2011–2013 Polaris RZR Ranger RZR / RZR S / RZR 4 Service Manual (P/N 9923142)

• Coverage and document identity: Covers the 2011-2013 Polaris RANGER RZR, RZR S, and RZR 4 RZR 800 family, with non-EPS, EPS, and RZR S International systems. This is a 418-page OEM PDF, PN 9923142, printed September 2010, Rev 1.
• Engine repair procedures include removal of the engine/transmission/rear gearcase assembly, engine-to-transmission separation, cylinder-head and crankcase disassembly, valve and cylinder inspection, honing, reassembly, oil-system priming, cooling-system pressure testing, and coolant bleeding.
• Bosch M17 EFI diagnostics cover the ECU, T-MAP, CPS, TPS, IAC, ECT, cam-phase sensor, injectors, fuel pump, and ignition coil, along with trouble-code retrieval, Digital Wrench operation, guided diagnostics, and engine-controller reprogramming.
• PVT and drivetrain service addresses belt inspection, clutch offset, drive and driven clutch rebuilding, shift-cable adjustment, transfer-case and shift-housing overhaul, Centralized Hilliard AWD diagnosis, CV joints, propeller-shaft U-joints, and standard or International rear gearcases.
• Chassis, suspension, steering, and brake sections distinguish EPS and non-EPS steering, two-seat and RZR 4 body layouts, A-arms, ball joints, stabilizer bars, FOX and Walker Evans shocks, hydraulic brake bleeding, caliper rebuilding, disc inspection, and brake burnishing.
• Technical references include 56 exploded-view component diagrams, 15 torque specification tables, fluid and lubrication data, wear limits, clearance specifications, electrical test values, diagnostic flowcharts, system breakout drawings, and model-specific wiring schematics.

Polaris designed this service manual primarily for certified Polaris Master Service Dealer technicians working in a properly equipped shop. Its repair procedures assume a sound knowledge of mechanical theory, measuring equipment, special-tool use, and established shop practices.

The covered engine is the 760cc H.O. liquid-cooled OHV twin, engine designation 1204276, with Bosch M17 electronic fuel injection. This is the RZR 800-family publication, not the RZR XP 900 service manual.

The detailed model-identification table lists the 2011 configurations as R11VH76AA/AD/AF/AH for RZR, R11VY76AO for RZR EPS, R11VE76AC/AD/AW for RZR S, R11VM76FX for RZR S EPS INT'L, R11XH76AW for RZR 4, and R11XY76AA for RZR 4 EPS.

Model- and System-Specific Repair Coverage

Variant differences are carried into the repair sections rather than limited to the specification pages. EPS models receive separate steering-shaft, power-steering-unit, connector, breakout, and troubleshooting coverage. RZR 4 procedures account for its cab frame, four-seat body components, brake layout, propeller shaft, and center support bearing.

The RZR S International material covers its separate rear differential design and AWD/2WD/TURF operation, rear differential solenoid, International ignition switch, turn-signal and hazard circuits, and related body controls. Suspension coverage distinguishes standard shocks, FOX PODIUM X and FOX 2.0 piggyback units, and the Walker Evans compression-adjuster reservoir shock used on RZR L.E. models.

Diagnostics, Diagrams, and Special Tools

Electrical troubleshooting includes instrument-cluster diagnostic mode and pinouts, charging-system and starting-system test flowcharts, fan-control testing, an EPS system breakout, and individual AWD, vehicle-speed-sensor, cooling-fan, charging, chassis-power, key-on-power, and starter-interlock circuits.

Five two-page wiring-diagram sets are supplied for the 2011 RANGER RZR/RZR S, RZR EPS, RZR 4, RZR 4 EPS, and RZR S INT'L. Other useful visual references include the engine oil-flow chart, EFI component-location views, Centralized Hilliard exploded view, charging-system flowchart, starting-system flowchart, and EPS breakout.

Special-tool listings identify the equipment required for advanced diagnosis and repair. Examples include TPS Tester 2201519-A, Fuel Pressure Gauge Kit PU-43506-A with adaptor PV-48656, Digital Wrench kit PU-47063-A, Cam Gear Spring Installation Kit PU-45497-1, Clutch Spider Removal and Installation Tool 2870341, and Gas Shock Recharging Kit 2200421.

The manual flags several easy-to-miss repair risks. Disconnecting EFI components with the ignition on can send a damaging voltage spike through the ECU, while incorrect installation of the oil-pressure-relief valve can cause oil-pressure and priming problems. Fuel-system components may remain pressurized with the engine off, and gas-charged shocks must be fully depressurized before disassembly; observe the manual's warnings and use suitable support and protective equipment when servicing brakes or heavy assemblies.