Polaris 2009 Ranger RZR 800 EFI User Manual

GENERAL INFORMATION
1.1
CHAPTER 1
GENERAL INFORMATION
1
MODEL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
MODEL IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
ENGINE DESIGNATION NUMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
VIN IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
ENGINE SERIAL NUMBER LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
UNIT SERIAL NUMBER (VIN) LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3
VEHICLE INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4
PUBLICATION NUMBERS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.4
PAINT CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4
REPLACEMENT KEYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4
GENERAL SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5
GENERAL: 2009 RANGER RZR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5
GENERAL: 2009 RANGER RZR “S” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.5
DETAILED: 2009 RANGER RZR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6
DETAILED: 2009 RANGER RZR “S” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.7
MISC. SPECIFICATIONS AND CHARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8
CONVERSION TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8
STANDARD TORQUE SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.9
SAE TAP / DRILL SIZES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.10
METRIC TAP / DRILL SIZES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.10
DECIMAL EQUIVALENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.10
GLOSSARY OF TERMS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.11

Polaris 2009 Ranger RZR 800 EFI Specifications

General

Brand	Polaris
Model	2009 Ranger RZR 800 EFI
Category	Utility Vehicle
Language	English

Summary

Chapter 1: General Information

Chapter 2: Maintenance

Periodic Maintenance Chart

Outlines maintenance intervals and procedures for regular service.

Lubricants / Service Products

Lists recommended lubricants, fluids, and service products.

Chapter 3: Engine

Engine Specifications

Details engine specifications, including exploded views and torque patterns.

Engine Disassembly and Inspection

Detailed procedures for engine disassembly and component inspection.

Chapter 4: Electronic Fuel Injection

Fuel Tank / Fuel Pump Replacement

Procedures for replacing the fuel tank and fuel pump assembly.

Throttle Position Sensor (TPS)

Information on TPS testing, adjustment, and replacement.

Chapter 5: Body / Steering / Suspension

Chapter 6: Clutching

Drive Clutch Service

Procedures for servicing the drive clutch, including springs and weights.

Driven Clutch Service

Procedures for servicing the driven clutch.

Chapter 7: Final Drive

Chapter 8: Transmission

Chapter 9: Brakes

Front Brake Pads

Procedures for front brake pad removal, inspection, and installation.

Front Caliper Service

Rear Brake Pad

Chapter 10: Electrical

Instrument Cluster

Starting System

Charging System