Polaris RZR 800 (2008-2013) - Repair, Service Manual, Wiring Diagrams and Owners Manual

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POLARIS RZR 800 (2008-2013) - REPAIR, SERVICE, WORKSHOP MANUAL - OWNERS

- English Service Manual, Wiring Diagram and Owners Manual to Polaris RZR 800.


CONTENTS:

SERVICE MANUAL:

GENERAL INFORMATION
 
- VEHICLE IDENTIFICATION
- Model number designation
- Engine designation number
- Vehicle identification number (vin) designation
- Vehicle and engine serial number locations
- VEHICLE INFORMATION
- Publication numbers
- Replacement keys
- SPECIAL TOOLS
- GENERAL SPECIFICATIONS
- Model: 2013 ranger rzr
- Model: 2013 ranger rzr eps
- Model: 2013 ranger rzr / eps
- Model: 2013 ranger rzr s
- Model: 2013 ranger rzr s int’l
- Model: 2013 ranger rzr s / int’l
- Model: 2013 ranger rzr 4
- Model: 2013 ranger rzr 4 eps
- Model: 2013 ranger rzr 4 / eps
- MISC. SPECIFICATIONS AND CHARTS
- Conversion table
- Standard bolt torque specification
- Metric bolt torque specification
- Sae tap / drill sizes
- Metric tap / drill sizes
- Decimal equivalents

MAINTENANCE
 
- PERIODIC MAINTENANCE CHART
- Periodic maintenance overview
- Break-in period
- Maintenance chart key
- Pre-ride - 50 hour maintenance interval
- 100 - 300 hour maintenance interval
- Maintenance quick reference
- Maintenance quick reference, continued.....
- Grease lubrication points
- LUBRICANTS / SERVICE PRODUCTS
- Polaris lubricants, maintenance and service products
- GENERAL VEHICLE INSPECTION AND MAINTENANCE
- Pre-ride / daily inspection
- Frame, nuts, bolts, and fasteners
- Shift cable inspection / adjustment
- FUEL SYSTEM AND AIR INTAKE
- Fuel system
- Fuel line
- Fuel pump / fuel filters
- Vent lines
- Throttle pedal inspection
- Throttle freeplay adjustment
- Air filter service
- ENGINE
- Engine oil level
- Engine oil and filter service
- Engine breather hose inspection
- Engine and transmission mounts
- Compression and leakdown test
- Exhaust - spark arrestor
- TRANSMISSION AND GEARCASES
- Transmission / gearcase specification chart
- Transmission lubrication
- Front gearcase lubrication
- Rear gearcase lubrication
- COOLING SYSTEM
- Cooling system overview
- Coolant level inspection
- Coolant strength / type
- Cooling system pressure test
- Cooling system hoses
- Radiator
- Coolant drain
- FINAL DRIVE / WHEEL AND TIRE
- Wheel and hub torque table
- Wheel removal
- Wheel installation
- Tire inspection
- Tire pressure
- Drive shaft boot inspection
- ELECTRICAL AND IGNITION SYSTEM
- Battery maintenance
- Battery removal
- Battery installation
- Battery off season storage
- Battery charging (maintenance free)
- Spark plug service
- Engine to frame ground
- STEERING
- Steering inspection
- Steering wheel freeplay
- Tie rod end / wheel hub inspection
- Wheel toe alignment inspection
- Wheel toe adjustment
- SUSPENSION (STANDARD)
- Spring preload adjustment
- SUSPENSION (FOX™)
- Spring preload adjustment
- Shock compression adjustment
- BRAKE SYSTEM
- Brake fluid inspection
- Brake pad / disc inspection
- Brake hose and fitting inspection

ENGINE / COOLING
 
- ENGINE SPECIFICATIONS
- Crankcase exploded views
- Oil pump / gears / engine cover exploded view
- Stator cover / starter / water pump / lubrication system exploded view
- Cylinder / cylinder head / piston exploded view
- Engine efi sensors / valve cover / general components exploded view
- Engine torque specifications
- 800 efi engine service specifications
- Special tools
- ENGINE COOLING SYSTEM
- Cooling system specifications
- Cooling system pressure test
- Pressure cap test
- Cooling system exploded view
- Radiator removal
- Cooling system bleeding procedure
- GENERAL ENGINE SERVICE
- Engine lubrication specifications
- Oil pressure test
- Accessible engine components
- Oil flow chart
- Engine removal
- Engine / transmission separation
- ENGINE DISASSEMBLY AND INSPECTION
- Cylinder head assembly exploded view
- Rocker arms
- Push rods
- Cylinder head removal
- Cylinder head inspection
- Cylinder head warp
- Valve seal / spring service (on engine)
- Cylinder head disassembly
- Valve inspection
- Combustion chamber
- Valve seat reconditioning
- Cylinder head reassembly
- Valve sealing test
- Cylinder removal
- Valve lifter removal / inspection
- Piston removal
- Cylinder inspection
- Cylinder hone selection and honing procedure
- Honing to deglaze
- Cleaning the cylinder after honing
- Piston-to-cylinder clearance
- Piston / rod inspection
- Piston ring installed gap
- Starter drive bendix removal / inspection
- Flywheel / stator removal / inspection
- Engine crankcase disassembly / inspection
- Camshaft inspection
- ENGINE REASSEMBLY
- Crankcase reassembly
- Flywheel / stator installation
- Cylinder head reassembly
- Oil pump priming
- ENGINE INSTALLATION
- Engine assembly and installation
- Engine break-in period
- TROUBLESHOOTING
- Engine
- Cooling system


ELECTRONIC FUEL INJECTION
 
- GENERAL INFORMATION
- Special tools
- Service notes
- Efi system exploded view
- Efi system component locations
- FUEL TANK
- Exploded view
- Fuel line removal / installation
- ELECTRONIC FUEL INJECTION

- Principal components
- Efi operation overview
- Initial priming / starting procedure
- ELECTRONIC CONTROL UNIT (ECU)
- Operation overview
- Ecu service
- Ecu replacement
- TEMP / MANIFOLD ABSOLUTE PRESSURE SENSOR (T-MAP)
- Operation overview
- T-map sensor test
- T-map sensor replacement
- CRANKSHAFT POSITION SENSOR (CPS)
- Operation overview
- Cps test
- Cps replacement
- FUEL INJECTORS
- Operation overview
- Fuel injector service
- Fuel injector test
- Fuel injector replacement
- FUEL PUMP
- Operation overview
- Fuel sender test
- Fuel pump test
- Fuel pump replacement
- Fuel tank removal (rzr / rzr s)
- Fuel tank removal (rzr 4)
- Fuel tank installation
- IDLE AIR CONTROL (IAC)
- Operation overview
- Iac test
- Iac replacement
- THROTTLE POSITION SENSOR (TPS)
- Operation overview
- Tps resistance tests
- Tps tester / regulator
- Tps replacement
- CAMSHAFT PHASE SENSOR
- Operation overview
- Cam phase sensor test
- Cam phase sensor replacement
- ENGINE COOLANT TEMPERATURE SENSOR (ECT)
- Operation overview
- Ect sensor test
- Ect sensor replacement
- IGNITION COIL
- Operation overview
- Ignition coil / ht lead replacement
- Ignition coil tests
- EFI DIAGNOSTICS
- Instrument cluster trouble code display
- Efi troubleshooting
- DIGITAL WRENCH™ OPERATION
- Digital wrench™ diagnostic software overview
- Special tools (also refer to page 4.2)
- Diagnostic software version
- Ecu replacement
- Guided diagnostic available
- Digital wrench™ communication errors
- Digital wrench™ - diagnostic connector
- Digital wrench™ serial number location
- Digital wrench™ version and update id
- Digital wrench™ updates
- Digital wrench™ feature map
- Engine controller reprogramming (reflash)

BODY / STEERING / SUSPENSION
 
- TORQUE SPECIFICATIONS
- SPECIAL TOOLS
- Multi-function pliers
- CAB FRAME (RZR / RZR S)
- Assembly / removal
- CAB FRAME (RZR 4)
- Assembly / removal
- BODY EXPLODED VIEWS
- Side safety nets
- Dash instruments / controls / glovebox
- Hood / front body work
- Rear bumper
- Seat assembly
- Seat belts / mounting (rzr / rzr s)
- Seat belts / mounting (rzr 4)
- Floor / rocker panels (rzr / rzr s)
- Floor / rocker panels (rzr 4)
- Rear cargo box / fenders (rzr / rzr s)
- Rear cargo box / fenders (rzr 4)
- Chassis / main frame (rzr / rzr s)
- Chassis / main frame (rzr 4)
- BODY COMPONENT REMOVAL
- Seats
- Rear service panel (rzr / rzr s)
- Rear console cover (rzr 4)
- Front bumper
- Rear bumper
- Hood and front body work
- Rear fender, flair and tie down removal
- Cargo box assembly removal
- Rocker panels, console and floor
- STEERING ASSEMBLY
- Exploded view (non-eps models)
- Steering wheel removal (non-eps models)
- Steering shaft removal (non-eps models)
- Steering shaft bearing replacement
- ELECTRONIC POWER STEERING ASSEMBLY
- Exploded view (eps models)
- Upper steering shaft removal (eps models)
- Steering wheel removal (eps models)
- Power steering unit removal
- Lower steering shaft removal (eps models)
- Lower steering shaft installation (eps models)
- Power steering unit installation
- Upper steering shaft installation (eps models)
- FRONT A-ARMS
- Removal / replacement
- Exploded view (rzr)
- Exploded view (rzr s / rzr 4)
- BALL JOINT SERVICE
- Service preparation
- Ball joint removal
- Ball joint installation
- FRONT STABILIZER BAR (RZR / RZR S INT’L)
- Stabilizer bar linkage removal
- Stabilizer bar removal
- Exploded view
- REAR A-ARMS
- Removal
- Installation
- Exploded view (rzr)
- Exploded view (rzr s / rzr 4)
- REAR STABILIZER BAR (RZR)
- Removal / installation
- REAR STABILIZER BAR (RZR S / RZR 4)
- Removal / installation
- DECAL REPLACEMENT
- SHOCKS / SPRINGS / FASTENERS
- Exploded view (rzr / rzr s)
- Exploded view (rzr s / rzr s int’l)
- Exploded view (rzr 4)
- Shock removal / installation
- Shock replacement
- FOX™ PODIUM PIGGYBACK SHOCK SERVICE
- Fox™ 1.5 podium ‘piggyback’ shock (rzr s)
- Fox™ 1.5 podium ‘piggyback - general service information
- Front shock service (rzr s)
- Rear shock service (rzr s)
- Fox™ 2.0 podium ‘piggyback’ shock (rzr 4 l.e. Models)
- Fox™ 2.0 podium ‘piggyback - general service information
- Front shock service (rzr 4 l.e models)
- Rear shock service (rzr 4 l.e. Models)
- Fox™ podium ‘piggyback’ rebuild information
- Fox™ podium ‘piggyback’ special tools
- Fox™ podium ‘piggyback’ disassembly
- Fox™ podium ‘piggyback’ body and reservoir service
- Fox™ podium ‘piggyback’ component rebuild
- Fox™ podium ‘piggyback’ assembly
- FOX™ PODIUM TOP FILL SHOCK SERVICE
- Fox™ 2.0 podium top fill shock (rzr 4 base models)
- Fox™ 2.0 podium top fill - general service information
- Front shock service (rzr 4 base models)
- Rear shock service (rzr 4 base models)
- Fox™ 2.0 podium top fill disassembly
- Fox™ 2.0 podium top fill reassembly

CLUTCHING

- SPECIAL TOOLS AND SUPPLIES
- TORQUE SPECIFICATIONS
- Pvt system fastener torques
- HIGH ALTITUDE CLUTCH CHARTS
- Ranger rzr / rzr s / rzr 4
- Ranger rzr eps (ebs model)
- PVT SYSTEM OVERVIEW
- General operation
- Drive clutch operation
- Driven clutch operation
- Pvt break-in (drive belt / clutches)
- Maintenance / inspection
- Overheating / diagnosis
- PVT SYSTEM SERVICE
- Pvt covers and ducting components
- Pvt disassembly
- Pvt assembly
- Clutch offset procedure
- DRIVE BELT (NON-EBS)
- Belt removal
- Belt inspection
- Belt installation
- DRIVE BELT (EBS)
- Belt removal
- Belt inspection
- Belt installation
- DRIVE CLUTCH SERVICE
- Exploded view
- Shift weights
- Clutch disassembly
- Bearing inspection
- Drive clutch spring inspection
- Shift weight inspection
- Button to tower clearance inspection
- Spider removal
- Roller, pin, and thrust washer inspection
- Clutch inspection
- Moveable sheave bushing inspection
- Bushing service
- Clutch assembly
- DRIVEN CLUTCH SERVICE (NON-EBS)
- Exploded view
- Clutch disassembly / inspection
- Clutch assembly
- DRIVEN CLUTCH SERVICE (EBS)
- Clutch disassembly
- Bushing service
- Clutch assembly
- Exploded view
- TROUBLESHOOTING

FINAL DRIVE
 
- SPECIAL TOOLS
- TORQUE SPECIFICATIONS
- Wheel and hub torque table
- FRONT BEARING CARRIER
- Bearing carrier inspection / removal
- Bearing replacement
- Bearing carrier installation
- FRONT DRIVE SHAFT
- Drive shaft removal
- Drive shaft / cv joint handling tips
- Outer cv joint / boot replacement
- Inner plunging joint / boot replacement
- Drive shaft installation
- PROPSHAFT SERVICE
- Removal / installation (rzr / rzr s)
- Removal / installation (rzr 4)
- Support bearing replacement (rzr 4)
- PROPSHAFT U-JOINT SERVICE
- Disassembly
- Assembly
- FRONT GEARCASE / CENTRALIZED HILLIARD
- Centralized hilliard exploded view
- All wheel drive operation

- Awd diagnosis
- Gearcase removal
- Gearcase disassembly / inspection
- Gearcase assembly
- Gearcase installation
- REAR BEARING CARRIER
- Bearing carrier inspection / removal
- Bearing replacement
- Bearing carrier bushing replacement
- Bearing carrier installation
- REAR DRIVE SHAFT
- Drive shaft removal
- Outer cv joint / boot replacement
- Inner plunging joint / boot replacement
- Drive shaft exploded view
- Drive shaft installation
- REAR GEARCASE
- Gearcase removal
- Gearcase disassembly
- Gearcase assembly
- Gearcase installation
- Gearcase exploded view
- REAR GEARCASE (RZR S INT’L)
- General operation
- Gearcase removal
- Gearcase disassembly
- Differential disassembly
- Differential assembly
- Gearcase assembly
- Gearcase installation
- Gearcase exploded view
- WHEEL HUBS
- Front hub exploded view
- Rear hub exploded view

TRANSMISSION
 
- TORQUE VALUES / SPECIFICATIONS
- SHIFT LEVER
- Removal
- Installation
- Shift cable inspection / adjustment
- TRANSMISSION SERVICE
- Transmission removal / service notes
- Transfer case disassembly
- Transfer case reassembly
- Transmission shift housing disassembly
- Transmission shift housing reassembly
- TROUBLESHOOTING
- Troubleshooting checklist
- TRANSMISSION EXPLODED VIEW
- Shift housing / transfer case exploded view

BRAKES
 
- GENERAL SPECIFICATIONS
- TORQUE SPECIFICATIONS
- SPECIAL TOOLS
- BRAKE SYSTEM SERVICE NOTES
- BRAKE NOISE TROUBLESHOOTING
- HYDRAULIC BRAKE SYSTEM OPERATION
- BRAKE SYSTEM EXPLODED VIEW
- Rzr / rzr s / rzr s int’l
- Rzr 4
- MASTER CYLINDER
- Removal
- Installation
- BRAKE PEDAL LEVER
- Pedal removal
- Pedal installation
- BRAKE BLEEDING / FLUID CHANGE
- FRONT BRAKE PADS
- Pad removal
- Pad inspection
- Pad assembly / installation
- Brake burnishing procedure
- FRONT CALIPER SERVICE
- Caliper exploded view (rzr / rzr s / rzr s int’l)
- Caliper exploded view (rzr 4)
- Caliper removal
- Caliper disassembly
- Caliper inspection
- Caliper assembly
- Caliper installation
- FRONT BRAKE DISC
- Disc runout
- Disc inspection
- Disc replacement
- REAR BRAKE PADS
- Pad removal
- Pad inspection
- Pad assembly / installation
- Brake burnishing procedure
- REAR CALIPER SERVICE
- Caliper exploded view
- Caliper removal
- Caliper disassembly
- Caliper inspection
- Caliper assembly
- Caliper installation
- REAR BRAKE DISC
- Disc inspection
- Disc replacement
- TROUBLESHOOTING
- Brakes squeal / poor brake performance
- Pedal vibration
- Caliper overheats (brakes drag)
- Brakes lock

CHAPTER 10 - ELECTRICAL
 
- GENERAL INFORMATION
- Special tools
- Electrical service notes
- Under-dash components
- SWITCHES / CONTROLS
- Brake light switch
- Headlamp switch
- Ignition key switch
- Ignition key switch (int’l)
- Awd / 2wd switch
- Awd / 2wd / turf switch (int’l)
- Turn signal switch (int’l)
- Hazard switch (int’l)
- Transmission (gear position) switch
- Throttle release switch (trs)
- VEHICLE SPEED SENSOR
- Speed sensor location
- Speed sensor testing
- REAR DIFF SOLENOID (INT’L)
- Differential solenoid overview
- Differential solenoid circuit operation
- ALL WHEEL DRIVE COIL
- Operation overview
- Diagnosing system failures
- Instrument Cluster
- Overview
- Rider information display
- Information display area
- Diagnostic mode
- Instrument cluster pinouts
- Instrument cluster removal
- Instrument cluster installation
- HEAD LIGHTS (INCANDESCENT)
- Headlight adjustment
- Headlamp bulb replacement
- Headlamp housing removal
- Headlamp housing installation
- HEAD LIGHTS (led)
- Headlight adjustment
- Headlamp replacement
- Headlamp installation
- TAIL / BRAKE LIGHTS
- Bulb replacement
- COOLING SYSTEM
- Cooling system break-out diagram
- Fan control circuit operation / testing
- Fan control circuit bypass test
- Coolant temperature sensor
- EFI DIAGNOSTICS
- Efi component testing
- FUEL SENDER
- Testing
- FUSE BOX: FUSES / RELAYS / CIRCUIT BREAKER
- Overview / operation
- Fuse box detail
- Relay operation
- CHARGING SYSTEM
- Current draw - key off
- Charging system “break even” test
- Charging system alternator tests
- Regulator / rectifier
- Charging system testing flow chart
- BATTERY SERVICE
- Battery specifications
- General battery information
- Battery removal / installation
- Battery off season storage
- Battery testinG
- Ocv - open circuit voltage test
- Load test
- Battery conductance analyzer
- Charging procedure
- STARTING SYSTEM
- Troubleshooting
- Voltage drop test
- Starter motor removal
- Starter installation
- Starter drive bendix
- Starter solenoid bench test
- Starter solenoid operation
- STARTING SYSTEM TESTING FLOW CHART
- Condition: starter fails to turn over the engine.
- ELECTRONIC POWER STEERING (EPS)
- Eps operation
- Proper eps system diagnosing
- Eps system breakout
- Eps troubleshooting (power steering non-functional with mil on)
- Eps troubleshooting (power steering non-functional with mil off)
- Eps troubleshooting (using digital wrench™)

9924125_WIRE_DIAGRAMS_11X17

9924125_Wire_Diagram_RZR_11x17
9924125_Wire_Diagram_RZR_11x17_2
9924125_Wire_Diagram_RZR_EPS_11x17
9924125_Wire_Diagram_RZR_EPS_11x17_2
9924125_Wire_Diagram_RZRS_11x17
9924125_Wire_Diagram_RZRS_11x17_2
9924125_Wire_Diagram_RZRS_INTL_11x17
9924125_Wire_Diagram_RZRS_INTL_11x17_2
9924125_Wire_Diagram_RZR4_11x17
9924125_Wire_Diagram_RZR4_11x17_2
9924125_Wire_Diagram_RZR4_EPS_11x17
9924125_Wire_Diagram_RZR4_EPS_11x17_2
9924125_Wire_Diagram_RZR_RZRS_RZR4_CargoBox_11x17
9924125_Wire_Diagram_RZRS_INTL_CargoBox_11x17




OWNER’S MANUAL:


FEATURES AND CONTROLS
 
- Component Locations
- Rear Service Panel
- Steering Wheel
- Passenger Hand Hold
- Hood
- Fuel Cap
- Cab Nets
- Seat Belts
- Switches
- Gear Selector
- Brake Pedal
- Throttle Pedal
- All Wheel Drive (AWD) System
- Instrument Cluster

OPERATION
 
- Vehicle Break-in Period
- Pre-Ride Inspection
- Safe Operation Practices
- Starting the Engine
- Stopping the Engine
- Braking
- Parking the Vehicle
- Know Your Riding Area/Tread Lightly
- Trail Etiquette
- New Operator Driving Procedures
- Driving with Passengers
- Driving on Slippery Surfaces
- Driving Uphill
- Driving on a Sidehill (Sidehilling)
- Driving Downhill
- Driving Through Water
- Driving Over Obstacles
- Driving in Reverse
- Parking on an Incline
- Hauling Cargo

EMISSION CONTROL SYSTEMS

MAINTENANCE
 
- Periodic Maintenance Chart
- Lubrication Recommendations
- Engine Oil
- Gearcases
- Spark Plugs
- Fuses
- Cooling System
- POLARIS Variable Transmission (PVT) System
- Filter Systems
- Spark Arrestor
- Throttle System
- Brakes
- Suspension Settings
- Tires
- Lights
- Battery
- Cleaning and Storage

SPECIFICATIONS

POLARIS PRODUCTS

TROUBLESHOOTING

DECLARATION OF CONFORMITY

WARRANTY

MAINTENANCE LOG

INDEX