Polaris RANGER RZR 4 Manuals

Manuals and User Guides for Polaris RANGER RZR 4. We have 2 Polaris RANGER RZR 4 manuals available for free PDF download: Service Manual, Owner's Manual

Polaris RANGER RZR 4 Service Manual

Polaris RANGER RZR 4 Service Manual (418 pages)

Brand: Polaris | Category: Offroad Vehicle | Size: 39.29 MB

Table of Contents

General Information Chapter 1 1

6
- Table of Contents
  6
- Chapter 1
  7
- Engine Designation Number
  7
- General Information
  7
- Model Identification
  7
- Model Information
  7
- Vehicle and Engine Serial Number Location
  7
- Vin Identification
  7
- Special Tools
  8
- Vehicle Information
  8
  - Publication Numbers
    8
  - Replacement Keys
    8
- General Specifications
  9
- Misc. Specifications and Charts
  15
  - Conversion Table
    15
  - Standard Torque Specifications
    16
  - Sae Tap / Drill Sizes
    17
  - Metric Tap / Drill Sizes
    17
  - Glossary of Terms
    18
Maintenance Chapter 2 Maintenance 2

20
- Break-In Period / Maintenance Chart Key
  22
- Chapter 2
  22
- Periodic Maintenance Chart
  22
- Pre-Ride - 25 Hour Maintenance Interval
  23
- 50 - 500 Hour Maintenance Interval
  24
- Maintenance Quick Reference
  25
- Maintenance Quick Reference, Continued
  26
- Grease Lubrication Points
  27
- Lubricants / Service Products
  28
- General Vehicle Inspection and Maintenance
  29
- Fuel System and Air Intake
  30
- Engine
  34
- Transmission and Gearcases
  37
- Cooling System
  41
  - Coolant Level Inspection
    41
  - Coolant Strength / Type
    41
  - Cooling System Pressure Test
    42
  - Cooling System Hoses / Radiator
    42
  - Coolant Drain / Radiator Removal
    42
  - Wheel Installation
    43
- Final Drive / Wheel and Tire
  43
- Electrical and Ignition System
  45
  - Battery Maintenance
    45
  - Battery Removal
    45
  - Battery Installation
    46
  - Battery off Season Storage
    46
  - Battery Charging (Maintenance Free)
    46
  - Spark Plug Service
    46
  - Engine to Frame Ground
    47
- Steering
  47
- Suspension (Fox™)
  50
  - Shock Compression Adjustment
    51
- Suspension (Standard)
  50
  - Spring Preload Adjustment
    50
- Suspension (Walker Evans™)
  52
  - Spring Preload Adjustment
    52
  - Shock Compression Adjustment
    52
- Brake System
  53
- Maintenance Log
  54
Chapter 3 Engine

56
- Crankcase
  57
- Engine Specifications
  57
- Oil Pump / Gears / Engine Cover
  58
- Stator Cover / Starter / Water Pump / Lubrication System
  59
- Cylinder / Cylinder Head / Piston
  60
- Engine Efi Sensors / Valve Cover / General Components
  61
- Engine Torque Specifications
  62
- 800 EFI Engine Service Specifications
  63
- Special Tools
  65
- Engine Cooling System
  66
- General Engine Service
  69
- Engine Disassembly and Inspection
  79
  - Cylinder Head Assembly Exploded View
    79
  - Rocker Arms / Push Rods
    80
  - Cylinder Head Removal
    80
  - Cylinder Head Inspection / Warp
    81
  - Valve Seal / Spring Service (on Engine)
    81
  - Cylinder Head Warp
    81
  - Cylinder Head Disassembly
    82
  - Valve Inspection
    83
  - Combustion Chamber
    84
  - Valve Seat Reconditioning
    84
  - Cylinder Head Reassembly
    86
  - Valve Sealing Test
    87
  - Cylinder Removal
    87
  - Valve Lifter Removal / Inspection
    87
  - Piston Removal
    88
  - Cylinder Inspection
    89
  - Cylinder Hone Selection and Honing Procedure
    90
  - Honing to Deglaze / Cleaning the Cylinder after Honing
    90
  - Piston-To-Cylinder Clearance
    91
  - Piston / Rod Inspection
    91
  - Piston Ring Installed Gap
    92
  - Starter Drive Bendix Removal / Inspection
    92
  - Flywheel / Stator Removal / Inspection
    93
  - Engine Crankcase Disassembly / Inspection
    93
  - Camshaft Inspection
    101
- Engine Reassembly
  102
  - Crankcase Reassembly
    102
  - Flywheel / Stator Installation
    111
  - Cylinder Head Reassembly
    111
  - Oil Pump Priming
    113
- Engine Installation
  114
  - Engine Assembly and Installation
    114
  - Engine Break-In Period
    115
- Troubleshooting
  116
Chapter 4 Electronic Fuel Injection

118
- Electronic Fuel Injection
  119
- General Information
  119
- Special Tools
  119
- Service Notes
  121
- Efi System Exploded View
  122
- Efi System Component Locations
  123
- Fuel Tank
  125
  - Fuel Lines - Quick Connect
    126
- Electronic Fuel Injection
  126
  - Principal Components / Efi Operation Overview
    126
  - Initial Priming / Starting Procedure
    127
- Electronic Control Unit (Ecu)
  127
- Temp / Manifold Absolute Pressure Sensor (T-Map)
  128
- Crankshaft Position Sensor (Cps)
  129
  - Cps Test
    129
  - Cps Replacement
    130
- Fuel Injectors
  133
  - Fuel Injector Service
    134
  - Fuel Injector Replacement
    135
- Fuel Pump
  136
  - Fuel Sender Test
    136
  - Fuel Pump Test
    137
  - Fuel Pump Replacement
    138
  - Fuel Tank Removal (Rzr / Rzr S)
    141
  - Fuel Tank Removal (Rzr 4)
    143
  - Fuel Tank Installation
    145
- Idle Air Control (Iac)
  146
- Throttle Position Sensor (Tps)
  147
  - Tps Replacement
    148
- Camshaft Phase Sensor
  150
- Engine Coolant Temperature Sensor (Ect)
  151
  - Overview, Test and Replacement
    151
- Ignition Coil
  152
- Efi Diagnostics
  153
  - Instrument Cluster Trouble Code Display
    153
  - Diagnostic Trouble Code Table
    153
  - Efi Troubleshooting
    156
- Digital Wrench™ Operation
  157
- Efi System Electrical Operation
  165
Chapter 5 Body / Steering / Suspension

166
- Special Tools
  168
- Torque Specifications
  168
- Cab Frame (Rzr / Rzr S)
  169
- Cab Frame (Rzr 4)
  170
- Body Exploded Views
  171
- Side Safety Nets
  171
- Dash Instruments / Controls / Glovebox
  172
- Hood / Front Body Work
  173
- Seat Assembly
  175
- Seat Belts / Mounting (Rzr / Rzr S)
  175
- Seat Belts / Mounting (Rzr 4)
  176
- Floor / Rocker Panels (Rzr / Rzr S)
  177
- Floor / Rocker Panels (Rzr 4)
  178
- Rear Cargo Box / Fenders (Rzr / Rzr S)
  179
- Rear Cargo Box / Fenders (Rzr 4)
  180
- Chassis / Main Frame (Rzr / Rzr S)
  181
- Chassis / Main Frame (Rzr 4)
  182
- Body Component Removal
  183
  - Seats
    183
  - Rear Service Panel (Rzr / Rzr S)
    183
  - Rear Console Cover (Rzr 4)
    183
  - Front Bumper
    183
  - Rear Bumper
    184
  - Hood and Front Body Work
    184
  - Rear Fender, Flair and Tie down Removal
    185
  - Cargo Box Assembly Removal
    185
  - Rocker Panels, Console and Floor
    186
- Steering Assembly
  187
- Electronic Power Steering Assembly
  190
- Front A-Arms
  196
  - Removal / Replacement
    196
  - Exploded View
    197
- Ball Joint Service
  198
  - Removal
    198
  - Installation
    199
- Front Stabilizer Bar (Rzr / Rzr S Int'l)
  199
  - Sway Bar Linkage Removal
    199
  - Stabilizer Bar Removal
    199
  - Exploded View
    200
- Rear A-Arms
  201
  - Removal
    201
  - Installation
    202
  - Exploded View
    203
- Rear Stabilizer Bar (Rzr)
  204
- Rear Stabilizer Bar (Rzr S / Rzr 4)
  205
- Decal Replacement
  206
- Shocks / Springs / Fasteners
  206
  - Exploded View (Rzr / Rzr S)
    206
  - Exploded View (Rzr S / Rzr S Int'l)
    206
  - Exploded View (Rzr 4)
    207
- Fox™ Shock Exploded Views
  208
  - Fox™ Podium X 'Piggyback' Shock (Rzr S)
    208
  - Fox™ 2.0 'Piggyback' Shock (Rzr 4)
    209
- Fox™ Shock Service
  210
  - General Service Information
    210
  - Fox™ Shock Rebuild Information
    212
  - Fox™ Shock Disassembly
    213
  - Fox™ Shock Rebuild
    215
  - Fox™ Shock Reassembly
    216
- Walker Evans™ Shock Exploded View
  219
  - Walker Evans™ Compression Adjuster Reservoir Shock (Rzr L.e.)
    219
- Walker Evans™ Shock Service
  220
  - Recommended Service Intervals
    220
  - Walker Evans™ Shock Rebuild Information
    221
  - Special Tools
    221
  - Valve Shim Arrangement
    221
  - Piston Orientation
    221
  - Walker Evans™ Shock Disassembly
    222
  - Walker Evans™ Shock Assembly
    224
Clutching Chapter 6 Clutching

228
- Chapter 6
  229
- Drive Clutch Operation
  229
- General Operation
  229
- Pvt System Overview
  229
- Special Tools and Supplies
  229
- Torque Specifications
  229
- Driven Clutch Operation
  230
- Maintenance / Inspection
  230
- Pvt Break-In (Drive Belt / Clutches)
  230
- Overheating / Diagnosis
  231
- Pvt System Service
  232
  - Pvt Covers and Ducting Components
    232
  - Pvt Disassembly
    233
  - Pvt Assembly
    234
  - Clutch Offset Procedure
    235
- Drive Belt
  237
  - Pvt Break-In (Drive Belt / Clutches)
    237
- Drive Clutch Service
  238
  - Spring Specifications
    238
  - Shift Weights
    239
  - Drive Clutch Exploded View
    239
  - Clutch Disassembly
    240
  - Spider Removal
    240
  - Roller, Pin, and Thrust Washer Inspection
    241
  - Button to Tower Clearance Inspection
    242
  - Shift Weight Inspection
    242
  - Bearing Inspection
    242
  - Clutch Inspection
    243
  - Moveable Sheave Bushing Inspection
    244
  - Bushing Service
    244
  - Clutch Assembly
    246
- Driven Clutch Service
  248
  - Exploded View
    248
  - Clutch Disassembly / Inspection
    248
  - Clutch Assembly
    250
- Troubleshooting
  251
Chapter 7 Final Drive

254
- Bearing Carrier Inspection / Removal
  255
- Front Bearing Carrier
  255
- Special Tools
  255
- Torque Specifications
  255
- Bearing Replacement
  256
- Bearing Carrier Installation
  257
- Front Drive Shaft
  259
  - Drive Shaft Removal
    259
  - Drive Shaft / CV Joint Handling Tips
    260
  - Outer CV Joint / Boot Replacement
    260
  - Inner Plunging Joint / Boot Replacement
    261
  - Drive Shaft Installation
    263
- Propshaft Service
  264
- Propshaft U-Joint Service
  267
- Front Gearcase / Centralized Hilliard
  269
  - Centralized Hilliard Exploded View
    269
  - All Wheel Drive Operation
    270
  - Awd Diagnosis
    271
  - Gearcase Removal
    272
  - Gearcase Assembly
    275
  - Gearcase Installation
    277
- Rear Bearing Carrier
  279
  - Bearing Carrier Inspection / Removal
    279
  - Bearing Replacement
    280
  - Bearing Carrier Bushing Replacement
    280
  - Bearing Carrier Installation
    281
- Rear Drive Shaft
  282
  - Drive Shaft Removal
    282
  - Outer CV Joint / Boot Replacement
    283
  - Inner Plunging Joint / Boot Replacement
    286
  - Drive Shaft Exploded View
    288
- Rear Gearcase
  290
  - Gearcase Removal
    290
  - Gearcase Disassembly
    291
  - Gearcase Assembly
    293
  - Gearcase Installation
    294
  - Gearcase Exploded View
    295
- Rear Gearcase (Rzr S Int'l)
  296
  - General Operation
    296
  - Gearcase Removal
    297
  - Gearcase Disassembly
    298
  - Differential Disassembly
    302
  - Differential Assembly
    303
  - Gearcase Assembly
    304
  - Gearcase Installation
    306
  - Gearcase Exploded View
    307
- Wheel Hubs
  308
Transmission Chapter 8 Transmission

310
- Shift Lever
  311
- Torque Values / Specifications
  311
- Chapter 8 Shift Cable Inspection / Adjustment
  312
- Transmission Service
  313
- Troubleshooting
  327
  - Troubleshooting Checklist
    327
- Transmission Exploded View
  328
Brakes Chapter 9 Brakes

330
- Brake Noise Troubleshooting
  332
- Brake System Service Notes
  332
- Hydraulic Brake System Operation
  333
- Brake System Exploded View
  334
- Chapter 9
  334
- Rzr / Rzr S / Rzr S Int'l
  334
- Rzr 4
  334
- Brake Pedal Lever
  335
- Master Cylinder
  335
- Brake Bleeding / Fluid Change
  336
- Front Brake Pads
  337
  - Pad Removal
    337
  - Brake Burnishing Procedure
    339
- Front Caliper Service
  340
  - Caliper Exploded View (Rzr / Rzr S / Rzr S Int'l)
    340
  - Caliper Exploded View (Rzr 4)
    340
  - Caliper Removal
    341
  - Caliper Disassembly
    342
  - Caliper Inspection
    343
  - Caliper Assembly
    344
- Front Brake Disc
  345
  - Disc Replacement
    346
- Rear Brake Pads
  347
  - Pad Removal
    347
  - Brake Burnishing Procedure
    348
- Rear Caliper Service
  349
  - Caliper Exploded View
    349
  - Caliper Removal
    349
  - Caliper Assembly
    351
  - Caliper Installation
    352
- Rear Brake Disc
  352
  - Disc Inspection
    352
  - Disc Replacement
    353
- Troubleshooting
  353
  - Pedal Vibration
    353
  - Brakes Lock
    353
Chapter 10 Electrical

354
- General Information
  356
- Switches / Controls
  356
  - Electrical Service Notes
    356
  - Brake Light Switch
    356
  - Headlamp Switch
    357
  - Ignition Key Switch
    357
  - Ignition Key Switch (Int'l)
    358
  - Awd / 2Wd Switch
    358
  - Awd / 2Wd / Turf Switch (Int'l)
    359
  - Turn Signal Switch (Int'l)
    359
  - Hazard Switch (Int'l)
    359
  - Transmission (Gear Position) Switch
    360
- Vehicle Speed Sensor
  360
- Rear Diff Solenoid (Int'l)
  361
- Instrument Cluster
  362
  - Rider Information Display
    363
  - Information Display Area
    363
  - Diagnostic Mode
    366
  - Instrument Cluster Pinouts
    367
  - Instrument Cluster Installation
    367
  - Instrument Cluster Removal
    367
- All Wheel Drive Coil
  368
- Head Lights
  368
  - Headlight Adjustment
    368
  - Headlamp Bulb Replacement
    369
- Tail / Brake Lights
  370
  - Bulb Replacement
    370
- Cooling System
  371
  - Cooling System Break-Out Diagram
    371
  - Coolant Temperature Sensor
    372
- Efi Diagnostics
  372
- Fuel Sender
  372
- Fuse Box: Fuses / Relays / Circuit Breaker
  373
  - Fuse Box Detail
    374
  - Relay Operation
    375
- Charging System
  377
  - Current Draw - Key off
    377
  - Regulator / Rectifier
    378
  - Charging System Testing Flow Chart
    379
- Battery Service
  380
  - Battery Testing
    381
  - Ocv - Open Circuit Voltage Test
    381
  - Load Test
    381
  - Battery Conductance Analyzer
    382
  - Charging Procedure
    382
- Starting System
  383
  - Voltage Drop Test
    383
  - Starter Motor Removal / Disassembly
    383
  - Brush Inspection / Replacement
    384
  - Armature Testing
    385
  - Starter Reassembly / Installation
    385
  - Starter Drive
    386
  - Starter Solenoid Bench Test
    387
  - Starter Solenoid Operation
    387
  - Starter Exploded View
    388
- Starting System Testing Flow Chart
  389
- Electronic Power Steering (Eps)
  390
  - Eps Operation
    390
  - Eps 8-Way Wire Harness Connector
    390
  - Proper Eps System Diagnosing
    390
  - Eps System Breakout
    391
  - Eps Troubleshooting (Using Digital Wrench™)
    394
- Electrical System Breakouts
  395
  - Awd
    395
  - Vehicle Speed Sensor
    395
  - Cooling Fan
    396
  - Charging System
    397
  - Chassis Power
    398
  - Key-On Battery Power
    399
  - Electronic Power Steering (Eps)
    400
  - Engine Start (Starter Interlock)
    401

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Polaris RANGER RZR 4 Owner's Manual

Polaris RANGER RZR 4 Owner's Manual (148 pages)

Brand: Polaris | Category: Offroad Vehicle | Size: 3.84 MB

Table of Contents

Table of Contents
7
Introduction
8
Vehicle Identification Numbers
10
Safety
11
- Safe Riding Gear
  12
- Safety Warnings
  14
- Protective Apparel
  15
- Operating on Pavement
  17
- Operating on Public Roads
  17
- Operating at Excessive Speeds
  17
- Improper Hill Climbing
  18
- Turning Improperly
  18
- Jumps and Stunts
  18
- Descending Hills Improperly
  19
- Crossing Hillsides
  19
- Stalling While Climbing a Hill
  19
- Improper Tire Maintenance
  20
- Operating in Unfamiliar Terrain
  20
- Operating on Slippery Terrain
  20
- Skidding or Sliding
  21
- Improper Cargo Loading
  22
- Operating a Damaged Vehicle
  22
- Handling Gasoline
  23
- Exposure to Exhaust
  23
- Hot Exhaust Systems
  23
- Age Warning
  27
Features and Controls
32
- Component Locations
  33
- Seat Removal
  35
- Steering Wheel
  36
  - Fuel Cap
    38
  - Seat Belt Inspection
    39
- Seat Belts
  39
- Auxiliary Outlet
  40
- Headlight Switch
  41
- Ignition Switch
  41
  - Gear Selector
    42
  - Brake Pedal
    43
  - Throttle Pedal
    43
  - Engaging Awd
    44
- Instrument Cluster
  45
- Mode Button
  45
- Indicator Lamps
  46
- Rider Information Center
  47
Operation
54
- Brake System Break-In
  55
- Safe Operation Practices
  57
- Starting the Engine
  58
- Stopping the Engine
  58
- Parking the Vehicle
  59
  - Trail Etiquette
    59
  - Driving with Passengers
    62
  - Driving on Slippery Surfaces
    63
  - Driving Uphill
    64
  - Driving Downhill
    65
  - Driving through Water
    66
  - Driving over Obstacles
    67
  - Driving in Reverse
    68
- Parking on an Incline
  69
- Hauling Cargo
  70
- Belt Life
  71
- Towing Loads
  71
- Crankcase Emission Control System
  72
Emission Control Systems
72
Maintenance
73
- Severe Use Definition
  73
- Maintenance Chart Key
  74
- Periodic Maintenance Chart
  74
- Lubrication Recommendations
  78
- Engine Oil
  80
- Oil Recommendations
  80
- Oil Check
  81
- Oil and Filter Change
  82
- Rear Gearcase
  89
- Spark Plugs
  90
- Spark Plug Condition
  91
  - Cooling System
    94
  - Radiator and Cooling Fan
    95
- Radiator Coolant Level
  95
- Coolant Level
  96
- Pvt Drying
  98
- Air Filter
  99
- Spark Arrester
  100
  - Throttle Freeplay Inspection
    101
  - Throttle System
    101
  - Throttle Freeplay Adjustment
    102
  - Brake Fluid
    104
  - Brake Inspection
    105
- Steering Wheel Inspection
  105
  - Suspension Settings
    106
  - Tire Tread Depth
    109
  - Wheel Installation
    110
  - Wheel Removal
    110
- Headlight Lamp Replacement
  111
- Headlight High Beam Adjustment
  112
- Brake Lights
  113
  - Vehicle Immersion
    113
  - Battery Removal
    115
  - Battery Installation
    116
  - Battery Storage
    117
  - Cleaning and Storage
    120
- Polishing the Vehicle
  121
- Washing the Vehicle
  121
- Storage Tips
  123
- Removal from Storage
  125
- Transporting the Vehicle
  125
Specifications
126
POLARIS Products
130
Troubleshooting
131
Warranty
135
Maintenance Log
142
Index
144

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