Written from hands-on experience gained from the complete strip-down and rebuild of a Polaris RZR , Clymer can help you understand, care for and repair your Polaris RZR We do it ourselves to help you do-it-yourself, and whatever your mechanical ability, the practical step-by-step explanations, linked to over photos, will help you get the job done right. Regular servicing and maintenance of your Polaris RZR can help maintain its resale value, save you money, and make it safer to drive. Access this manual immediately on your internet browser on your mobile, desktop or tablet.
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Quick Links. Table of Contents. The model and VIN numbers are also located on a sticker under the hood B. Page 6: Vehicle Information Special tools may be required while servicing this vehicle. Some of the tools listed or depicted are mandatory, while other tools maybe substituted with a similar tool, if available.
Polaris recommends the use of Polaris Special Tools when servicing any Polaris Page 7: Misc. There are exceptions in the steering, suspension, and engine areas. Always consult the exploded views or each manual section for torque values of fasteners before using standard torque. Center Distance: Distance between center of crankshaft and center of driven clutch shaft. Chain Pitch: Distance between chain link pins No.
Polaris measures chain length in number of pitches. CI: Cubic inches. Page Periodic Maintenance Chart Polaris dealer. NOTE: Inspection may reveal the need for replacement parts. Always use genuine Polaris parts. Page 50 - Hour Maintenance Interval Clean out Inspect periodically; adjust when parts are Toe Adjustment replaced Headlight Aim Adjust as needed Perform these procedures more often for vehicles subjected to severe use.
Part No. Replace fuel line every two years. If the throttle pedal has excessive play due to cable stretch or cable misadjustment, it will cause a delay in throttle speed. Also, the throttle may not open fully. Installation Inspect the main air filter element and replace if necessary. Clean the air box thoroughly. Do not clean the main filter, the filter should be replaced.
Install a new or clean pre-filter over the main air filter NOTE: If the filter has been soaked with fuel or oil it element. To check the oil level follow the procedure listed below. Remove dipstick and fill sump with 2 quarts 1. Crankcase Drain Plug Torque: 16 ft.
Low engine compression is rarely a factor in running condition The engine is equipped with a breather hose. Inspect the problems above idle speed. The hose is form fit- A cylinder leakdown test is the best indication of engine ted for a proper fit. Maintain the fluid level even with the bottom of the fill plug hole. Position vehicle on a level surface. Remove the fill plug. The front gearcase lubricant level should be checked and Remove the fill plug and check the fluid level.
Add the recommended fluid as needed. Page Cooling System Remove recovery bottle cap and add coolant using a funnel. Refer to Chapter 3 for cooling system pressure test procedure. Remove any obstructions with compressed air or low pressure water. Wheel, Hub, and Spindle Torque Table Remove the upper engine outlet hose and recovery hose from the top of the radiator. Operating a RANGER with worn tires will increase the possibility of the vehicle skidding If hub nut was removed, install a new cotter pin after the easily with possible loss of control.
Battery Maintenance Keep battery terminals and connections free of corrosion. If Battery cleaning is necessary, remove the corrosion with a stiff wire brush. Wash with a solution of one tablespoon baking soda and one cup water. Allow engine to cool or wear protective once a month to make up for normal self-discharge.
Page Engine To Frame Ground Install spark plug and torque to specification. Due to the critical nature of the procedures outlined in Recommended Spark Plug: this chapter, Polaris recommends steering component Champion RC7YC3 repair and adjustment be performed by an authorized Polaris MSD certified technician when replacing Spark Plug Torque: worn or damaged steering parts.
Set steering wheel in a straight ahead position and secure the steering wheel in this position. If toe alignment is incorrect, measure the distance between vehicle center and each wheel. This will tell you which tie rod Stop the engine. Raise and safely support the front or rear of the vehicle off NOTE: Be sure steering wheel is straight ahead the ground to allow the suspension to fully extend.
Brake Fluid Inspection Inspect the brake pad wear surface for excessive wear. Always check the brake pedal travel and inspect the brake fluid reservoir level before each operation. Nm ft. Page Engine Cooling System CAUTION: Using tap water in the cooling system will lead to a buildup of deposits which may restrict coolant flow and reduce heat dissipation, resulting in possible engine damage. Place the vehicle in of air. Page General Engine Service Place the vehicle in neutral and set the parking brake.
Block the rear wheels. Capacity - Approximately 2 U. Quarts 1. Beginning in the crankcase sump, the oil is drawn through an oil galley to the feed side of the oil pump. The oil is then pumped through the oil filter.
If the oil filter is obstructed, a bypass valve contained in the filter allows oil to bypass the filter element. Because of its design configuration, Polaris recommends removing the engine, transmission, and rear gearcase as one assembly.
Use the following procedure when engine removal is required. Elevate the rear of the vehicle off the ground using a Remove the 6 fasteners retaining the upper bolt-in frame suitable ATV lift and remove both rear wheels. Loosen the hose clamp between the throttle body and intake Remove the airbox and throttle body from the vehicle as an adaptor.
Take care in not allowing the throttle cable to bend excessively or kink. Carefully place the assembly on the floor next to the vehicle. Mark the upper jam nut and loosen the lower jam nut. Pull Disconnect the transmission speed sensor harness. NOTE: If the upper jam nut is moved, shift cable adjustment will Remove the through-bolt that attaches the upper A-arm to Disconnect the engine coolant temperature ECT sensor the rear hub on both sides of the vehicle.
Connector Pivot the A-arms upward and rear hub carriers downward Remove RH engine mount fastener. Remove LH transmission mount fastener. Remove propshaft from the transmission output shaft. Remove only the 4 outer fasteners retaining the engine to the transmission bracket. 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.
Remove the valve cover. Mark or tag rocker arms in order of disassembly to keep them in order for reassembly. Cylinder Head Removal NOTE: The cargo box assembly and the upper frame bolt-in brace must be removed to allow enough clearance to remove all the cylinder head bolts.
Carefully remove the cylinder components. Hardened, cracked or worn valve seals will cause excessive oil consumption and carbon buildup. Mark the valves with a white pen. Check valve face for runout, pitting, and burnt spots. Valve Seat Reconditioning Apply cutting oil to valve seat and cutter.
Place 46 cutter on the pilot and make a light cut. Rinse and dry with compressed air. NOTE: Assemble the valves one at a time to maintain proper order. Lubricate the valve guides with clean engine oil, and apply oil or water based lapping compound to the face of the Apply engine oil to valve guides and seats.
Remove the valve lifters by reaching into the crankcase and pushing the lifter up through the lifter bore by hand. Thoroughly clean the lifters in cleaning solvent and wipe them with a clean, lint-free cloth.
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