Description
This Official 2011 – 2012 Polaris Ranger RZR Razor 800 Factory Service Manual provides detailed service information, step-by-step repair instruction and maintenance specifications for:
2011 Polaris Ranger RZR 800 ATVs
2012 Polaris Ranger RZR 800 ATVs
Table of Contents
General Information
Maintenance
Engine
Electronic Fuel Injection
Body / Steering / Suspension
Clutching
Final Drive
Transmission
Brakes
Electrical
Index of Topics
A
Air Filter Service
All Wheel Drive (AWD) Coil
Authorization Key
Authorization, Reflash
AWD, Diagnosis
AWD, Operation
B
Balance Shaft Gear, Removal
Ball Joint Service
Battery Charging
Battery Installation
Battery Maintenance
Battery Removal
Battery Service
Battery Storage
Body Removal
Brake Burnishing
Brake Caliper Assembly, Front
Brake Caliper Assembly, Rear
Brake Caliper Inspection, Front
Brake Caliper Installation, Front
Brake Caliper Removal, Front
Brake Disc, Front
Brake Disc, Rear
Brake Hose and Fitting Inspection
Brake Pad Assembly, Front
Brake Pad Inspection
Brake Pad Thickness, Front
Brake Pads, Front
Brake Pads, Rear
Brake Pads, Removal, Front
Brake Pedal, Installation
Brake Pedal, Removal
Brake System Inspection
Brake System, Bleeding
Brake System, Exploded View
Brake System, Operation
Brake, Front Pad Assembly
Break-In Period
Break-In, PVT System (Belt)
Breather Hose Inspection
C
Cab Frame, Assembly / Removal (RZR / RZR S)
Cab Frame, Assembly / Removal (RZR 4)
Caliper, Front
Caliper, Rear
Cam Gear, Reassembly
Cam Gear, Removal
Camshaft Phase Sensor
Cargo Box Removal
Centralized Hilliard, Exploded View
Charging System
Charging System, Alternator Tests
Chassis (2011 RZR 4)
Chassis (2012 RZR 4)
Chassis (RZR / RZR S)
Circuit Breaker
Clutch Offset Procedure
Combustion Chamber
Communication Problems, Digital Wrench
Compression Test
Console and Floor Panel Removal (RZR / RZR S)
Console and Floor Panel Removal (RZR 4)
Conversion Table
Coolant Level Inspection
Coolant Strength and Type
Cooling System Bleeding Procedure
Cooling System Hoses
Cooling System Specifications
Cooling System, Pressure Test
Crankshaft Gear, Removal
Crankshaft Position Sensor (CPS)
Cylinder Head Assembly
Cylinder Head Assembly Exploded View
Cylinder Head Disassembly
Cylinder Honing To De-glaze
Cylinder Inspection
D
Dash Instruments / Controls / Glovebox
Decal Replacement
Decimal Equivalent Chart
Diagnostic Codes, Instrument Cluster
Diagnostic Trouble Code Table
Digital Wrench Communication Errors
Digital Wrench Diagnostic Software
Digital Wrench Versions
Digital Wrench, Controller Reprogramming
Digital Wrench, Updates
Digital Wrench, Version and Update ID
Drive Belt, Inspection
Drive Belt, Installation
Drive Belt, Removal
Drive Clutch, Assembly
Drive Clutch, Exploded View
Drive Clutch, Operation
Drive Clutch, Service
Drive Clutch, Shift Weights
Drive Clutch, Spring
Drive Shaft Boot Inspection
Driven Clutch, Assembly
Driven Clutch, Disassembly
Driven Clutch, Exploded View
Driven Clutch, Operation
Driven Clutch, Service
Driveshaft / CV Joint, Handling Tips
E
ECU Replacement
EFI Operation Overview
EFI Priming / Starting Procedure
EFI System, Component Locations
EFI System, Electrical Layout
EFI System, Exploded View
EFI, Diagnostic Trouble Codes
EFI, Service Notes
EFI, Troubleshooting
Electrical, AWD
Electrical, Charging System
Electrical, Chassis Power
Electrical, Cooling Fan
Electrical, Cooling System Breakout Diagram
Electrical, Electronic Power Steering (EPS)
Electrical, Engine Start (Starter Interlock)
Electrical, Key-On Power
Electrical, System Breakouts
Electrical, Vehicle Speed Sensor
Electronic Control Unit (ECU)
Engine and Transmission Separation
Engine Assembly and Installation
Engine Break-In Period
Engine Coolant Temperature Sensor (ECT)
Engine Cooling System
Engine Designation Number
Engine Exploded Views
Engine Lubrication
Engine Oil and Filter Change
Engine Oil Flow Chart
Engine Oil Level
Engine Oil Pressure Test
Engine Oil Priming
Engine Oil Pump Installation
Engine Removal
Engine Serial Number Location
Engine Service Specifications
Engine Temperature Sensor Replacement
Engine Temperature Sensor Test
Engine Torque Specifications
Engine, Accessible Components
Engine, Balance Shaft Removal
Engine, Camshaft Inspection
Engine, Camshaft Installation
Engine, Cooling System Troubleshooting
Engine, Crankcase Assembly
Engine, Crankshaft Gear Removal
Engine, Crankshaft Installation
Engine, Cylinder Head Assembly
Engine, Cylinder Head Inspection
Engine, Cylinder Head Removal
Engine, Cylinder Head Warp
Engine, Cylinder Honing
Engine, Cylinder Inspection
Engine, Cylinder Installation
Engine, Cylinder Removal
Engine, Flywheel / Stator Installation
Engine, Flywheel / Stator Removal
Engine, Flywheel Removal
Engine, Gear(s) Removal
Engine, Gears, Installation
Engine, Oil Pump Removal
Engine, Piston Installation
Engine, Piston Removal, Inspection
Engine, Piston Ring Installed Gap
Engine, Piston to Cylinder Clearance
Engine, Piston to Rod Clearance
Engine, Push Rod Inspection
Engine, Rocker Arm Inspection
Engine, Starter Drive Removal
Engine, Stator Gear Cover Seal(s) Installation
Engine, Stator Installation
Engine, Troubleshooting
Engine, Valve Inspection
Engine, Valve Lifter Removal, Inspection
Engine, Valve Seal/Spring Service
Engine, Valve Sealing Test
Engine, Valve Seat Reconditioning
EPS, Operation
EPS, System Breakout
EPS, Troubleshooting
Exhaust, Spark Arrestor
F
Fan Control Circuit Bypass Test
Fan Control Circuit Operation
Floor (RZR / RZR S)
Floor (RZR 4)
Flywheel / Stator Removal
Flywheel, Removal
Fox Shock Service
Front A-arm, Replacement
Front Bearing Carrier
Front Body / Dash Removal
Front Body Work
Front Bumper
Front Caliper, Piston Bore ID
Front Driveshaft, CV Joint / Boot Replacement
Front Driveshaft, Installation
Front Driveshaft, Removal
Front Fender Flair Removal
Front Gearcase Lubrication
Front Gearcase, Assembly
Front Gearcase, Centralized Hilliard
Front Gearcase, Disassembly / Inspection
Front Gearcase, Installation
Front Gearcase, Removal
Front Stabilizer Bar (RZR, RZR S INT’L)
Fuel Filter
Fuel Injectors
Fuel Line
Fuel Lines
Fuel Pump Assembly
Fuel Pump Replacement
Fuel Pump Test
Fuel Sender Test
Fuel System
Fuel System Diagnostics
Fuel Tank Removal (RZR / RZR S)
Fuel Tank Removal (RZR 4)
Fuel Tank, Exploded View
Fuse Box
Fuses
G
Gear / Stator Housing Seal Replacement
General Specifications, Brakes
Ground, Engine
Guided Diagnostics
H
Head Lights
Head Lights (LED)
High Altitude Clutch Charts
Hood
Hood Removal
I
Idle Air Control (IAC)
Ignition Coil
Ignition Coil Replacement
Ignition Coil Test
Instrument Cluster
Instrument Cluster, Installation
Instrument Cluster, Removal
K
Key, Reprogramming Authorization
Keys, Replacement
L
LeakdownTest
Lower Steering Shaft, Installation (EPS)
Lower Steering Shaft, Removal (EPS)
Lubrication Grease Points
M
Main Frame (2011 RZR 4)
Main Frame (2012 RZR 4)
Main Frame (RZR / RZR S)
Maintenance Quick Reference Chart
Maintenance Schedule
Maintenance, Brake System
Maintenance, Cooling System
Maintenance, Electrical and Ignition
Maintenance, Engine
Maintenance, Final Drive
Maintenance, Fuel System
Maintenance, General Vehicle Inspection
Maintenance, Service Products and Lubricants
Maintenance, Steering
Maintenance, Transmission and Gearcases
Master Cylinder, Installation
Master Cylinder, Removal
Metric Bolt Torque Specification
Model Identification
N
Nets, Side
o
Oil Pump Priming
Oil Pump, Disassembly
Oil Pump, Reassembly
Oil Pump, Removal
P
Periodic Maintenance Chart
Piston Ring Installed Gap
Piston to Cylinder Clearance
Piston to Rod Inspection
Power Steering Unit, Installation
Power Steering Unit, Removal
Power Steering, Exploded View
Pre-Ride / Daily Inspection
Propshaft Removal / Installation (RZR / RZR S)
Propshaft Removal / Installation (RZR 4)
Propshaft Support Bearing Replacement (RZR 4)
Propshaft, U-Joint Service
Publication Numbers
PVT System, Assembly
PVT System, Disassembly
PVT System, Maintenance
PVT System, Overheating Diagnostics
PVT System, Overview
PVT System, Service
PVT Troubleshooting
PVT, Button to Tower Clearance
PVT, Drive Clutch Bushing Service
PVT, Drive Clutch Cover Bushing
PVT, Drive Clutch Disassembly
PVT, Drive Clutch Spider Removal
PVT, Moveable Sheave Inspection
R
Radiator
Radiator, Removal
Rear A-arm, Replacement
Rear Bearing Carrier
Rear Bumper
Rear Cargo Box (RZR / RZR S)
Rear Cargo Box (RZR 4)
Rear Console Cover (RZR 4)
Rear Drive Shaft, CV Joint / Boot Replace
Rear Drive Shaft, Plunging Joint / Boot Replace
Rear Driveshaft, Installation
Rear Driveshaft, Removal
Rear Fender, Flair, and Tie Down Removal
Rear Fenders (RZR / RZR S)
Rear Fenders (RZR 4)
Rear Gearcase
Rear Gearcase (RZR S INT’L)
Rear Gearcase Lubrication
Rear Gearcase, Assembly
Rear Gearcase, Assembly (RZR S INT’L)
Rear Gearcase, Diff Assembly (RZR S INT’L)
Rear Gearcase, Diff Disassembly (RZR S INT’L)
Rear Gearcase, Disassembly
Rear Gearcase, Disassembly (RZR S INT’L)
Rear Gearcase, Exploded View
Rear Gearcase, Exploded View (RZR S INT’L)
Rear Gearcase, Installation
Rear Gearcase, Installation (RZR S INT’L)
Rear Gearcase, Removal
Rear Gearcase, Removal (RZR S INT’L)
Rear Service Panel (RZR / RZR S)
Rear Stabilizer Bar (RZR S / RZR 4)
Rear Stabilizer Bar (RZR)
Reflash Authorization
Regulator/Rectifier Location
Relays
Reprogramming Authorization
Rocker Panel Removal
Rocker Panels (RZR / RZR S)
Rocker Panels (RZR 4)
S
Safety Nets
Seat Assembly
Seat Belts / Mounting (RZR / RZR S)
Seat Belts / Mounting (RZR 4)
Seats
Shift Cable Inspection and Adjustment
Shift Lever
Shift Lever, Installation
Shift Lever, Removal
Shock Piston Orientation, Walker Evans
Shock Rebuilding Tools, Walker Evans
Shock Valve Shim Arrangement, Walker Evans
Shock, FOX 20, Exploded View (2011 RZR 4)
Shock, FOX 20, Exploded View (2012 RZR 4)
Shock, FOX PODIUM X, Exploded View (RZR S)
Shock, FOX, Rebuild Information
Shock, FOX, Service (RZR S / RZR4)
Shock, Walker Evans, Exploded View
Shock, Walker Evans, Rebuild Information
Shocks and Springs
Software Version
Solenoid, Rear Differential (INT’L)
Spark Plug Service
Special Tool, Cam Gear Installation Kit
Special Tools
Special Tools, Body/Steering/Suspension
Special Tools, Brakes
Special Tools, Clutching
Special Tools, EFI
Special Tools, Electrical
Special Tools, Engine
Special Tools, Final Drive
Specification Chart, Maintenance
Specification, Balance Shaft Gear Bolt Torque
Specification, Cam Lobe Height
Specification, Cam Thrust Plate Fastener Torque
Specification, Camshaft Gear Bolt Torque
Specification, Coolant Sensor Resistance
Specification, Cylinder Head Warp
Specification, Cylinder Taper Limit
Specification, Cylinder Warp Limit
Specification, Oil Pump Bolt Torque
Specification, Oil Pump Rotor Clearance
Specification, Timing Gear Alignment
Specification, Valve Seat Contact Width
Specification, Valve Spring Free Length
Specification, Valve Stem Diameter
Specification, Valve Stem Guide ID
Specification, Wheel Toe-Out
Specifications, Camshaft
Specifications, Cooling System
Specifications, Crankcase Fastener Torque
Specifications, Engine
Specifications, Engine Lubrication
Specifications, Engine Oil Pressure
Specifications, FOX 20 Shocks
Specifications, FOX PODIUM X Shocks
Specifications, General (2011)
Specifications, General (2012)
Specifications, Oil Baffle Bolt Torque
Specifications, Oil Pick-Up Bolt Torque
Specifications, Walker Evans Shocks
Speed Sensor
Speedometer
Standard Bolt Torque Specification
Starter Armature Testing
Starter Assembly, Exploded View
Starter Brush Inspection / Replacement
Starter Drive
Starter Drive Removal
Starter Motor, Removal
Starter Reassembly / Installation
Starter Solenoid, Operation
Starter Solenoid, Test
Starter System Flow Chart
Starter System, Troubleshooting
Stator, Removal
Steering Shaft, Bearing Replacement
Steering Shaft, Removal (Non-EPS)
Steering Wheel Freeplay
A r- I D ml / f” H O
Steering Wheel Removal (Non-EPS)
Steering, Exploded View (Non-EPS)
Steering, Inspection
Suspension, (FOX)
Suspension, (Walker Evans)
Suspension, Comp Adjustment (FOX)
Suspension, Comp Adjustment (Walker Evans)
Suspension, Preload Adjustment (FOX)
Suspension, Preload Adjustment (Standard)
Suspension, Preload Adjustment (Walker Evans)
Sway Bar Linkage Removal
Switch, AWD/2WD
Switch, AWD/2WD/TURF (INT’L)
Switch, Brake Light
Switch, Gear Position
Switch, Hazard (INT’L)
Switch, Headlamp
Switch, Ignition
Switch, Ignition (INT’L)
Switch, Turn Signal (INT’L)
T
Tail Lights
Tap/Drill Sizes
Throttle Freeplay Adjustment
Throttle Pedal Inspection
Throttle Position Sensor (TPS)
Tie Rod End and Steering Inspection
Timing Gear Mark Alignment
Tire Inspection
Tire Pressure
T-MAP Sensor
Toe Adjustment
Torque Specifications – Engine
Torque Specifications, Body/Steering/Suspension
Torque Specifications, Brakes
Torque Specifications, Clutching
Torque Specifications, Final Drive
Torque Specifications, Transmission
Torque Specifications, Wheel and Hub
Transfer Case, Disassembly
Transfer Case, Reassembly
Transmission Lubrication
Transmission, Exploded View
Transmission, Removal
Transmission, Shift Housing Disassembly
Transmission, Shift Housing Reassembly
Trouble Codes
Troubleshooting, Brake Noise
Troubleshooting, Brake System
Troubleshooting, Clutching
Troubleshooting, Transmission
U
Upper Steering Shaft Removal (EPS)
Upper Steering Shaft, Installation (EPS)
V
Valve Seal/Spring Service
Valve Sealing Test
Valve Seat Reconditioning
Vent Lines
Version, Software
VIN Identification
VIN Location
Voltage Drop Test
W
Wheel Alignment
Wheel Hubs
Wheel, Installation
Wheel, Removal
SKU: 9917206
SKU: 9917203
SKU: U9913681
