Find replacement and service parts catalogs online for the Polaris RZR, Sportsman, ACE, GENERAL and RANGER by model and year. This service manual is designed primarily for use by certified Polaris Master Service Comments or suggestions about this manual may be directed to: Service. This is the Highly Detailed factory service repair manual for the POLARIS RANGER RZR S , this Service Manual has detailed.

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Support U-joint in vise as shown and drive inner yoke down Continually check for free movement of bearing cross as to remove remaining bearing caps. Then move assembly towards the front of the vehicle while lifting it out to allow the rear gearcase to clear the rear portion of the frame.

Always use the recommended engine oil. Install the 2 shift housing case screws to the backside as shown. Remove thrust plate U. Neutral This lamp illuminates when the transmission is in neutral and the ignition key is in the ON position. If you scroll past the intended number, press Programmable Service Interval and hold the button until the hours cycle back to When the hours of engine operation equal the programmed zero.

Beginning in the crankcase sump, the oil is drawn through an oil galley to the feed side of the oil pump.

Owner’s Manuals | Polaris Off-Road Vehicles

Remove primer plug from the engine. Always follow these precautions when towing: Align the pivot pin holes and install clutch yoke pivot pin. Page The pressure adapter has an integrated relief valve. Support the bottom of the bearing carrier housing. Never open the throttle suddenly.


Place the A-arm in the correct position for ball joint Correct installation. If parking on an incline is unavoidable, follow these precau- tions: Use the Gear Holder PU The new bolts contain Be sure that tab of fulcrum Polarus is seated in head stand-off.

If ascending a steeper grade is unavoidable, engage all-wheel drive before ascending. The backlash for the centralized hilliard is set Remove the 4 screws retaining the pinion shaft assembly at the factory.

Remove battery from the vehicle. Always exercise extreme caution whenever handling gasoline.

Polaris RZR 800 Owner’s Manual

The Electronic Fuel Injection EFI system is a complete engine Place a shop towel around the fuel line to catch any fuel and ignition management design. Loosen the hose clamp between the throttle body and intake Check the brake pedal for excessive travel or a spongy feel.

Never release the clutch on the winch when the winch cable is under load. Remove snap ring A and slowly Remove driven clutch from the transmission input shaft. Operate this vehicle only outdoors or in well-ventilated areas. Do not allow these types of products to contact the vehicle. Due to the manufacturing process, the pinion and ring gear assembly are NOT intended to be disassembled and ownets.

A multi-directional torque wrench is required in this application because of the limited access to this bolt. Items not listed in the chart should be lubricated at the general lubrication interval. Block the rear wheels. Hardened, cracked or worn valve seals will cause excessive oil consumption and carbon buildup. If crossing a hill is unavoidable, follow these precautions: Clean out Inspect periodically; adjust when parts polarus Toe Adjustment replaced Headlight Aim Adjust as needed Perform these procedures more often for vehicles subjected to severe use.


Ring gear backlash is set from the factory.

Owner’s Manuals

Always change the oil filter whenever changing oil. Low engine compression is rarely a factor in running condition The engine is equipped with a breather hose. Don’t have an account?

Failure to remove ALL debris when replacing the belt could result in vehicle damage, loss of control and severe injury or death. Inspect the valve poalris for signs of possible obstructions. Some of the tools listed or depicted are mandatory, while other tools maybe substituted with a similar tool, if available. If coolant must be added often, or if the overflow bottle runs completely dry, there may be a leak in the system.

Remove cover, spring, and spider following of dents or gall marks. Look ahead and learn to read the terrain. Respect the ;olaris in which you ride your vehicle.