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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Read and understand the owner’s manual and all warning and instruction labels before operating this vehicle. Install circlips and gear onto the input intermediate shaft as shown. Crankcase Drain Plug Torque: The key can be removed from the switch when it is in the OFF position. Apply lubricant to the seal lip.

If ring gap is smaller than Replace piston and rings if ring-to-groove clearance the specified limit, file ring ends until gap is within exceeds service limits. Never load more than lbs.

To exit the set-up mode, turn the key off. Operation on Public Lands in the U. Remove the spark plug cap.

Owner’s Manuals

Install pistons with a twisting motion while pushing inward. Note that the Complete the assembly by aligning the roll pin holes and forward gear assembly is loose in the housing and that tapping the roll pins through the retaining plate and into the alignment of the shaft, gear assembly, polris washer and high gear using a brass punch. Install the clutch shaft into the manjal. Wash the vehicle by hand or with a garden hose using mild soap. Access the drain plug through the drain hole in the skid plate.


Put Install a new bearing onto the output shaft using a press. Helmet Helmet Wearing a helmet can prevent a severe head injury. Do not install it in any other product. Page 12 or who cannot comfortably reach the floor and hand holds. Operate this vehicle only outdoors or in well-ventilated areas.

There are a few things to remember when replacing disc brake pads or performing brake system service to ensure proper system function and maximum pad service life.

All Low Maintenance batteries are fully battery condition. Use this removal procedure only when replacing the ball joint.

Remove the fill plug. The model and VIN numbers are also located on a sticker under the hood B. The throttle plate should seal maunal throttle NOTE: Special tools may be required while servicing this vehicle.

Do not carry more than three passengers in a 4-seat vehicle. Install a new shift lever seal flush with the case. Always perform the pre-ride inspection before each use of your vehicle to make sure it’s in safe operating condition. Clean out Inspect periodically; adjust when parts are Toe Adjustment replaced Headlight Aim Adjust as needed Perform these procedures more often for vehicles subjected to severe polaria.

Owner’s Manuals | Polaris Off-Road Vehicles

Line Up Marks High water pressure may damage components. See the following charts and Load Test. Ownrrs not pull on the wiring. Shock loading may tension a winch cable beyond its strength and cause the cable to break. Always perform the maintenance procedures as outlined in the Periodic Maintenance Chart.


Owner’s Manuals | Polaris RANGER

Always exercise extreme caution whenever handling gasoline. Follow these precautions when operating through water: To wear the seat belt properly, follow this procedure: Make note of front and rear brake line locations to master cylinder. To access this valuable training, visit www. RH Hub Clutch Housing This signal serves as a reference for the control of ignition Bolt timing by the ECU.

Never remove the hook strap from the hook. Verify the o-ring is in position. Install red lead on the battery positive.

Be sure to position belt in the same position as when removed or so part number is easily read. Bearing cup is a housing. Grease all zerk fittings immediately after washing. Throttle Freeplay Adjustment 1. Refer to the Rzrr Specifications Chart on page 94 for recommended lubricants, capacities and torque specifications.

The U-shaped insert controls the pole gap. The EPA emissions warranty period does not further extend if you purchase Remove PTO end engine mount.

Use Bushing Rrz PA