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.

Author: Zulugore Migis
Country: Mongolia
Language: English (Spanish)
Genre: Business
Published (Last): 1 March 2010
Pages: 70
PDF File Size: 4.61 Mb
ePub File Size: 14.70 Mb
ISBN: 334-3-45639-903-5
Downloads: 13659
Price: Free* [*Free Regsitration Required]
Uploader: Dout

Shift weights should not be changed or altered without first having a thorough understanding of their positioning and the effects they may have on belt to sheave clearance, clutch balance and shifting pattern.

When replacing a damaged boot, check the Refit CV joint on the shaft by tapping with a plastic hammer grease for contamination by rubbing it between two on the joint housing.

RZR Service Manuals

Clutch seals should be inspected for damage if repeated leaking occurs. Never operate the vehicle on pavement or on any public street, road or highway, including dirt and gravel roads. Lubricate connecting rods with 0W engine oil.


Replace clutch assembly if worn or damaged. Put Install a new bearing onto the output shaft using a press. Socket Set Manuap B. Inspect the top of the cylinder B for warp using a straight edge A and feeler manial C.

RZR Service Manual | eBay

Pinion and ring gear shimming information is NOT provided. It is important that the same number and Inspect area on shaft where bushing rides for wear, galling, thickness of washers are reinstalled beneath the nicks, or scratches. Loads should be centered and carried as low as possible in the rzt.

The components are matched at the factory which requires special OEM tooling in order to properly assemble and shim the gears.

Owner’s Manuals | Polaris

Never remove the hook strap from the hook. A separate amp circuit breaker protects the fan motor circuit see wire diagram for details. Manuap of the transmission is not possible without removing the engine and differential.

Install the cover screws onto the rear gearcase. Don’t have an account?

Rollers are spring loaded. If the instrument cluster fails to illuminate, a front wheel. Replace any worn or damaged components. Never load more than lbs.

Do not obstruct or deflect air flow through the radiator by installing unauthor- ized accessories in front of the radiator or behind the cooling fan. Verify the o-ring is in position. Install red lead on the battery positive.


The drain plug is located on the bottom right side of the rear Rear Gearcase Specifications gearcase. Carefully place the assembly on the floor next to the vehicle.

Brake Fluid Inspect the level of the brake fluid before each operation. Be sure bushings and pivot tubes are installed. Bearing cup is a housing. Remove the roll cage assembly and rollers from the clutch Do not loosen the It is important to tighten the bottom starter Remove the retaining ring, mnaual washer, spring retainers bolt first circleas the bottom hole acts as a pilot and clutch return spring.

Polaris RZR 800 Owner’s Manual

Press shaft into the new bearing. Remove the rear service panel.

This manual also for: To print the manual completely, please, download it. The U-shaped insert controls the pole gap.