2012 Polaris Ranger RZR 570 Factory Service & Work Shop Manual

SERVICE MANUAL 2011 RANGER RZR / RZR S / RZR 4 PN 9923142

2011 RANGER RZR / RZR S / RZR 4 SERVICE MANUAL FOREWORD The information printed within this publication includes the latest product information at time of print. The most recent version of this Service Manual is available in electronic format at www.polarisdealers.com . This Service Manual is designed primarily for use by certified Polaris Master Service Dealer  technicians in a properly equipped shop and should be kept available for reference. All references to left and right side of the vehicle are from the operator's perspective when seated in a normal riding position. Some procedures outlined in this manual require a sound knowledge of mechanical theory, tool use, and shop procedures in order to perform the work safely and correctly. Technicians should read the text and be familiar with the service procedures before starting any repair. Certain procedures require the use of special tools. Use only the proper tools as specified. If you have any doubt as to your ability to perform any of the procedures outlined in this Service Manual, contact an authorized dealer for service. We value your input and appreciate any assistance you can provide in helping make these publications more useful. Please provide any feedback you may have regarding this manual. Authorized dealers can submit feedback using 'Ask Polaris'. Click on 'Ask Polaris', and then click on 'Publications Question'. Consumers, please provide your feedback in writing to: Polaris Industries Inc. ATTN: Service Publications Department, 2100 Hwy 55, Medina, MN 55340. Publication Printed September 2010 (PN 9923142) Rev 1 © Copyright 2010 Polaris Sales Inc. All information contained within this publication is based on the latest product information at the time of publication. Due to constant improvements in the design and quality of production components, some minor discrepancies may result between the actual vehicle and the information presented in this publication. Depictions and/or procedures in this publication are intended for reference use only. No liability can be accepted for omissions or inaccuracies. Any reprinting or reuse of the depictions and/or procedures contained within, whether whole or in part, is expressly prohibited. Printed in U.S.A.

UNDERSTANDING MANUAL SAFETY LABELS AND DIRECTIONS Throughout this manual, important information is brought to your attention by the following symbols: SAFETY ALERT WARNING indicates a potential hazard that may result in severe injury or death to the operator, bystander or person(s) inspecting or servicing the vehicle. SAFETY ALERT CAUTION indicates a potential hazard that may result in minor personal injury or damage to the vehicle. CAUTION indicates special precautions that must be taken to avoid vehicle damage or property damage. NOTE: NOTE provides key information by clarifying instructions. IMPORTANT: IMPORTANT provides key reminders during disassembly, assembly and inspection of components. TRADEMARKS POLARIS ACKNOWLEDGES THE FOLLOWING PRODUCTS MENTIONED IN THIS MANUAL: Loctite, Registered Trademark of the Loctite Corporation Nyogel, Trademark of Wm. F. Nye Co. Fluke, Registered Trademark of John Fluke Mfg. Co. Mity-Vac, Registered Trademark of Neward Enterprises, Inc. Torx, Registered Trademark of Textron Hilliard, Trademark of the Hilliard Corporation Warn, Trademark of Warn Industries FOX, Registered Trademark of FOX RACING SHOX RydeFX, Registered Trademark of ArvinMeritor Some Polaris factory publications can be downloaded from www.polarisindustries.com, purchased from www.purepolaris.com or by contacting the nearest Polaris dealer. WARNING CAUTION CAUTION

1 GENERAL INFORMATION 2 MAINTENANCE 3 ENGINE 4 ELECTRONIC FUEL INJECTION 5 BODY / STEERING / SUSPENSION 6 CLUTCHING 7 FINAL DRIVE 8 TRANSMISSION BRAKES 9 ELECTRICAL 10

GENERAL INFORMATION 1.1 CHAPTER 1 GENERAL INFORMATION 1 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc. MODEL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 MODEL IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 ENGINE DESIGNATION NUMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 VIN IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 VEHICLE AND ENGINE SERIAL NUMBER LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 VEHICLE INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3 PUBLICATION NUMBERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3 REPLACEMENT KEYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3 SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3 GENERAL SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4 GENERAL: 2011 RANGER RZR / EPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4 DETAILED: 2011 RANGER RZR / EPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5 GENERAL: 2011 RANGER RZR S / EPS INT’L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6 DETAILED: 2011 RANGER RZR S / EPS INT’L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.7 GENERAL: 2011 RANGER RZR 4 / EPS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8 DETAILED: 2011 RANGER RZR 4 / EPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.9 MISC. SPECIFICATIONS AND CHARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.10 CONVERSION TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.10 STANDARD TORQUE SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.11 SAE TAP / DRILL SIZES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.12 METRIC TAP / DRILL SIZES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.12 DECIMAL EQUIVALENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.12 GLOSSARY OF TERMS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.13

1.2 GENERAL INFORMATION 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc. MODEL INFORMATION Model Identification The machine model number must be used with any correspondence regarding warranty or service. Engine Designation Number 1204276 RZR800HO-11 ................................................................... Twin Cylinder, Liquid Cooled, OHV 4 Stroke, Electric Start VIN Identification Vehicle and Engine Serial Number Location Whenever corresponding about a Polaris ORV, refer to the vehicle identification number (VIN) and the engine serial number. The VIN can be found stamped on a portion of the front left frame rail, close to the left front wheel (see Figure 1-1). The engine model and serial number can be found on a decal applied to the cylinder on the side of the engine (see Figure 1-2). } Machine Model Number Identification } } Model Year Designation Basic Chassis Designation Engine Designation Emissions & Model Option R 1 1 V H 7 6 A D } 4 X A V H 7 6 A * B P 0 0 0 0 0 0 } 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 World Mfg. ID Engine Vehicle Description Vehicle Identifier Check Digit Model Year Body Style Plant No. Individual Serial No. * This could be either a number or a letter Powertrain Emissions VIN Figure 1-1 Engine Serial Figure 1-2 Number

1.3 GENERAL INFORMATION 1 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc. VEHICLE INFORMATION Publication Numbers NOTE: When ordering service parts be sure to use the correct parts manual. NOTE: Polaris factory publications can be found at www.polarisindustries.com or purchased from www.purepolaris.com. Replacement Keys Replacement keys can be made from the original key. To identify which series the key is, take the first two digits on the original key and refer to the chart to the right for the proper part number. SPECIAL TOOLS Special tools may be required while servicing this vehicle. Some of the tools listed or depicted are mandatory, while other tools maybe substituted with a similar tool, if available. Polaris recommends the use of Polaris Special Tools when servicing any Polaris product. Dealers may order special tools through Polaris’ official tool supplier, SPX Corporation, by phone at 1-800-328-6657 or on-line at http://polaris.spx.com/ . Model Model No. Owner’s Manual Parts Manual 2011 RANGER RZR R11VH76AA, AD, AF, AH 9922973 9922974 2011 RANGER RZR EPS R11VY76AO 9922973 9922974 2011 RANGER RZR S R11VE76AC, AD, AW 9922973 9923141 2011 RANGER RZR S EPS INT’L R11VM76FX 9922973 9922977 2011 RANGER RZR 4 R11XH76AW 9923148 9923149 2011 RANGER RZR 4 EPS R11XY76AA 9923148 9923149 Series# Part Number 20 4010278 21 4010278 22 4010321 23 4010321 27 4010321 28 4010321 31 4110141 32 4110148 67 4010278 68 4010278 Key Series Number KEY COVER P/N 5533534

1.4 GENERAL INFORMATION 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc. GENERAL SPECIFICATIONS MODEL: 2011 RANGER RZR MODEL NUMBER: R11VH76AA, AD, AF, AH ENGINE NUMBER: 1204276 MODEL: 2011 RANGER RZR EPS MODEL NUMBER: R11VY76AO ENGINE NUMBER: 1204276 Category Dimension / Capacity Length 103 in. / 261.6 cm Width 50 in. / 127 cm Height 69 in. / 175.3 cm Wheel Base 77 in. / 196 cm Ground Clearance 10 in. / 25.4 cm Dry Weight 945 lbs. / 429 kg Gross Vehicle Weight 1727 lbs. / 783 kg Front Storage Capacity 25 lbs. / 11.3 kg Cargo Box Dimension 42 in. x 22 in. / 107 cm x 56 cm Cargo Box Capacity 300 lbs. / 136 kg Maximum Weight Capacity (Payload) 740 lbs. / 335.6 kg (Includes rider(s), cargo, accessories and trailer tongue weight) Hitch Towing Capacity 1500 lbs. / 680 kg Hitch Tongue Capacity 150 lbs. / 68 kg Category Dimension / Capacity Length 103 in. / 261.6 cm Width 50 in. / 127 cm Height 69 in. / 175.3 cm Wheel Base 77 in. / 196 cm Ground Clearance 10 in. / 25.4 cm Dry Weight 961 lbs. / 436 kg Gross Vehicle Weight 1727 lbs. / 783 kg Front Storage Capacity 25 lbs. / 11.3 kg Cargo Box Dimension 42 in. x 22 in. / 107 cm x 56 cm Cargo Box Capacity 300 lbs. / 136 kg Maximum Weight Capacity (Payload) 740 lbs. / 335.6 kg (Includes rider(s), cargo, accessories and trailer tongue weight) Hitch Towing Capacity 1500 lbs. / 680 kg Hitch Tongue Capacity 150 lbs. / 68 kg

1.5 GENERAL INFORMATION 1 9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2010 Polaris Sales Inc. MODEL: 2011 RANGER RZR / EPS MODEL NUMBER: R11VH76AA, AD, AF, AH MODEL NUMBER: R11VY76AO ENGINE NUMBER: 1204276 CLUTCH CHART (B) = Bushed Shift Weight Engine Platform H.O. Domestic Twin Cylinder, Liquid Cooled, 4-Stroke Engine Number 1204276 Engine Displacement 760cc H.O. Number of Cylinders 2 Bore & Stroke (mm) 80 x 76.5 mm Compression Ratio 11:1 Compression Pressure 165 - 185 psi Engine Idle Speed 1250 ± 100 RPM Engine Max Operating RPM 6600 RPM Lubrication Pressurized Wet Sump Oil Requirements PS-4 Plus Synthetic Oil Capacity 2 qts. / 1.9 liters Coolant Capacity 4.8 qts. / 4.5 liters Overheat Warning Instrument Cluster Indicator Exhaust System Dual Headpipe / Single Silencer Fuel System Fuel System Type Bosch M17 EFI Fuel Delivery Electronic Fuel Pump (in tank) Fuel Pressure 45 +/- 2 psi (310 +/- 14kPa) Fuel Filters See Chapter 4 Fuel Capacity / Requirement 7.25 gal. (27.4 liters) 87 Octane (minimum) Electrical Alternator Max Output 500 Watts @ 3000 RPM Headlights 2 - Halogen: Low 55 W / High 60 W Tail / Brake 2 - 6 Watts / 2 - 27 Watts Starting System Electric Start Ignition System Bosch M17 (ECU Controlled) Ignition Timing (Variable) 3° - 10° BTDC @ 1200 RPM Spark plug / Gap RC7YC3 / .035 in. (0.9 mm) Battery (RZR) Yuasa YTX20HL / 18 Amp Hr. / 310 CCA / 12 Volt Battery (RZR EPS) Deka ETX30L / 30 AH 365 CCA / 12 Volt Instrument Type Multifunction Instrument Cluster DC Outlet Standard 12 Volt Relays Chassis / EFI / Fan Fuel Pump / EPS Circuit Breaker Fan Motor: 20 Amp Fuses (Fuse/Relay Box) Drive / Fuel Pump: 10 Amp Lights / EFI / Accessory: 20 Amp Fuses (Power Fuse Holder) EFI: 20 Amp Chassis / EPS: 30 Amp Drivetrain Transmission Type Polaris Automatic PVT Drive Ratio - Front 3.82:1 Drive Ratio - Final 3.70:1 Shift Type In Line Shift - H / L / N / R / P Front Gearcase Fluid Type / Capacity Polaris Demand Drive Plus 6.75 oz. (200 ml) Transmission: Main Gearcase Fluid Type / Capacity Polaris AGL Plus 24 oz. (710 ml) Transmission: Transfer Case Fluid Type / Capacity Polaris AGL Plus 14 oz. (414 ml) Rear Gearcase Fluid Type / Capacity Polaris Premium ADF 26 oz. (769 ml) Belt 3211113 Steering / Suspension Front Suspension Independent Dual A-arm w/Anti-Sway Bar Front Travel 9 in. / 23 cm Rear Suspension Rolled IRS w/Anti-Sway Bar Rear Travel 9.5 in. / 24 cm Shock Preload Adjustment Front / Rear Standard: Cam Adjustment Walker Evans: Threaded Spanner Wrench Adjustment Toe Out 1/8 - 1/4 in. (3 - 6.4 mm) Wheels / Brakes Front Wheel Size Front Tire Type / Size 12 x 6 / Steel 12 x 6 / Cast Aluminum Maxxis / 25 x 8 R12 Rear Wheel Size Rear Tire Type / Size 12 x 8 / Steel 12 x 8 / Cast Aluminum Maxxis / 25 x 10 R12 Tire Air Pressure - Front / Rear 8 psi (55 kPa) Brake - Front / Rear Foot Actuated - 4 Wheel Hydraulic Disc Brake Fluid DOT 4 Altitude Shift Weight Drive Spring Driven Spring Meters (Feet) 0-1500 (0-5000) 23-62 (5632337) Black (7043594) Blk / Almond (7043167) 1500-3700 (5000 - 12000) 23-58 (B) (1322911) Black (7043594) Blk / Almond (7043167)

2012 Polaris Ranger RZR 570 Factory Service & Work Shop Manual

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