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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Install the plug and torque to specification. Vehicle rollover can cause severe injury or death. Look ahead and learn to read the terrain. Rollers are spring loaded.

Take care not to damage threads on fingers. Enter text from picture: Install adapter reducer Item 9. If crossing a hill is unavoidable, follow these precautions: The part number is printed on the label. This will ensure proper sealing when Flywheel Nut Torque installing bolts. Trip Meter Mode The trip meter records the distance traveled by the vehicle if reset before each trip.

Polaris RZR 800 Owner’s Manual

Take care in not allowing the throttle cable to bend excessively or kink. Note the clips, spring and plate orientation.

Main gearcase oil 25 H Break-in oil level check Transfer case oil 25 Manuak Break-in oil level check Perform these procedures more often for vehicles subjected to severe use. Capacity – Approximately 2 U. Measure bore size and compare to specifications. Thoroughly clean the front bearing carrier housing and the outer race on the new bearing.


It is important to tighten the bottom starter Remove the retaining ring, thrust washer, spring retainers bolt first circleas the bottom hole acts as a pilot and clutch return spring. Hardened, cracked or worn valve seals will cause excessive oil consumption and carbon buildup.

If toe alignment is incorrect, measure the distance between vehicle center and each wheel.

Use a engine passages. Install piston D with a twisting motion while pushing inward. Piston should slide in and out of bore smoothly with light resistance. Inspect the bearing for wear. Inspect caliper body for nicks, scratches or wear. Manial not polariw it in any other product.

When reinstalling the transmission to rear gearcase mount bracket, it is extremely important Remove to torque all 7 fasteners to specification. Do not pull on the wiring. Reading should fully charged shop battery to continue test.

Do not clean the main filter, the filter should be replaced. The ONLY time a winch-equipped vehicle should be moving when using the winch is when that vehicle itself is stuck. Inspect both output hub assemblies. Don’t have an account? Page This EPA emissions warranty period is extended for at least as long as the standard factory warranty that Polaris provides on the vehicle as a whole. To remove the driver or passenger seat, lift upward on the latch lever located behind the seat bottom.


Engine Oil Change 25 H Perform a break-in oil change at one month Break-In Period Perform these procedures more often for vehicles subjected to severe use.

Remove the rear drive shafts from each side of the rear gearcase. Brake Fluid Inspection Inspect the brake pad wear surface for excessive wear. Turn roller with your finger.

See the following charts and Load Test. When the switch is on AWD, the vehicle is in all wheel drive and the 4X4 indicator in the instrument cluster will be on.


Poor engine performance Check for fouled plugs or foreign material in gas tank or fuel lines. Install puller adapter Item 10 onto puller. The original instructions for this vehicle are in English. Part Description Part removal process.