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Ranger RZR 800
Polaris Ranger RZR 800 Manuals
Manuals and User Guides for Polaris Ranger RZR 800. We have
2
Polaris Ranger RZR 800 manuals available for free PDF download: Manual, Owner's Manual
Polaris Ranger RZR 800 Manual (406 pages)
Brand:
Polaris
| Category:
Utility Vehicle
| Size: 77.49 MB
Table of Contents
General Information Chapter
1
Table of Contents
1
Chapter 1
2
Engine Designation Number
2
Model Identification
2
Model Information
2
Vehicle and Engine Serial Number Location
2
Vin Identification
2
Special Tools
3
Vehicle Information
3
Publication Numbers
3
Replacement Keys
3
General Specifications
4
Misc. Specifications and Charts
10
Conversion Table
10
Standard Torque Specifications
11
Sae Tap / Drill Sizes
12
Metric Tap / Drill Sizes
12
Glossary of Terms
13
Maintenance Chapter 2 Maintenance 2
15
Break-In Period / Maintenance Chart Key
17
Chapter 2
17
Periodic Maintenance Chart
17
Pre-Ride - 25 Hour Maintenance Interval
18
50 - 500 Hour Maintenance Interval
19
Maintenance Quick Reference
20
Maintenance Quick Reference, Continued
21
Grease Lubrication Points
22
Lubricants / Service Products
23
General Vehicle Inspection and Maintenance
24
Pre-Ride / Daily Inspection
24
Frame, Nuts, Bolts, and Fasteners
24
Shift Cable Inspection / Adjustment
24
Fuel System and Air Intake
25
Fuel Line / Fuel Pump / Fuel Filters / Vent Lines
25
Throttle Pedal Inspection
26
Throttle Freeplay Adjustment
26
Air Filter Service
27
Engine
29
Engine Oil Level
29
Engine Oil and Filter Service
30
Engine Breather Hose Inspection
31
Engine and Transmission Mounts
31
Compression and Leakdown Test
31
Exhaust - Spark Arrestor
31
Transmission and Gearcases
32
Transmission Lubrication
32
Front Gearcase Lubrication
34
Rear Gearcase Lubrication
35
Cooling System
36
Coolant Level Inspection
36
Coolant Strength / Type
36
Cooling System Pressure Test
37
Cooling System Hoses / Radiator
37
Coolant Drain / Radiator Removal
37
Final Drive / Wheel and Tire
38
Wheel and Hub Torque Table
38
Wheel Removal / Installation
38
Wheel Installation
38
Tire Inspection / Pressure
39
Drive Shaft Boot Inspection
39
Electrical and Ignition System
40
Battery Maintenance
40
Battery Removal
40
Battery Installation
41
Battery off Season Storage
41
Battery Charging (Maintenance Free)
41
Spark Plug Service
41
Engine to Frame Ground
42
Steering
42
Steering Inspection / Steering Wheel Freeplay
42
Tie Rod End / Wheel Hub Inspection
43
Wheel Toe Alignment Inspection
43
Wheel Toe Adjustment
44
Suspension (Fox™)
45
Shock Compression Adjustment
46
Suspension (Standard)
45
Spring Preload Adjustment
45
Suspension (Walker Evans™)
47
Spring Preload Adjustment
47
Shock Compression Adjustment
47
Brake System
48
Brake Fluid / Pad / Disc Inspection
48
Brake Hose and Fitting Inspection
48
Maintenance Log
49
Engine Chapter 3 Engine
51
Chapter 3
52
Crankcase
52
Engine Specifications
52
Oil Pump / Gears / Engine Cover
53
Stator Cover / Starter / Water Pump / Lubrication System
54
Cylinder / Cylinder Head / Piston
55
Engine Efi Sensors / Valve Cover / General Components
56
Engine Torque Specifications
57
800 EFI Engine Service Specifications
58
Special Tools
60
Engine Cooling System
61
Cooling System Specifications / Pressure Test / Cap Test
61
Cooling System Exploded View
62
Cooling System Bleeding Procedure
63
General Engine Service
64
Engine Lubrication Specifications
64
Accessible Engine Components / Oil Pressure Test
64
Oil Flow Chart
65
Engine Removal
66
Engine / Transmission Separation
73
Engine Disassembly and Inspection
74
Cylinder Head Assembly Exploded View
74
Rocker Arms / Push Rods
75
Cylinder Head Removal
75
Cylinder Head Inspection / Warp
76
Valve Seal / Spring Service (on Engine)
76
Cylinder Head Disassembly
77
Valve Inspection
78
Combustion Chamber
79
Valve Seat Reconditioning
79
Cylinder Head Reassembly
81
Valve Sealing Test
82
Cylinder Removal
82
Valve Lifter Removal / Inspection
82
Piston Removal
83
Cylinder Inspection
84
Cylinder Hone Selection and Honing Procedure
85
Honing to Deglaze / Cleaning the Cylinder after Honing
85
Piston-To-Cylinder Clearance
86
Piston / Rod Inspection
86
Piston Ring Installed Gap
87
Starter Drive Bendix Removal / Inspection
87
Flywheel / Stator Removal / Inspection
88
Engine Crankcase Disassembly / Inspection
88
Camshaft Inspection
96
Engine Reassembly
97
Crankcase Reassembly
97
Flywheel / Stator Installation
106
Cylinder Head Reassembly
106
Oil Pump Priming
108
Engine Installation
109
Engine Assembly and Installation
109
Engine Break-In Period
110
Troubleshooting
111
Electronic Fuel Injection Chapter 4 Electronic Fuel Injection
113
Chapter 4
114
Electronic Fuel Injection Chapter
114
General Information
114
Special Tools
114
Service Notes
116
Efi System Exploded View
117
Efi System Component Locations
118
Fuel Tank
120
Fuel Lines - Quick Connect
121
Electronic Fuel Injection
121
Principal Components / Efi Operation Overview
121
Initial Priming / Starting Procedure
122
Electronic Control Unit (Ecu)
122
Temp / Manifold Absolute Pressure Sensor (T-Map)
123
Crankshaft Position Sensor (Cps)
124
Cps Test
124
Cps Replacement
125
Fuel Injectors
128
Fuel Injector Replacement
130
Fuel Pump
131
Fuel Sender Test
131
Fuel Pump Test
132
Fuel Pump Replacement
133
Fuel Tank Removal (Rzr / Rzr S)
136
Fuel Tank Removal (Rzr 4)
138
Fuel Tank Installation
140
Idle Air Control (Iac)
141
Throttle Position Sensor (Tps)
142
Tps Replacement
143
Camshaft Phase Sensor
145
Engine Coolant Temperature Sensor (Ect)
146
Ignition Coil
147
Efi Diagnostics
148
Instrument Cluster Trouble Code Display
148
Efi Troubleshooting
151
Digital Wrench™ Operation
152
Special Tools / Diagnostic Software Version
152
Ecu Replacement / Guided Diagnostic Available
152
Digital Wrench™ Communication Errors
152
Digital Wrench™ - Diagnostic Connector
153
Digital Wrench™ Updates
154
Digital Wrench™ Feature Map
155
Engine Controller Reprogramming (Reflash)
156
Efi System Electrical Operation
160
Body / Steering / Suspension Chapter 5 Body / Steering / Suspension
161
Special Tools
163
Torque Specifications
163
Cab Frame (Rzr / Rzr S)
164
Cab Frame (Rzr 4)
165
Body Exploded Views
166
Chapter 5
166
Side Safety Nets
166
Dash Instruments / Controls / Glovebox
167
Hood / Front Body Work
168
Front / Rear Bumper
169
Seat Assembly
170
Seat Belts / Mounting (Rzr / Rzr S)
170
Seat Belts / Mounting (Rzr 4)
171
Floor / Rocker Panels (Rzr / Rzr S)
172
Floor / Rocker Panels (Rzr 4)
173
Rear Cargo Box / Fenders (Rzr / Rzr S)
174
Rear Cargo Box / Fenders (Rzr 4)
175
Chassis / Main Frame (Rzr / Rzr S)
176
Chassis / Main Frame (Rzr 4)
177
Body Component Removal
178
Seats
178
Rear Service Panel (Rzr / Rzr S)
178
Rear Console Cover (Rzr 4)
178
Front Bumper
178
Rear Bumper
179
Hood and Front Body Work
179
Rear Fender, Flair and Tie down Removal
180
Cargo Box Assembly Removal
180
Rocker Panels, Console and Floor
181
Steering Assembly
182
Exploded View (Non-Eps Models)
182
Steering Wheel Removal (Non-Eps Models)
183
Steering Shaft Removal (Non-Eps Models)
183
Steering Shaft Bearing Replacement
184
Electronic Power Steering Assembly
185
Exploded View (Eps Models)
185
Upper Steering Shaft Removal (Eps Models)
186
Steering Wheel Removal (Eps Models)
187
Power Steering Unit Removal
187
Power Steering Unit Installation
189
Upper Steering Shaft Installation (Eps Models)
190
Front A-Arms
191
Removal / Replacement
191
Exploded View
192
Ball Joint Service
193
Removal
193
Installation
194
Front Stabilizer Bar (Rzr / Rzr S Int'l)
194
Sway Bar Linkage Removal
194
Stabilizer Bar Removal
194
Exploded View
195
Rear A-Arms
196
Removal
196
Installation
197
Exploded View
198
Rear Stabilizer Bar (Rzr)
199
Rear Stabilizer Bar (Rzr S / Rzr 4)
200
Decal Replacement
201
Shocks / Springs / Fasteners
201
Exploded View (Rzr / Rzr S)
201
Exploded View (Rzr S / Rzr S Int'l)
201
Exploded View (Rzr 4)
202
Fox™ Shock Exploded Views
203
Fox™ Podium X 'Piggyback' Shock (Rzr S)
203
Fox™ 2.0 'Piggyback' Shock (Rzr 4)
204
Fox™ Shock Service
205
General Service Information
205
Fox™ Shock Rebuild Information
207
Fox™ Shock Disassembly
208
Fox™ Shock Rebuild
210
Fox™ Shock Reassembly
211
Walker Evans™ Shock Exploded View
214
Walker Evans™ Compression Adjuster Reservoir Shock (Rzr L.e.)
214
Walker Evans™ Shock Service
215
Recommended Service Intervals
215
Walker Evans™ Shock Rebuild Information
216
Special Tools
216
Valve Shim Arrangement
216
Piston Orientation
216
Walker Evans™ Shock Disassembly
217
Walker Evans™ Shock Assembly
219
Clutching Chapter 6 Clutching
223
Chapter 6
224
Drive Clutch Operation
224
General Operation
224
Pvt System Overview
224
Special Tools and Supplies
224
Torque Specifications
224
Driven Clutch Operation
225
Maintenance / Inspection
225
Pvt Break-In (Drive Belt / Clutches)
225
Overheating / Diagnosis
226
Pvt System Service
227
Pvt Covers and Ducting Components
227
Pvt Disassembly
228
Pvt Assembly
229
Clutch Offset Procedure
230
Drive Belt
232
Pvt Break-In (Drive Belt / Clutches)
232
Drive Clutch Service
233
Spring Specifications
233
Shift Weights
234
Drive Clutch Exploded View
234
Clutch Disassembly
235
Spider Removal
235
Roller, Pin, and Thrust Washer Inspection
236
Button to Tower Clearance Inspection
237
Shift Weight Inspection
237
Bearing Inspection
237
Clutch Inspection
238
Moveable Sheave Bushing Inspection
239
Bushing Service
239
Clutch Assembly
241
Driven Clutch Service
243
Exploded View
243
Clutch Disassembly / Inspection
243
Clutch Assembly
245
Troubleshooting
246
Final Drive Chapter 7 Final Drive
249
Bearing Carrier Inspection / Removal
250
Chapter 7
250
Front Bearing Carrier
250
Special Tools
250
Torque Specifications
250
Bearing Replacement
251
Bearing Carrier Installation
252
Front Drive Shaft
254
Drive Shaft Removal
254
Drive Shaft / CV Joint Handling Tips
255
Outer CV Joint / Boot Replacement
255
Inner Plunging Joint / Boot Replacement
256
Drive Shaft Installation
258
Propshaft Service
259
Removal / Installation (Rzr / Rzr S)
259
Removal / Installation (Rzr 4)
260
Support Bearing Replacement (Rzr 4)
261
Propshaft U-Joint Service
262
Front Gearcase / Centralized Hilliard
264
Centralized Hilliard Exploded View
264
All Wheel Drive Operation
265
Awd Diagnosis
266
Gearcase Assembly
270
Gearcase Installation
272
Rear Bearing Carrier
274
Bearing Carrier Inspection / Removal
274
Bearing Replacement
275
Bearing Carrier Bushing Replacement
275
Bearing Carrier Installation
276
Rear Drive Shaft
277
Drive Shaft Removal
277
Outer CV Joint / Boot Replacement
278
Inner Plunging Joint / Boot Replacement
281
Rear Gearcase
285
Gearcase Removal
285
Gearcase Disassembly
286
Gearcase Assembly
288
Gearcase Installation
289
Gearcase Exploded View
290
Rear Gearcase (Rzr S Int'l)
291
General Operation
291
Gearcase Removal
292
Gearcase Disassembly
293
Differential Disassembly
297
Differential Assembly
298
Gearcase Assembly
299
Gearcase Installation
301
Gearcase Exploded View
302
Wheel Hubs
303
Transmission Chapter 8 Transmission
305
Shift Lever
306
Torque Values / Specifications
306
Chapter 8 Shift Cable Inspection / Adjustment
307
Transmission Service
308
Transmission Removal / Service Notes
308
Transfer Case Disassembly
308
Transfer Case Reassembly
311
Transmission Shift Housing Disassembly
313
Transmission Shift Housing Reassembly
317
Troubleshooting
322
Transmission Exploded View
323
Brakes Chapter 9 Brakes
325
Brake Noise Troubleshooting
327
Brake System Service Notes
327
Hydraulic Brake System Operation
328
Brake System Exploded View
329
Chapter 9
329
Rzr / Rzr S / Rzr S Int'l
329
Rzr 4
329
Brake Pedal Lever
330
Master Cylinder
330
Brake Bleeding / Fluid Change
331
Front Brake Pads
332
Pad Removal
332
Brake Burnishing Procedure
334
Front Caliper Service
335
Caliper Exploded View (Rzr / Rzr S / Rzr S Int'l)
335
Caliper Exploded View (Rzr 4)
335
Caliper Removal
336
Caliper Disassembly
337
Caliper Inspection
338
Front Brake Disc
340
Disc Replacement
341
Rear Brake Pads
342
Pad Removal
342
Brake Burnishing Procedure
343
Rear Caliper Service
344
Caliper Exploded View
344
Caliper Removal
344
Caliper Assembly
346
Caliper Installation
347
Rear Brake Disc
347
Disc Inspection
347
Disc Replacement
348
Troubleshooting
348
Electrical Chapter 10 Electrical
349
Chapter 10 Under-Dash Components
351
General Information
351
Switches / Controls
351
Brake Light Switch
351
Headlamp Switch
352
Ignition Key Switch
352
Ignition Key Switch (Int'l)
353
Awd / 2Wd Switch
353
Awd / 2Wd / Turf Switch (Int'l)
354
Turn Signal Switch (Int'l)
354
Hazard Switch (Int'l)
354
Transmission (Gear Position) Switch
355
Vehicle Speed Sensor
355
Rear Diff Solenoid (Int'l)
356
Instrument Cluster
357
Rider Information Display
358
Information Display Area
358
Diagnostic Mode
361
All Wheel Drive Coil
363
Head Lights
363
Headlight Adjustment
363
Headlamp Bulb Replacement
364
Tail / Brake Lights
365
Bulb Replacement
365
Cooling System
366
Cooling System Break-Out Diagram
366
Coolant Temperature Sensor
367
Efi Diagnostics
367
Fuel Sender
367
Fuse Box: Fuses / Relays / Circuit Breaker
368
Fuse Box Detail
369
Relay Operation
370
Charging System
372
Current Draw - Key off
372
Regulator / Rectifier
373
Charging System Testing Flow Chart
374
Battery Service
375
Battery Testing
376
Ocv - Open Circuit Voltage Test
376
Load Test
376
Battery Conductance Analyzer
377
Charging Procedure
377
Starting System
378
Troubleshooting
378
Voltage Drop Test
378
Starter Motor Removal / Disassembly
378
Brush Inspection / Replacement
379
Armature Testing
380
Starter Reassembly / Installation
380
Starter Drive
381
Starter Solenoid Bench Test
382
Starter Solenoid Operation
382
Starter Exploded View
383
Starting System Testing Flow Chart
384
Electronic Power Steering (Eps)
385
Eps Operation
385
Eps 8-Way Wire Harness Connector
385
Proper Eps System Diagnosing
385
Eps System Breakout
386
Eps Troubleshooting (Using Digital Wrench™)
389
Electrical System Breakouts
390
Awd
390
Vehicle Speed Sensor
390
Cooling Fan
391
Charging System
392
Chassis Power
393
Key-On Battery Power
394
Electronic Power Steering (Eps)
395
Engine Start (Starter Interlock)
396
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Polaris Ranger RZR 800 Owner's Manual (157 pages)
Brand:
Polaris
| Category:
Offroad Vehicle
| Size: 3.8 MB
Table of Contents
Table of Contents
5
Introduction
6
Vehicle Identification Numbers
8
Safety
9
Safe Riding Gear
10
Safety Warnings
16
Protective Apparel
17
Operating on Pavement
19
Operating on Public Roads
19
Operating at Excessive Speeds
19
Descending Hills Improperly
20
Improper Hill Climbing
20
Jumps and Stunts
20
Turning Improperly
20
Crossing Hillsides
21
Stalling While Climbing a Hill
21
Operating in Unfamiliar Terrain
21
Skidding or Sliding
22
Operating a Damaged Vehicle
23
Improper Cargo Loading
24
Exposure to Exhaust
25
Hot Exhaust Systems
25
Equipment Modifications
26
Features and Controls
27
Component Locations
28
Seat Removal
29
Steering Wheel
30
Fuel Cap
32
Seat Belt Inspection
33
Seat Belts
33
Auxiliary Outlet
34
Headlight Switch
35
Ignition Switch
35
Gear Selector
36
Brake Pedal
37
Throttle Pedal
37
All Wheel Drive System
38
Engaging Awd
38
Instrument Cluster
39
Indicator Lamps
40
Rider Information Center
41
Clock Mode
44
Engine Error Codes
47
Operation
48
Brake System Break-In
49
Safe Operation Practices
51
Starting the Engine
52
Stopping the Engine
52
Parking the Vehicle
53
Trail Etiquette
53
Driving with Passengers
56
Driving on Slippery Surfaces
57
Driving Uphill
58
Driving Downhill
59
Driving through Water
60
Driving over Obstacles
61
Driving in Reverse
62
Parking on an Incline
63
Hauling Cargo
64
Belt Life
65
Towing Loads
66
Winch Guide
67
Winch Safety Precautions
68
Winch Operation
70
Winch Cable Care
75
Winch Maintenance and Service Safety
77
Crankcase Emission Control System
78
Emission Control Systems
78
Maintenance
79
Severe Use Definition
79
Maintenance Chart Key
80
Periodic Maintenance Chart
80
Lubrication Recommendations
84
Engine Oil
86
Engine Oil Check
87
Oil Check
87
Oil and Filter Change
88
Rear Gearcase
95
Gearcase Specification Chart
96
Spark Plugs
96
Spark Plug Condition
97
Fuses
99
Cooling System
100
Radiator and Cooling Fan
101
Radiator Coolant Level
101
Coolant Level
102
Pvt Drying
104
Air Filter
105
Spark Arrester
106
Throttle Freeplay
107
Throttle Freeplay Inspection
107
Throttle System
107
Throttle Freeplay Adjustment
108
Brake Fluid
110
Brake Inspection
111
Steering Wheel Inspection
112
Suspension Settings
113
Tire Tread Depth
117
Wheel Installation
118
Wheel Removal
118
Brake Lights
121
Vehicle Immersion
121
Battery Removal
123
Battery Installation
124
Battery Storage
125
Cleaning and Storage
128
Polishing the Vehicle
129
Washing the Vehicle
129
Storage Tips
131
Removal from Storage
133
Transporting the Vehicle
133
Specifications
134
POLARIS Products
138
Troubleshooting
139
Warranty
143
Maintenance Log
150
Index
152
Gearcase Oil
153
Fluid Change
153
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