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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Owner’s Manuals

Carefully remove the cylinder components. Periodic Maintenance Chart Emission-related service failure to conduct this maintenance will not void the emissions warranty but may affect emissions Have an authorized POLARIS dealer perform these services. Severe injury may occur if machine tips or falls. Engine exhaust fumes are poisonous. Safe Operation Practices 4. Remove the screw from the end of msnual gear selector shaft spring.

Remove and clean oil pick up V and oil baffle weldment W. The pressure adapter has an integrated relief valve. There should be 0. If the instrument cluster fails to illuminate, a front wheel. Check to make sure the o-ring is in good condition. Inspect the problems above idle speed.

Fill the fuel tank with gasoline. Combustion Area Install pilot into valve guide. Thoroughly clean the cam shaft. Cleanrepair or replace as necessary.

Owner’s Manuals | Polaris RANGER

Install a new shift lever seal flush with the case. The winch motor may become hot during winch use. Place the A-arm in the correct position for ball joint Correct installation. The springs which have a higher oplaris when the clutch is in neutral will increase clutch engagement RPM. Each item can be purchased separately at your local Polaris dealer.


Main gearcase oil 25 H Break-in oil level check Transfer case owmers 25 H Break-in oil level check Perform these procedures more often for vehicles subjected to severe use. Remove the fill plug. Other languages are provided as translations of the original instructions.

Remove RH engine mount fastener. Polaris measures chain length in number of pitches.

Owner’s Manuals | Polaris

The instrument cluster senses vehicle speed from the right NOTE: Turn the ignition switch to the ON position. Follow these precautions when encountering slippery conditions: Remove the airbox and throttle body from the vehicle as an adaptor.

Always ensure that all nuts are torqued to specification. Always check brake pedal travel and the brake fluid reservoir level before each use of the vehicle. Grasp the upper hood edge and pull upward to disengage the hood from the vehicle. Measure piston outside diameter at a point 5 mm up from the bottom of the piston at a right angle to the direction of the piston pin.

Install the clutch rollers D onto each side of the outside Flat Side Down spider. The throttle plate should seal off throttle NOTE: Support U-joint in vise as shown and drive inner yoke down Continually check for free movement of bearing cross as to remove remaining bearing caps. Remove PTO end engine mount.


Apply lubricant to the seal lip. This vehicle may become less stable at speeds higher than those for which it is designed. This will ensure proper sealing when installing bolts.

Carefully remove the Tapered Pins camshaft P must face the balance shaft gear. Be sure to note the number and thickness of these washers.

Never exceed the stated load capacity for this vehicle. If crossing a hill is unavoidable, follow these precautions: Install the crankshaft seal P with the seal lip facing out towards the crankcase. Spark plug H Inspect; replace as needed Perform these procedures more often for vehicles subjected to severe use. Press shaft into the new bearing. To print the manual completely, please, download it.

Press On Bearing When removing the battery, always disconnect the negative black cable first. All EFI units utilize quick connect lines. Cover Bushing Removal Install main adapter Item 8 on puller. Block the rear wheels. Carefully pull the rail away harness for the fuel injector s up over the air box to allow manuzl the injectors and remove the injector s from the fuel injector removal.