Bearing Replacement
    344
  - Bearing Carrier Bushing Replacement
    345
  - Bearing Carrier Installation
    345
- Rear Drive Shaft
  347
  - Drive Shaft Removal
    347
  - Outer CV Joint / Boot Replacement
    348
  - Inner Plunging Joint / Boot Replacement
    351
  - Drive Shaft Exploded View
    354
  - Drive Shaft Installation
    354
- Rear Gearcase
  356
  - Gearcase Removal
    356
  - Gearcase Disassembly
    357
  - Gearcase Assembly
    360
  - Gearcase Installation
    363
- Rear Gearcase (Rzr S Int
  363
  - General Operation
    365
  - Gearcase Removal
    366
  - Gearcase Disassembly
    368
  - Differential Disassembly
    372
  - Differential Assembly
    373
  - Gearcase Assembly
    374
  - Gearcase Installation
    377
  - Gearcase Exploded View
    378
- Wheel Hubs
  379
  - Front Hub Exploded View
    379
  - Rear Hub Exploded View
    379
Chapter 8 Transmission

381
- Removal
  382
- Shift Lever
  382
- Torque Values / Specifications
  382
- Installation
  383
- Shift Cable Inspection / Adjustment
  383
- Transmission Service
  384
- Troubleshooting
  404
  - Troubleshooting Checklist
    404
- Transmission Exploded View
  405
  - Shift Housing / Transfer Case Exploded View
    405
Chapter 9 Brakes

407
- General Specifications
  409
- Special Tools
  410
- Torque Specifications
  410
- Brake System Service Notes
  411
- Brake Noise Troubleshooting
  412
- Hydraulic Brake System Operation
  413
- Brake System Exploded View
  414
  - Rzr / Rzr S / Rzr S Int'l
    414
  - Rzr 4
    414
- Master Cylinder
  415
  - Removal
    415
  - Installation
    415
- Brake Bleeding / Fluid Change
  416
- Brake Pedal Lever
  416
  - Pedal Removal
    416
  - Pedal Installation
    416
- Front Brake Pads
  417
  - Pad Removal
    417
  - Pad Inspection
    419
  - Pad Assembly / Installation
    419
  - Brake Burnishing Procedure
    420
- Front Caliper Service
  421
  - Caliper Exploded View (Rzr / Rzr S / Rzr S Int
    421
  - Caliper Exploded View (Rzr 4)
    421
  - Caliper Removal
    422
  - Caliper Disassembly
    423
  - Caliper Inspection
    424
  - Caliper Assembly
    425
  - Caliper Installation
    426
- Front Brake Disc
  427
  - Disc Runout
    427
  - Disc Inspection
    428
  - Disc Replacement
    428
- Rear Brake Pads
  429
  - Pad Removal
    429
  - Pad Inspection
    430
  - Pad Assembly / Installation
    431
  - Brake Burnishing Procedure
    431
- Rear Caliper Service
  432
  - Caliper Exploded View
    432
  - Caliper Removal
    432
  - Caliper Disassembly
    433
  - Caliper Inspection
    434
  - Caliper Assembly
    435
  - Caliper Installation
    435
- Rear Brake Disc
  436
  - Disc Inspection
    436
  - Disc Replacement
    437
- Troubleshooting
  438
  - Pedal Vibration
    438
  - Caliper Overheats (Brakes Drag)
    438
  - Brakes Lock
    438
Chapter 10 Electrical

439
- Electrical Service Notes
  441
- General Information
  441
- Special Tools
  441
- Under-Dash Components
  441
- Switches / Controls
  442
  - Brake Light Switch
    442
  - Headlamp Switch
    442
  - Ignition Key Switch
    443
  - Awd / 2Wd Switch
    444
  - Transmission (Gear Position) Switch
    446
  - Throttle Release Switch (Trs)
    446
- Vehicle Speed Sensor
  448
  - Speed Sensor Location
    448
  - Speed Sensor Testing
    448
- Rear Diff Solenoid (Int'l)
  449
  - Differential Solenoid Overview
    449
  - Differential Solenoid Circuit Operation
    449
- All Wheel Drive Coil
  450
  - Operation Overview
    450
  - Diagnosing System Failures
    450
- Instrument Cluster
  451
  - Overview
    451
  - Rider Information Display
    452
  - Information Display Area
    452
  - Diagnostic Mode
    455
  - Instrument Cluster Pinouts
    456
  - Instrument Cluster Removal
    456
  - Instrument Cluster Installation
    456
- Head Lights (Incandescent)
  457
  - Headlight Adjustment
    458
  - Headlamp Housing Removal
    458
  - Headlamp Housing Installation
    458
- Head Lights (Led)
  458
  - Headlamp Replacement
    459
  - Headlamp Installation
    460
- Tail / Brake Lights
  460
  - Bulb Replacement
    460
- Cooling System
  461
- Efi Diagnostics
  461
  - Efi Component Testing
    461
- Fuel Sender
  462
  - Testing
    462
- Fuse Box: Fuses / Relays / Circuit Breaker
  463
  - Overview / Operation
    463
  - Fuse Box Detail
    464
  - Relay Operation
    465
- Charging System
  466
  - Current Draw - Key off
    466
  - Charging System "Break Even" Test
    466
  - Charging System Alternator Tests
    467
  - Regulator / Rectifier
    468
  - Charging System Testing Flow Chart
    469
- Battery Service
  470
  - Battery Specifications
    470
  - General Battery Information
    470
  - Battery Removal / Installation
    471
  - Battery off Season Storage
    471
  - Battery Testing
    471
  - Ocv - Open Circuit Voltage Test
    471
  - Load Test
    471
  - Battery Conductance Analyzer
    471
  - Charging Procedure
    472
- Starting System
  473
  - Troubleshooting
    473
  - Voltage Drop Test
    473
  - Starter Motor Removal
    473
  - Starter Motor Installation
    473
  - Starter Drive Bendix
    474
  - Starter Solenoid Bench Test
    474
  - Starter Solenoid Operation
    474
- Starting System Testing Flow Chart
  475
  - Condition: Starter Fails to Turn over the Engine
    475
- Electronic Power Steering (Eps)
  476

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