2009-2010 Polaris Ranger RZR S 800 UTV Service Manual

Description

This 2009-2010 Polaris Ranger RAZR 800 Factory Service Manual provides detailed service information, step-by-step repair instruction and maintenance specifications for the following Razor UTV models:

2009 Polaris Ranger RZR 800

2009 Polaris Ranger RZR-S 800 H.O

2010 Polaris Ranger RZR 800

2010 Polaris Ranger RZR-S 800 H.O

Table of Contents

General Information
Maintenance
Engine
Electronic Fuel Injection
Body / Steering I Suspension
Clutching
Final Drive
Transmission
Brakes
Electrical

Index of Topics

A
Air Filter Service
All Wheel Drive (AWD) Coil
Authorization Key
Authorization, Reflash
AWD Diagnostics
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 4)
Cab Frame, Assembly / Removal (RZR S)
Cab Frame, Assembly / Removal (RZR)
Caliper, Front
Caliper, Rear
Cam Gear, Reassembly
Cam Gear, Removal
Cargo Box Removal
Centralized Hilliard, Exploded View
Charging System
Charging System, Alternator Tests
Chassis (RZR / RZR S)
Chassis (RZR 4)
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 (RZR / RZR S / RZR 4)
Dash Instruments / Controls (RZR S INT’L)
Decal Replacement
Decimal Equivalent Chart
Diagnostic Codes, Instrument Cluster
Diagnostics, AWD
Diagnostics, Gear Circuit
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 (2009 RZR S)
Drive Clutch, Exploded View (2009 RZR)
Drive Clutch, Exploded View (2010)
Drive Clutch, Operation
Drive Clutch, Service
Drive Clutch, Shift Weights
Drive Clutch, Spring
Drive Shaft Boot Inspection
Driven Clutch Service (Removable Helix)
Driven Clutch, Assembly (Fixed Helix)
Driven Clutch, Disassembly (Fixed Helix)
Driven Clutch, Exploded View (Fixed Helix)
Driven Clutch Exdoded View (Removable Helixt
Driven Clutch, Operation
Driven Clutch, Service (Fixed Helix)
Driveshaft / CV Joint, Handling Tips
E
ECU Replacement
EFI Operation Overview
EFI Priming / Starting Procedure
EFI System, Component Locations
EFI System, Exploded View
EFI, Diagnostic Codes
EFI, Service Notes
EFI, Troubleshooting
Electrical, Cooling System Breakout Diagram
Electronic Control Unit (ECU)
Electronic Power Steering (EPS)
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 Fastener Torque Patterns
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 Speed Display
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, 8-Pin Connector
EPS, Malfunction Indicator Light (MIL)
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, Backlash Adjustment
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, Quick Connect
Fuel Pump Assembly
Fuel Pump Replacement
Fuel Pump Test
Fuel Sender Test
Fuel System
Fuel System Diagnostics
Fuel Tank Replacement (RZR / RZR S)
Fuel Tank Replacement (RZR 4)
Fuel Tank, Exploded View
Fuse Box, Removal
Fuses
G
Gear / Stator Flousing Seal Replacement
Gear Circuit Diagnostics
Gear Position Indicator Switch Test
General Specifications, Brakes
Ground, Engine
Guided Diagnostics
H
Head Lights
Hood
Hood Removal
Hour Meter
I
Ignition Coil
Ignition Coil Replacement
Ignition Coil Test
Indicator, Service Interval
Instrument Cluster
Instrument Cluster, Installation
Instrument Cluster, Removal
Instrument Cluster, Troubleshooting Tests
K
Key, Reprogramming Authorization
Keys, Replacement
Kilometers to Miles Toggle
L
Leakdown Test
Lower Steering Shaft, Installation (EPS)
Lower Steering Shaft, Removal (EPS)
Lubrication Grease Points
M
Main Frame (RZR / RZR S)
Main Frame (RZR 4)
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
Miles to Kilometers Toggle
Model Identification
N
Nets, Side
o
Odometer
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
Programmable Service Interval
Propshaft Removal / Installation (RZR / RZR S)
Propshaft Removal / Installation (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, Driven Clutch Assembly (Removable Helix)
PVT, Driven Clutch Bushing Service (Removable Helix)
PVT, Driven Clutch Disassembly (Removable Helix)
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 Replacement
Rear Drive Shaft, Plunging Joint / Boot Replacement
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)
Rectifier Test
Reflash Authorization
Regulator/Rectifier Test
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
Service Interval Indicator
Shift Cable Inspection and Adjustment
Shift Lever
Shift Lever, Installation
Shift Lever, Removal
Walker Evans, Assembly
Walker Evans, Disassembly
Shock Piston Orientation, Walker Evans (RZR LE)
Shock Rebuilding Tools, Walker Evans (RZR LE)
Shock Valve Shims, Walker Evans (RZR LE)
Shock, FOX 20, Exploded View (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 (RZR LE)
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, Cam Shaft
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 (2009)
Specifications, General (2010)
Specifications, Oil Baffle Bolt Torque
Specifications, Oil Pick-Up Bolt Torque
Specifications, Walker Evans Shocks
Speed Sensor
Speedometer
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 Inspection
Steering Shaft, Bearing Replacement
Steering Shaft, Removal (Non-EPS)
Steering Wheel Freeplay
Steering Wheel Removal (EPS)
Steering Wheel Removal (Non-EPS)
Steering, Exploded View (RZR / RZR S / RZR 4)
Steering, Exploded View (RZR S INT’L)
Steering, Inspection
Steering, Toe Adjustment
Steering, Wheel Toe Alignment
Suspension, (FOX)
Suspension, (Walker Evans)
Suspension, Compression Adjustment (FOX)
Suspension, Compression Adjustment (Walker Evans)
Suspension, Spring Preload Adjustment (FOX)
Suspension, Spring Preload Adjustment (Standard)
Suspension, Spring Preload Adjustment (Walker Evans)
Sway Bar Linkage Removal
Switch, AWD/2WD
Switch, AWD/2WD/TURF (INT’L)
Switch, Brake Light
Switch, Headlamp
Switch, Ignition
Switch, Turn Signal (INT’L)
T
Tachometer
Tail Lights
Tap/Drill Sizes
Temperature / Barometric Air Pressure Sensor (T-BAP)
Throttle Cable Replacement
Throttle Freeplay Adjustment
Throttle Pedal Inspection
Throttle Position Sensor (TPS)
Timing Gear Mark Alignment
Tire Inspection
Tire Pressure
Toe Adjustment
Torque Chart
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
TPS, Adjustment
TPS, Replacement
Transfer Case, Disassembly
Transfer Case, Reassembly
Transmission Lubrication
Transmission, Exploded View (2009)
Transmission, Exploded View (2010)
Transmission, Removal
Transmission, Shift Housing Disassembly
Transmission, Shift Housing Reassembly
Trip Meter
Troubleshooting, Brake Noise
Troubleshooting, Brake System
Troubleshooting, Clutching
Troubleshooting, No AWD
Troubleshooting, No AWD Hub Safety Limiter
Troubleshooting, No Fuel Gauge Display
Troubleshooting, No Gear Indicator Display
Troubleshooting, No Instrument Display
Troubleshooting, Transmission
Troubleshooting, Vehicle Speed Sensor
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
Voltage Drop Test
w
Wheel Hubs
Wheel, Installation