Polaris RZR 4 Offroad Vehicle User Manual


 
IX.4
Rear Gearcase, Assembly (RZR S INT’L) . . . . . . . . . . .7.51
Rear Gearcase, Diff Assembly (RZR S INT’L)
. . . . . . .7.50
Rear Gearcase, Diff Disassembly (RZR S INT’L)
. . . . .7.49
Rear Gearcase, Disassembly
. . . . . . . . . . . . . . . . . . . . . .7.38
Rear Gearcase, Disassembly (RZR S INT’L)
. . . . . . . . .7.45
Rear Gearcase, Exploded View
. . . . . . . . . . . . . . . . . . . .7.42
Rear Gearcase, Exploded View (RZR S INT’L)
. . . . . . .7.54
Rear Gearcase, Installation
. . . . . . . . . . . . . . . . . . . . . . .7.41
Rear Gearcase, Installation (RZR S INT’L)
. . . . . . . . . .7.53
Rear Gearcase, Removal
. . . . . . . . . . . . . . . . . . . . . . . . .7.37
Rear Gearcase, Removal (RZR S INT’L)
. . . . . . . . . . . .7.44
Rear Service Panel (RZR / RZR S)
. . . . . . . . . . . . . . . . .5.18
Rear Stabilizer Bar (RZR S / RZR 4)
. . . . . . . . . . . . . . .5.40
Rear Stabilizer Bar (RZR)
. . . . . . . . . . . . . . . . . . . . . . . .5.39
Reflash Authorization
. . . . . . . . . . . . . . . . . . . . . . . . . . .4.44
Regulator / Rectifier Location
. . . . . . . . . . . . . . . . . . . .10.25
Relays
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10.22
Reprogramming Authorization
. . . . . . . . . . . . . . . . . . . .4.44
Rocker Panel Removal
. . . . . . . . . . . . . . . . . . . . . . . . . .5.21
Rocker Panels (RZR / RZR S)
. . . . . . . . . . . . . . . . . . . .5.12
Rocker Panels (RZR 4)
. . . . . . . . . . . . . . . . . . . . . . . . . .5.13
S
Safety Nets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.6
Seat Assembly
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.10
Seat Belts / Mounting (RZR / RZR S)
. . . . . . . . . . . . . .5.10
Seat Belts / Mounting (RZR 4)
. . . . . . . . . . . . . . . . . . . .5.11
Seats
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.18
Shift Cable Inspection and Adjustment
. . . . . . . . . . 2.10, 8.3
Shift Lever
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.2
Shift Lever, Installation
. . . . . . . . . . . . . . . . . . . . . . . . . . .8.2
Shift Lever, Removal
. . . . . . . . . . . . . . . . . . . . . . . . . . . .8.2
Shock Maintenance
Walker Evans, Assembly 5.59
Walker Evans, Disassembly 5.57
Shock Piston Orientation, Walker Evans (RZR L.E.)
. . .5.56
Shock Rebuilding Tools, Walker Evans (RZR L.E.)
. . .5.56
Shock Valve Shim Arrangement, Walker Evans
. . . . . .5.56
Shock, FOX 2.0, Exploded View (RZR 4)
. . . . . . . . . . .5.44
Shock, FOX PODIUM X, Exploded View (RZR S)
. . . .5.43
Shock, FOX, Rebuild Information
. . . . . . . . . . . . . . . . .5.47
Shock, FOX, Service (RZR S / RZR4)
. . . . . . . . . . . . . .5.45
Shock, Walker Evans, Exploded View (RZR L.E.)
. . . .5.54
Shock, Walker Evans, Rebuild Information
. . . . . . . . . .5.56
Shocks and Springs
. . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.41
Software Version
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.40
Solenoid, Rear Differential (INT’L)
. . . . . . . . . . . . . . . .10.8
Spark Plug Service
. . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.27
Special Tool, Cam Gear Installation Kit
. . . . . . . . . . . . .3.41
Special Tools
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.3
Special Tools, Body/Steering/Suspension
. . . . . . . . . . . . .5.3
Special Tools, Brakes
. . . . . . . . . . . . . . . . . . . . . . . . . . . .9.2
Special Tools, Clutching
. . . . . . . . . . . . . . . . . . . . . . . . . .6.2
Special Tools, EFI
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.2
Special Tools, Electrical
. . . . . . . . . . . . . . . . . . . . . . . . .10.3
Special Tools, Engine
. . . . . . . . . . . . . . . . . . . . . . . . . . .3.10
Special Tools, Final Drive
. . . . . . . . . . . . . . . . . . . . . . . . 7.2
Specification Chart, Maintenance
. . . . . . . . . . . . . . . . . 2.18
Specification, Balance Shaft Gear Bolt Torque
. . . . . . . 3.52
Specification, Cam Lobe Height
. . . . . . . . . . . . . . . . . . 3.46
Specification, Cam Thrust Plate Fastener Torque
. . . . . 3.50
Specification, Camshaft Gear Bolt Torque
. . . . . . . . . . 3.52
Specification, Coolant Sensor Resistance
. . . . . . . . . . 10.19
Specification, Cylinder Head Warp
. . . . . . . . . . . . . . . . 3.26
Specification, Cylinder Taper Limit
. . . . . . . . . . . . . . . 3.34
Specification, Cylinder Warp Limit
. . . . . . . . . . . . . . . . 3.34
Specification, Oil Pump Bolt Torque
. . . . . . . . . . . . . . . 3.51
Specification, Oil Pump Rotor Clearance
. . . . . . . . . . . 3.43
Specification, Timing Gear Alignment
. . . . . . . . . . . . . 3.39
Specification, Valve Seat Contact Width
. . . . . . . . . . . . 3.30
Specification, Valve Spring Free Length
. . . . . . . . . . . . 3.27
Specification, Valve Stem Diameter
. . . . . . . . . . . . . . . 3.28
Specification, Valve Stem Guide I.D.
. . . . . . . . . . . . . . 3.28
Specification, Wheel Toe-Out
. . . . . . . . . . . . . . . . . . . . 2.29
Specifications, Camshaft
. . . . . . . . . . . . . . . . . . . . . . . . 3.47
Specifications, Cooling System
. . . . . . . . . . . . . . . . . . . 3.11
Specifications, Crankcase Fastener Torque
. . . . . . . . . . 3.48
Specifications, Engine
. . . . . . . . . . . . . . . . . . . . . . . . . . . 3.2
Specifications, Engine Lubrication
. . . . . . . . . . . .3.14, 3.60
Specifications, Engine Oil Pressure
. . . . . . . . . . . . . . . . 3.14
Specifications, FOX 2.0 Shocks
. . . . . . . . . . . . . . . . . . 5.45
Specifications, FOX PODIUM X Shocks
. . . . . . . . . . . 5.45
Specifications, General
. . . . . . . . . . . . . . . . . . . . . . . . . . 1.4
Specifications, Oil Baffle Bolt Torque
. . . . . . . . . . . . . 3.47
Specifications, Oil Pick-Up Bolt Torque
. . . . . . . . . . . . 3.47
Specifications, Walker Evans Shocks
. . . . . . . . . . . . . . 5.55
Speed Sensor
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.7
Speedometer
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.9
Starter Armature Testing
. . . . . . . . . . . . . . . . . . . . . . . 10.32
Starter Assembly, Exploded View
. . . . . . . . . . . . . . . . 10.35
Starter Brush Inspection / Replacement
. . . . . . . . . . . . 10.31
Starter Drive
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.33
Starter Drive Removal
. . . . . . . . . . . . . . . . . . . . . . . . . . 3.37
Starter Motor, Removal
. . . . . . . . . . . . . . . . . . . . . . . . 10.30
Starter Reassembly / Installation
. . . . . . . . . . . . . . . . . 10.32
Starter Solenoid, Operation
. . . . . . . . . . . . . . . . . . . . . 10.34
Starter Solenoid, Test
. . . . . . . . . . . . . . . . . . . . . . . . . . 10.34
Starter System Flow Chart
. . . . . . . . . . . . . . . . . . . . . . 10.36
Starter System, Troubleshooting
. . . . . . . . . . . . . . . . . 10.30
Stator, Removal
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.38
Steering Shaft, Bearing Replacement
. . . . . . . . . . . . . . 5.24
Steering Shaft, Removal (Non-EPS)
. . . . . . . . . . . . . . . 5.23
Steering Wheel Freeplay
. . . . . . . . . . . . . . . . . . . . . . . . 2.28
Steering Wheel Removal (EPS)
. . . . . . . . . . . . . . . . . . . 5.27
Steering Wheel Removal (Non-EPS)
. . . . . . . . . . . . . . . 5.23
Steering, Exploded View (Non-EPS)
. . . . . . . . . . . . . . . 5.22
Steering, Inspection
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.28
Suspension, (FOX)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.31
Suspension, (Walker Evans)
. . . . . . . . . . . . . . . . . . . . . 2.33
Suspension, Compression Adjustment (FOX)
. . . . . . . . 2.32
Suspension, Compression Adjustment (Walker Evans)
2.33