2011–2013 Polaris Ranger RZR SW UTV Service & Repair Manual (P/N 9922720-CD)

Polaris service publication P/N 9922720-CD (copyright 2010) covers the 2011–2013 Ranger RZR SW, with maintenance, diagnosis, and repair procedures for its RZR800HO-11 H.O. domestic twin-cylinder engine and chassis.

• Engine repair: Engine removal, cylinder-head and crankcase service, valve-seat reconditioning, hydraulic-lifter inspection, and oil-pump priming.

• Bosch M17 EFI: Fuel-pump and injector testing, throttle position sensor calibration, idle air control diagnosis, sensor checks, and ECU reprogramming documentation.

• PVT and transmission: Drive and driven clutch overhaul, clutch offset adjustment, drive-belt inspection, and transfer-case and shift-housing disassembly.

• Final drive: Centralized Hilliard front-gearcase repair, AWD diagnosis, rear-differential service, and front and rear CV joint and boot replacement.

• Steering, suspension, and brakes: Steering-shaft bearing replacement, A-arm and ball-joint service, FOX 2.0 Piggyback shock rebuilding, caliper service, and brake bleeding.

• Maintenance and cooling: Periodic service charts, lubrication points, compression/leakdown checks, radiator service, cooling-system pressure testing, and air bleeding.

• Electrical troubleshooting: Wiring diagrams, connector pinouts, charging and starting flowcharts, plus blackout, I.R. light, and winch switch tests.

Written primarily for certified Polaris Master Service Dealer technicians in a properly equipped shop, this manual assumes mechanical knowledge and access to the specified service tools.

Engine Repair and Cooling

Internal engine procedures cover crankshaft, camshaft, and counterbalance inspection, gear timing, cylinder honing, and piston/ring measurement. Multi-stage cylinder-head tightening sequences, an Engine Oil Flow Chart, and component-specific torque tables support reassembly.

Oil-system priming uses adapter PU-45778; the manual warns that skipping priming after a rebuild can damage the engine at initial startup.

A Coolant Flow Diagram accompanies radiator service, cooling-system pressure testing, water-pump seal work, and air bleeding. The seal procedure identifies shaft damage as a risk if the seal is serviced with the gear/stator housing still attached.

EFI Testing and Dealer Diagnostics

Electrical checks cover the crankshaft position sensor and ignition coil, with resistance tables for the idle air control motor and throttle position sensor. The Diagnostic Trouble Code Table links instrument-cluster SPN/FMI indications with Digital Wrench P-codes.

TPS calibration specifies tester 2201519-A or Digital Wrench. T-MAP diagnosis calls for dealer-only Digital Wrench software, while the documented ECU reflash procedure also requires the SmartLink interface and a dealer authorization key.

Clutch, Transmission, and Final Drive

Clutch-offset and shift-cable diagnostics help distinguish belt drag or linkage faults from internal transmission trouble before a teardown is planned. The Shift Housing / Transfer Case Exploded View supports internal assembly work. Separate fluid specifications distinguish the main gearcase, transfer case, and front and rear gearcases.

Rear-differential procedures cover the differential solenoid, shift yoke, clutch gear, and differential internals. Rear gearcase limits: Pinion disassembly and pinion/ring-gear shimming are outside the documented service scope; damage to the pinion, its bearings, or the housing calls for complete gearcase replacement.

FOX Suspension, Steering, and Brakes

FOX 2.0 Piggyback procedures address seal replacement, internal floating-piston setting, oil bleeding, nitrogen recharging, and preload/compression adjustment. Separate front and rear shock data include valving stacks.

Steering coverage includes gearbox checks and toe alignment. Brake sections extend beyond routine inspections to piston/bore limits, caliper rebuilding, master-cylinder replacement, and disc-runout measurement.

High-pressure shock service and heavy drivetrain removal require the specified equipment and technical training.

Wiring and Fault Isolation

The Charging System Testing Flow Chart and Starting System Testing Flow Chart accompany stator/alternator tests, starter motor and Bendix service, and fuse/relay identification.

Appended RZR Military chassis wiring sheets add connector/cavity identification and a cable/wire termination table. SW-specific blackout, I.R. lighting, winch, AWD-coil, and rear-differential circuits are documented.

A Preview of Engine Test and Cooling Data

These examples represent a small selection of the manual's engine and cooling specifications.

Engine checks: Cylinder compression is listed at 165–185 psi, with readings affected by cranking speed. Oil-pressure data specify 27–35 psi at 6000 RPM with PS-4 Plus Synthetic and the engine at operating temperature.

Cooling capacity: The cooling-system table lists 4.8 quarts (4.5 liters), alongside pressure-testing and bleeding procedures.

PDF Search, Bookmarks, and Wiring Sheets

Text navigation and drawing detail: Main chapter text is searchable, with embedded bookmarks for chapters, subsections, and the index. The appended wiring sheets and some illustration labels are not text-searchable. Small wiring labels require zooming; the appended sheets have no dedicated bookmarks.

One printable, English-language 346-page PDF, comprising 4 introductory pages (including 1 blank page), 336 chapter pages (including 6 Notes pages), a 4-page index, and 2 appended wiring sheets. All of these pages are included in the total.