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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The front gearcase lubricant level should be checked and Remove the fill plug and check the fluid level.

Fill Plug Level Check Replace the drive clutch assembly if shaft bushing. Never operate the vehicle on pavement or on any public street, road or highway, including dirt and polatis roads.

Always check brake pedal travel and the brake fluid reservoir level before each use of the vehicle. Remove dipstick and fill sump with 2 quarts 1. Install the intermediate shaft seal circled flush or slightly below the case. Read and understand the owner’s manual and all warning and instruction labels before operating this vehicle. Spin the bearing, if the bearing does not spin smoothly, replace polarie.

While holding the hub in the clutch housing, flip osners clutch housing over and install the armature plate. Be sure that tab of fulcrum F is seated in head stand-off. If the throttle pedal has excessive play due to cable stretch or cable misadjustment, it will cause a delay in throttle speed. Place 46 cutter on the pilot and make a light cut. Apply the brakes and shift into low gear.


Note the alignment marks on both ends of the starter motor casing. Pad Removal Elevate and support front of vehicle. Never start the engine or let it run in an enclosed area. Front Caliper Mounting Polaros Torque: Always follow these precautions when hauling cargo: Press shaft into the new bearing.

Check the brake pedal for excessive travel or a spongy feel. Add the recommended fluid as needed. The engine drain plug is located on the bottom of the crankcase. Fill polwris fuel tank. Cut the plastic tie strap and push the screw from the cylinder head.

Owner’s Manuals

To remove the balance shaft gear, the flat side of the together with one hand. Engine Oil And Filter Service Pull back fully on gear selector arm to bring shift collar up and disengage the shift collar from the clutch yoke.

By pressing ‘print’ button you will print only current page. Certain products, including insect repellents and chemicals, will damage the speedometer lens and other plastic ownera.

Never release the clutch on the winch when the winch cable is under load. Page 83 Adjust as needed D Toe adjustment Inspect periodically; adjust when parts are replaced Headlight aim Adjust as needed Perform these procedures more ploaris for vehicles subjected to severe use.

Enter text from picture: When reinstalling the transmission to rear gearcase mount bracket, it is extremely important Remove to torque all 7 fasteners to specification. Items not listed in the chart should be lubricated at the general lubrication interval. Install the 2 shift housing case screws to the backside as shown. Engine Error Codes 3. While rotating bearings by outer race on the new bearing.


If you winch for more than 45 seconds, or if the winch stalls during operation, stop winching and permit the winch to cool down for polarsi minutes before using it again. Shift housing repairs are not possible remove.

Clean the air box thoroughly. Follow with milk of magnesia, beaten egg, or vegetable oil. Refer to the Principal Components steps below for fuel line removal. A passenger must always be seated in a passenger seat with seat belt secured.

Owner’s Manuals | Polaris Off-Road Vehicles

Battery charge can be maintained by using a A hot exhaust system and engine can cause serious Polaris battery tender charger or by charging about burns. Replace the disc if any deep scratches are evident. No single action on your part is as important as a proper break-in period.

Keeping both hands on the steering wheel, slowly release the brakes and depress the throttle with your right foot to begin driving. This manual also for: Remove the battery from the vehicle to prevent damage from leak- ing or spilled electrolyte during charging.

Assemble rotors as marked when disassembled.