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Remove and inspect the armature mahual. Install the bearings by hand as they are a slip-fit. Connect the negative – battery cable and install the drivers seat.

Install the clutch cover outlet duct and tighten the clamps. Page Reinstall fuel tank cap once rocker panel is removed.

Carefully install the rollers into the roll cage assembly while installing the assembly into the clutch housing. Page Loctite Primer N commercially available to remove any debris. Align during installation 7.

You may have to loosen the front gearcase different directions. By pressing ‘print’ button you will print only current page. For stability on rough or hilly terrain, reduce both speed and cargo. Page Install washers with ownerrs carrier. Page At the engine, fuel is fed through the fuel rail and into the injectors, which inject into the intake ports. 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 10 minutes before using it again.


Install the bearing assembly retaining ring and clean excess shock oil. Output Shaft transfer case cover.


Inspect the ball bearing channels on both ends of the shift collar for excessive wear or damage. Gear Switch Connector 3. Align Timing Marks PU 3. If the stop screw is repositioned or adjusted, the throttle body assembly must be replaced. Be sure the hose fits tightly mahual fitting. Hitch Towing Capacity lbs.

Owner’s Manuals

See information provided above. Slow down before entering slippery areas. For ease installing Gear Alignment Tool PUuse a twisting motion when pushing down on the tool. Safe Operation Practices 4. Page 45 Battery Charging Maintenance Free the electrodes.

Owner’s Manuals | Polaris RZR

Fuel Gauge – The segments of the fuel gauge show the level of fuel in the fuel tank. Do not service axle nuts that have manuql cotter pin installed. If the valve is installed incorrectly, oil pressure and oil priming oolaris will occur. Inspect cylinder for wear, scratches, or damage. The engine drain plug is located on the bottom of the crankcase.

Page Be sure to keep the shims together for reassembly. Standard Bolt Torque Specification 59 80 85 81 1. Page Shift Yoke powered and the Clutch Gear plunger extends to disengage the clutch gear and unlock the differential.

Polaris RZR 800 Owner’s Manual

Disconnect oplaris from the wiring harness or power supply. Operate this vehicle only outdoors or in well-ventilated areas. Reinstall the arrestor and torque the screw to specification. Page 79 Push rods can also be checked with a dial indicator or rolled across a flat surface to check for straightness. Look ahead and learn to read the terrain.


Check your surroundings and determine your path of travel. Using the spark plug wrench provided in the tool kit, remove the plug by rotating it counter-clockwise. Wheel Removal Always ensure that all nuts are torqued to specification. Remove the slip fit bearing race and shim s. Remove the fender from the vehicle. Install the ring gear and torque the retaining bolts to specification.

Install the washers E and E-clips F to secure the rollers. Rzr sRzr 4 Page 10 seconds. Do not use alcohol to clean the instrument cluster. The following signal words and symbols appear throughout this manual and ownerd your vehicle. Remove the battery from the vehicle to prevent damage from leak- ing or majual electrolyte during charging.

Attach a clean, clear hose to fitting and place the other end in a clean container. Apply Crankcase Sealant PN to the top half of the crankcase. Before assembly, clean the bolts and bolt holes with Loctite Primer N commercially available to remove any debris.