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Ranger RZR SW
Polaris Ranger RZR SW User Manual
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345
Table of Contents
General Information Chapter 1 1
5
Table of Contents
5
Chapter 1
6
Engine Designation Number
6
Model Identification
6
Model Information
6
Vehicle and Engine Serial Number Location
6
Vin Identification
6
Special Tools
7
Vehicle Information
7
Publication Numbers
7
General Specifications
8
Model: 2011 Ranger Rzr Sw
8
Misc. Specifications and Charts
10
Conversion Table
10
Standard Torque Specifications
11
Sae Tap / Drill Sizes
12
Metric Tap / Drill Sizes
12
Glossary of Terms
13
Maintenance Chapter 2 Maintenance
15
Break-In Period
17
Chapter 2
17
Maintenance Chart Key
17
Periodic Maintenance Chart
17
Pre-Ride - 25 Hour Maintenance Interval
18
50 - 300 Hour Maintenance Interval
19
Maintenance Quick Reference
20
Maintenance Quick Reference, Continued
21
Grease Lubrication Points
22
Lubricants / Service Products
23
General Vehicle Inspection and Maintenance
24
Pre-Ride / Daily Inspection
24
Frame, Nuts, Bolts, and Fasteners
24
Shift Cable Inspection / Adjustment
24
Fuel System and Air Intake
25
Fuel System
25
Fuel Line
25
Fuel Pump / Fuel Filters
25
Vent Lines
25
Throttle Pedal Inspection
26
Throttle Freeplay Adjustment
26
Air Filter Service
27
Engine
29
Engine Oil Level
29
Engine Oil and Filter Service
29
Engine Breather Hose Inspection
31
Engine and Transmission Mounts
31
Compression and Leakdown Test
31
Exhaust - Spark Arrestor
31
Transmission and Gearcases
32
Transmission / Gearcase Specification Chart
32
Transmission Lubrication
32
Front Gearcase Lubrication
34
Rear Gearcase Lubrication
35
Cooling System
36
Cooling System Overview
36
Coolant Level Inspection
36
Coolant Strength / Type
36
Cooling System Pressure Test
37
Cooling System Hoses
37
Radiator
37
Coolant Drain / Radiator Removal
37
Final Drive / Wheel and Tire
38
Wheel and Hub Torque Table
38
Wheel Removal
38
Wheel Installation
38
Tire Inspection
39
Tire Pressure
39
Drive Shaft Boot Inspection
39
Electrical and Ignition System
40
Battery Maintenance
40
Battery Removal
40
Battery Installation
40
Battery off Season Storage
41
Battery Charging (Maintenance Free)
41
Spark Plug Service
41
Engine to Frame Ground
41
Steering
42
Steering Inspection
42
Steering Wheel Freeplay
42
Tie Rod End / Wheel Hub Inspection
42
Wheel Toe Alignment Inspection
43
Wheel Toe Adjustment
43
Suspension (Fox™)
44
Spring Preload Adjustment
44
Shock Compression Adjustment
45
Brake System
46
Brake Fluid Inspection
46
Brake Pad / Disc Inspection
46
Brake Hose and Fitting Inspection
46
Maintenance Log
47
Chapter 3 Engine
49
Crankcase Exploded Views
50
Engine Specifications
50
Engine Fastener Torque Patterns
55
Torque Specifications
56
800 EFI Engine Service Specifications
57
Special Tools
59
Engine Cooling System
60
Cooling System Specifications / Cooling System Pressure Test
60
Cooling System Exploded View
61
Cooling System Bleeding Procedure
62
General Engine Service
63
Engine Lubrication Specifications
63
Accessible Engine Components
63
Oil Pressure Test
63
Oil Flow Chart
64
Engine Removal
65
Engine / Transmission Separation
72
Engine Disassembly and Inspection
73
Cylinder Head Assembly Exploded View
73
Rocker Arms / Push Rods
74
Cylinder Head Removal
74
Cylinder Head Inspection / Cylinder Head Warp
75
Valve Seal / Spring Service (on Engine)
75
Cylinder Head Disassembly
76
Valve Inspection
77
Combustion Chamber
78
Valve Seat Reconditioning
78
Cylinder Head Reassembly
80
Valve Sealing Test
81
Cylinder Removal / Valve Lifter Removal / Inspection
81
Piston Removal
82
Cylinder Inspection
83
Cylinder Hone Selection and Honing Procedure
84
Piston-To-Cylinder Clearance
85
Piston / Rod Inspection
85
Piston Ring Installed Gap
86
Starter Drive Bendix Removal / Inspection
86
Flywheel / Stator Removal / Inspection
87
Engine Crankcase Disassembly / Inspection
87
Camshaft Inspection
95
Engine Reassembly
96
Crankcase Reassembly
96
Flywheel / Stator Installation
105
Cylinder Head Reassembly
105
Oil Pump Priming
107
Engine Installation
108
Engine Assembly and Installation
108
Engine Break-In Period
109
Troubleshooting
110
Engine
110
Cooling System
111
Chapter 4 Electronic Fuel Injection
113
General Information
114
Special Tools
114
Service Notes
116
Efi System Exploded View
117
Efi System Component Locations
118
Fuel Tank
121
Fuel Lines - Quick Connect
122
Electronic Fuel Injection
122
Principal Components / Efi Operation Overview
122
Initial Priming / Starting Procedure
123
Electronic Control Unit (Ecu)
123
Ecu Service / Replacement
124
Temp / Manifold Absolute Pressure Sensor (T-Map)
124
Crankshaft Position Sensor (Cps)
125
Cps Test
125
Cps Replacement
126
Fuel Injectors
129
Fuel Injector Service / Test
130
Fuel Injector Replacement
131
Fuel Pump
132
Fuel Sender Test
132
Fuel Pump Test
133
Fuel Pump Replacement
134
Fuel Tank Removal
137
Fuel Tank Installation
139
Idle Air Control (Iac)
139
Iac Test
139
Iac Replacement
140
Throttle Position Sensor (Tps)
140
Tps Resistance Tests
141
Tps Tester / Regulator
141
Tps Replacement
142
Camshaft Phase Sensor
144
Cam Phase Sensor Test / Replacement
144
Engine Coolant Temperature Sensor (Ect)
145
Ect Sensor Test / Replacement
145
Ignition Coil
146
Ignition Coil / Ht Lead Replacement / Tests
146
Efi Diagnostics
147
Instrument Cluster Trouble Code Display
147
Efi Troubleshooting
150
Digital Wrench™ Operation
151
Digital Wrench™ Communication Errors
151
Digital Wrench™ - Diagnostic Connector
152
Digital Wrench™ Updates
153
Digital Wrench™ Feature Map
154
Engine Controller Reprogramming (Reflash)
155
Body / Steering / Suspension Chapter 5 Body / Steering / Suspension
159
Special Tools
160
Torque Specifications
160
Cab Frame
161
Body Exploded Views
162
Chapter 5
162
Hood / Front Body Work
162
Front Bumper
163
Rear Bumper
163
Seat Assembly
164
Seat Belts / Mounting
164
Floor / Rocker Panels
165
Rear Cargo Box / Fenders
166
Chassis / Main Frame
167
Body Component Removal
168
Seats
168
Rear Service Panel
168
Front Bumper
168
Rear Bumper
168
Hood and Front Body Work
169
Rear Fender, Flair and Tie down Removal
170
Cargo Box Assembly Removal
170
Rocker Panels, Console and Floor
171
Steering Assembly
172
Exploded View
172
Steering Wheel Removal
173
Steering Shaft Removal
173
Steering Shaft Bearing Replacement
173
Front A-Arms
174
Removal / Replacement
174
Exploded View
175
Ball Joint Service
176
Removal
176
Installation
177
Rear A-Arms
177
Removal
177
Installation
179
Exploded View
179
Rear Stabilizer Bar
180
Removal / Installation
180
Decal Replacement
181
Shocks / Springs / Fasteners
182
Exploded View
182
Shock Removal / Installation
182
Shock Replacement
182
Fox™ Shock Exploded Views
183
Fox™ Shock Service
184
Clutching Chapter 6 Clutching
193
Chapter 6
194
Drive Clutch Operation
194
Engine
194
General Operation
194
Pvt System Overview
194
Special Tools and Supplies
194
Torque Specifications
194
Driven Clutch Operation
195
Maintenance / Inspection
195
Pvt Break-In (Drive Belt / Clutches)
195
Overheating / Diagnosis
196
Pvt System Service
197
Pvt Covers and Ducting Components
197
Pvt Disassembly
197
Clutching
197
Pvt Assembly
198
Clutch Offset Procedure
199
Transmission
199
Brakes
200
Drive Belt
201
Belt Removal
201
Belt Inspection
201
Belt Installation
201
Pvt Break-In (Drive Belt / Clutches)
201
Drive Clutch Service
202
Spring Specifications
202
Shift Weights
203
Non-Braking Exploded View (All Models)
203
Clutch Disassembly
204
Spider Removal
204
Roller, Pin, and Thrust Washer Inspection
205
Button to Tower Clearance Inspection
206
Shift Weight Inspection
206
Bearing Inspection
206
Clutch Inspection
207
Moveable Sheave Bushing Inspection
208
Bushing Service
208
Clutch Assembly
210
Driven Clutch Service
212
Exploded View
212
Clutch Disassembly / Inspection
212
Clutch Assembly
214
Troubleshooting
215
Chapter 7 Final Drive
217
Bearing Carrier Inspection / Removal
218
Front Bearing Carrier
218
Special Tools
218
Torque Specifications
218
Bearing Replacement
219
Bearing Carrier Installation
220
Front Drive Shaft
221
Drive Shaft Removal
221
Drive Shaft / CV Joint Handling Tips
222
Outer CV Joint / Boot Replacement
222
Inner Plunging Joint / Boot Replacement
224
Drive Shaft Installation
225
Propshaft Service
227
Removal / Installation
227
Propshaft U-Joint Service
228
Disassembly
228
Assembly
228
Front Gearcase / Centralized Hilliard
230
Centralized Hilliard Exploded View
230
All Wheel Drive Operation
231
Awd Diagnosis
232
Electrical
232
Gearcase Removal
233
Gearcase Disassembly / Inspection
233
Gearcase Assembly / Inspection
236
Gearcase Installation
238
Rear Bearing Carrier
239
Bearing Carrier Inspection / Removal
239
Bearing Replacement
240
Bearing Carrier Bushing Replacement
241
Bearing Carrier Installation
241
Rear Drive Shaft
243
Drive Shaft Removal
243
Outer CV Joint / Boot Replacement
244
Inner Plunging Joint / Boot Replacement
246
Drive Shaft Exploded View
249
Drive Shaft Installation
249
Rear Gearcase
251
General Operation
251
Gearcase Removal
252
Gearcase Disassembly
253
Differential Disassembly
257
Differential Assembly
258
Gearcase Assembly
259
Gearcase Installation
261
Gearcase Exploded View
262
Wheel Hubs
263
Front Hub Exploded View
263
Rear Hub Exploded View
263
Transmission Chapter 8 Transmission
265
Chapter 8
266
Installation
266
Removal
266
Shift Lever
266
Torque Values / Specifications
266
Shift Cable Inspection / Adjustment
267
Transmission Service
268
Transmission Removal / Service Notes
268
Transfer Case Disassembly
268
Transfer Case Reassembly
271
Transmission Shift Housing Disassembly
273
Transmission Shift Housing Reassembly
277
Troubleshooting
282
Troubleshooting Checklist
282
Transmission Exploded View
283
Shift Housing / Transfer Case Exploded View
283
Brakes Chapter 9 Brakes
285
Brake Noise Troubleshooting
287
Brake System Service Notes
287
Hydraulic Brake System Operation
288
Brake System Exploded View
289
Brake Pedal Lever
290
Pedal Removal
290
Pedal Installation
290
Chapter 9
290
Installation
290
Master Cylinder
290
Removal
290
Brake Bleeding / Fluid Change
291
Front Brake Pads
292
Pad Removal
292
Pad Inspection
292
Pad Assembly / Installation
293
Brake Burnishing Procedure
293
Front Caliper Service
294
Caliper Exploded View
294
Caliper Removal
294
Caliper Disassembly
295
Caliper Inspection
296
Caliper Assembly
296
Caliper Installation
297
Front Brake Disc
298
Disc Runout
298
Disc Inspection
298
Disc Replacement
298
Rear Brake Pads
299
Pad Removal
299
Pad Inspection
300
Pad Assembly / Installation
300
Brake Burnishing Procedure
301
Rear Caliper Service
302
Caliper Exploded View
302
Caliper Removal
302
Caliper Disassembly
303
Caliper Inspection
303
Caliper Assembly
304
Caliper Installation
304
Rear Brake Disc
305
Disc Inspection
305
Disc Replacement
305
Troubleshooting
306
Brakes Squeal / Poor Brake Performance
306
Pedal Vibration
306
Caliper Overheats (Brakes Drag)
306
Brakes Lock
306
Electrical Chapter 10 Electrical
307
Chapter 10
309
Electrical Service Notes
309
General Information
309
Special Tools
309
Switches / Controls
309
Brake Light Switch
309
Headlamp Switch
310
Ignition Key Switch
310
Awd / 2Wd / Turf Switch
311
Blackout Switch
311
I.R. Light Switch
312
Winch Switch
312
Transmission (Gear Position) Switch
313
Under-Dash Components
309
Vehicle Speed Sensor
313
Speed Sensor Location
313
Speed Sensor Testing
313
Rear Differential Solenoid
314
Differential Solenoid Overview
314
Differential Solenoid Circuit Operation
314
Instrument Cluster
315
Overview
315
Rider Information Display
316
Information Display Area
316
Diagnostic Mode
319
Instrument Cluster Pinouts
320
Instrument Cluster Removal
320
Instrument Cluster Installation
320
All Wheel Drive Coil
321
Operation Overview
321
Diagnosing System Failures
321
Head Lights
321
Headlight Adjustment
321
Headlamp Bulb Replacement
322
Headlamp Housing Removal
322
Headlamp Housing Installation
322
Tail / Brake Lights
323
Bulb Replacement
323
Cooling System Schematic
324
Cooling System Break-Out Diagram
324
Fan Control Circuit Operation / Testing
325
Fan Control Circuit Bypass Test
325
Coolant Temperature Sensor
325
Efi Diagnostics
325
Efi Component Testing
325
Fuel Sender
325
Testing
325
Electronic Fuel Injection
325
Fuse Box: Fuses / Relays / Circuit Breaker
326
Overview / Operation
326
Relay Operation
327
Charging System
328
Current Draw - Key off
328
Charging System "Break Even" Test
328
Charging System Alternator Tests
329
Regulator / Rectifier Test
330
Charging System Testing Flow Chart
331
Battery Service
332
Battery Specifications
332
General Battery Information
332
Battery Removal / Installation
332
Battery off Season Storage
332
Battery Testing
332
Ocv - Open Circuit Voltage Test
333
Load Test
333
Battery Conductance Analyzer
333
Charging Procedure
334
Starting System
334
Troubleshooting
334
Voltage Drop Test
335
Starter Motor Removal / Disassembly
335
Brush Inspection / Replacement
335
Armature Testing
336
Starter Reassembly / Installation
337
Starter Solenoid Bench Test
338
Starter Solenoid Operation
338
Starter Exploded View
339
Starting System Testing Flow Chart
340
Body / Steering / Suspension
343
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Polaris Ranger RZR SW Specifications
General
Brand
Polaris
Model
Ranger RZR SW
Category
Utility Vehicle
Language
English
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