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RZR 800 2013
Polaris RZR 800 2013 Manuals
Manuals and User Guides for Polaris RZR 800 2013. We have
1
Polaris RZR 800 2013 manual available for free PDF download: Manual
Polaris RZR 800 2013 Manual (500 pages)
Brand:
Polaris
| Category:
Offroad Vehicle
| Size: 82.18 MB
Table of Contents
Chapter 1 1 General Information
7
Table of Contents
7
Engine Designation Number
8
Model Number Designation
8
Vehicle Identification
8
Vehicle Identification Number (Vin) Designation
8
Vehicle and Engine Serial Number Locations
9
Vehicle Information
10
Publication Numbers
10
Replacement Keys
10
Special Tools
11
General Specifications
12
Model: 2013-2014 Rzr 800
12
Model: 2013-2014 Rzr Eps 800
12
Model: 2014 Rzr 800 XC
13
Model: 2013-2014 Rzr / Eps 800
13
Model: 2013-2014 Rzr S 800
15
Model: 2013-2014 Rzr S Int'l 800
15
Model: 2013 Rzr S / Int'l 800
16
Model: 2013-2014 Rzr 4 Eps 800
18
Model: 2013 Rzr 4 / Eps 800
18
Misc. Specifications and Charts
21
Conversion Table
21
Standard Bolt Torque Specification
22
Metric Bolt Torque Specification
22
Sae Tap / Drill Sizes
23
Metric Tap / Drill Sizes
23
Decimal Equivalents
24
Chapter 2 Maintenance
25
Break-In Period
27
Maintenance Chart Key
27
Periodic Maintenance Chart
27
Periodic Maintenance Overview
27
Pre-Ride - 50 Hour Maintenance Interval
28
100 - 300 Hour Maintenance Interval
29
Maintenance Quick Reference
30
Maintenance Quick Reference, Continued
31
Grease Lubrication Points
32
Lubricants / Service Products
33
Polaris Lubricants, Maintenance and Service Products
33
General Vehicle Inspection and Maintenance
34
Pre-Ride / Daily Inspection
34
Frame, Nuts, Bolts, and Fasteners
34
Shift Cable Inspection / Adjustment
34
Fuel System and Air Intake
35
Fuel System
35
Fuel Line
35
Fuel Pump / Fuel Filters
35
Vent Lines
36
Throttle Pedal Inspection
36
Throttle Freeplay Adjustment
36
Air Filter Service
37
Engine
39
Engine Oil Level
39
Engine Oil and Filter Service
40
Engine Breather Hose Inspection
41
Engine and Transmission Mounts
41
Compression and Leakdown Test
41
Exhaust - Spark Arrestor
41
Transmission and Gearcases
43
Transmission / Gearcase Specification Chart
43
Transmission Lubrication
43
Front Gearcase Lubrication
45
Rear Gearcase Lubrication
46
Cooling System
48
Cooling System Overview
48
Coolant Level Inspection
48
Coolant Strength / Type
48
Cooling System Pressure Test
49
Cooling System Hoses
49
Radiator
49
Coolant Drain
49
Final Drive / Wheel and Tire
50
Wheel and Hub Torque Table
50
Wheel Removal
50
Wheel Installation
50
Tire Inspection
51
Tire Pressure
51
Drive Shaft Boot Inspection
52
Electrical and Ignition System
52
Battery Maintenance
52
Battery Removal
53
Battery Installation
53
Battery off Season Storage
53
Battery Charging (Maintenance Free)
53
Spark Plug Service
53
Engine to Frame Ground
55
Steering
55
Steering Inspection
55
Steering Wheel Freeplay
55
Tie Rod End / Wheel Hub Inspection
56
Wheel Toe Alignment Inspection
57
Wheel Toe Adjustment
57
Suspension (Standard)
58
Spring Preload Adjustment
58
Suspension (Fox™)
59
Spring Preload Adjustment
59
Shock Compression Adjustment
60
Brake System
60
Brake Fluid Inspection
60
Brake Pad / Disc Inspection
61
Brake Hose and Fitting Inspection
61
Chapter 3 Engine
63
Crankcase Exploded Views
65
Engine Specifications
65
Oil Pump / Gears / Engine Cover Exploded View
66
Stator Cover / Starter / Water Pump / Lubrication System Exploded View
67
Cylinder / Cylinder Head / Piston Exploded View
68
Engine Efi Sensors / Valve Cover / General Components Exploded View
69
Engine Torque Specifications
70
800 EFI Engine Service Specifications
71
Special Tools
73
Engine Cooling System
74
Cooling System Pressure Test
74
Pressure Cap Test
74
Cooling System Exploded View
75
Radiator Removal
76
Cooling System Bleeding Procedure
77
General Engine Service
79
Engine Lubrication Specifications
79
Oil Pressure Test
79
Accessible Engine Components
79
Oil Flow Chart
80
Engine Removal
81
Engine / Transmission Separation
89
Engine Disassembly and Inspection
90
Cylinder Head Assembly Exploded View
90
Rocker Arms
91
Push Rods
91
Cylinder Head Removal
91
Cylinder Head Inspection
92
Cylinder Head Warp
92
Valve Seal / Spring Service (on Engine)
92
Cylinder Head Disassembly
93
Valve Inspection
94
Combustion Chamber
95
Valve Seat Reconditioning
95
Cylinder Head Reassembly
98
Valve Sealing Test
98
Cylinder Removal
98
Valve Lifter Removal / Inspection
99
Piston Removal
99
Cylinder Inspection
100
Cylinder Hone Selection and Honing Procedure
102
Honing to Deglaze
102
Cleaning the Cylinder after Honing
102
Piston-To-Cylinder Clearance
102
Piston / Rod Inspection
103
Piston Ring Installed Gap
104
Starter Drive Bendix Removal / Inspection
104
Flywheel / Stator Removal / Inspection
105
Engine Crankcase Disassembly / Inspection
106
Camshaft Inspection
115
Engine Reassembly
117
Crankcase Reassembly
117
Flywheel / Stator Installation
127
Cylinder Head Reassembly
128
Oil Pump Priming
131
Engine Installation
132
Engine Assembly and Installation
132
Engine Break-In Period
133
Troubleshooting
134
Engine
134
Cooling System
135
Chapter 4 Electronic Fuel Injection
137
General Information
139
Special Tools
139
Service Notes
141
Efi System Exploded View
142
Efi System Component Locations
143
Fuel Tank
146
Exploded View
146
Fuel Line Removal / Installation
147
Electronic Fuel Injection
148
Principal Components
148
Efi Operation Overview
148
Initial Priming / Starting Procedure
148
Electronic Control Unit (Ecu)
149
Operation Overview
149
Ecu Service
149
Ecu Replacement
149
Pressure Sensor (T-Map)
150
Operation Overview
150
T-Map Sensor Test
150
T-Map Sensor Replacement
150
Crankshaft Position Sensor (Cps)
151
Operation Overview
151
Cps Test
151
Cps Replacement
152
Fuel Injectors
156
Operation Overview
156
Fuel Injector Service
156
Fuel Injector Test
157
Fuel Injector Replacement
157
Fuel Pump
159
Operation Overview
159
Fuel Sender Test
159
Fuel Pump Test
160
Fuel Pump Replacement
161
Fuel Tank Removal (Rzr / Rzr
164
Fuel Tank Removal (Rzr 4)
167
Fuel Tank Installation
170
Idle Air Control (Iac)
170
Operation Overview
170
Iac Test
170
Iac Replacement
171
Throttle Position Sensor (Tps)
171
Tps Resistance Tests
172
Tps Tester / Regulator
172
Tps Replacement
173
Camshaft Phase Sensor
175
Operation Overview
175
Cam Phase Sensor Test
175
Cam Phase Sensor Replacement
175
Engine Coolant Temperature Sensor (Ect)
176
Operation Overview
176
Ect Sensor Test
176
Ect Sensor Replacement
176
Ignition Coil
177
Operation Overview
177
Ignition Coil / Ht Lead Replacement
177
Ignition Coil Tests
177
Efi Diagnostics
178
Instrument Cluster Trouble Code Display
178
Efi Troubleshooting
182
Digital Wrench® Operation
183
Digital Wrench® Diagnostic Software Overview
183
Special Tools
183
Diagnostic Software Version
183
Ecu Replacement
183
Guided Diagnostic Available
183
Digital Wrench® Communication Errors
184
Digital Wrench® - Diagnostic Connector
184
Digital Wrench® Serial Number Location
184
Digital Wrench® Version and Update
184
Digital Wrench® Updates
185
Digital Wrench® Feature Map
186
Engine Controller Reprogramming (Reflash)
187
Chapter 5 Body / Steering / Suspension
191
Special Tools
194
Torque Specifications
194
Cab Frame (Rzr / Rzr S)
195
Assembly / Removal
195
Cab Frame (Rzr 4)
197
Assembly / Removal
197
Body Exploded Views
199
Side Safety Nets
199
Dash Instruments / Controls / Glovebox
200
Hood / Front Body Work
201
Front Bumper
202
Rear Bumper
202
Seat Assembly
203
Seat Belts / Mounting (Rzr / Rzr
203
Seat Belts / Mounting (Rzr 4)
204
Floor / Rocker Panels (Rzr / Rzr
205
Floor / Rocker Panels (Rzr 4)
206
Rear Cargo Box / Fenders (Rzr / Rzr
207
Rear Cargo Box / Fenders (Rzr 4)
208
Chassis / Main Frame (Rzr / Rzr
209
Chassis / Main Frame (Rzr 4)
210
Body Component Removal
211
Seats
211
Rear Service Panel (Rzr / Rzr
211
Rear Console Cover (Rzr 4)
211
Front Bumper
211
Rear Bumper
212
Hood and Front Body Work
212
Rear Fender, Flair and Tie down Removal
213
Cargo Box Assembly Removal
213
Rocker Panels, Console and Floor
214
Steering Assembly
215
Exploded View (Non-Eps Models)
215
Steering Wheel Removal (Non-Eps Models)
216
Steering Shaft Removal (Non-Eps Models)
216
Steering Shaft Bearing Replacement
216
Electronic Power Steering Assembly
218
Exploded View (Eps Models)
218
Upper Steering Shaft Removal (Eps Models)
219
Steering Wheel Removal (Eps Models)
220
Power Steering Unit Removal
220
Lower Steering Shaft Removal (Eps Models)
221
Lower Steering Shaft Installation (Eps Models)
222
Power Steering Unit Installation
222
Upper Steering Shaft Installation (Eps Models)
223
Front A-Arms
224
Removal / Replacement
224
Exploded View (Rzr)
226
Exploded View (Rzr S / Rzr 4)
226
Ball Joint Service
227
Service Preparation
227
Ball Joint Removal
227
Ball Joint Installation
228
Front Stabilizer Bar (Rzr / Rzr S Int
229
Stabilizer Bar Linkage Removal
229
Stabilizer Bar Removal
229
Exploded View
231
Rear A-Arms
232
Removal
232
Installation
233
Exploded View (Rzr)
234
Exploded View (Rzr S / Rzr 4)
235
Rear Stabilizer Bar (Rzr)
235
Removal / Installation
236
Rear Stabilizer Bar (Rzr S / Rzr 4)
236
Decal Replacement
238
Shocks / Springs / Fasteners
238
Exploded View (Rzr / Rzr
238
Exploded View (Rzr S / Rzr S Int
238
Shock Removal / Installation
239
Shock Replacement
239
Fox™ Podium Piggyback Shock Service
240
Fox™ 1.5 Podium 'Piggyback' Shock (Rzr
240
Fox™ 1.5 Podium 'Piggyback - General Service Information
241
Fox™ 2.0 Podium 'Piggyback' Shock (Rzr 4 L.e. Models)
242
Fox™ 2.0 Podium 'Piggyback - General Service Information
243
Front Shock Service (Rzr 4 L.e Models)
243
Rear Shock Service (Rzr 4 L.e. Models)
243
Fox™ Podium 'Piggyback
244
Rebuild Information
244
Fox™ Podium 'Piggyback' Special Tools
244
Fox™ Podium 'Piggyback' Disassembly
244
Fox™ Podium 'Piggyback
246
Body and Reservoir Service
246
Fox™ Podium 'Piggyback
247
Component Rebuild
247
Fox™ Podium 'Piggyback' Assembly
248
Fox™ Podium Top Fill Shock Service
252
Fox™ 2.0 Podium Top Fill Shock (Rzr 4 Base Models)
252
Fox™ 2.0 Podium Top Fill - General Service Information
253
Front Shock Service (Rzr 4 Base Models)
253
Rear Shock Service (Rzr 4 Base Models)
253
Fox™ 2.0 Podium Top Fill Disassembly
254
Fox™ 2.0 Podium Top Fill Reassembly
257
Walker Evans™ Shock Exploded Views
262
Walker Evans™ 2.0" Shock
262
Walker Evans™ Shock Service
263
General Service Information
263
Rear Shock Service Information
264
Walker Evans™ Shock Rebuild Information
265
Special Tools
265
Valve Shim Arrangement
265
Piston Orientation
265
Walker Evans™ Shock Disassembly
266
Walker Evans™ Shock Assembly
268
Chapter 6 Clutching
275
Special Tools and Supplies
277
Torque Specifications
277
High Altitude Clutch Charts
278
Rzr / Rzr S / Rzr 4
278
Rzr Eps (Ebs Model)
278
Pvt System Overview
278
General Operation
278
Drive Clutch Operation
278
Driven Clutch Operation
279
Pvt Break-In (Drive Belt / Clutches)
279
Maintenance / Inspection
279
Overheating / Diagnosis
280
Pvt System Service
281
Pvt Covers and Ducting Components
281
Pvt Disassembly
282
Pvt Assembly
283
Clutch Offset Procedure
285
Drive Belt (Non-Ebs)
287
Belt Removal
287
Belt Inspection
287
Belt Installation
287
Drive Belt (Ebs)
288
Belt Removal
288
Belt Inspection
288
Belt Installation
288
Drive Clutch Service
289
Exploded View
289
Shift Weights
289
Clutch Disassembly
290
Bearing Inspection
290
Drive Clutch Spring Inspection
291
Shift Weight Inspection
291
Button to Tower Clearance Inspection
292
Spider Removal
292
Roller, Pin, and Thrust Washer Inspection
293
Clutch Inspection
293
Moveable Sheave Bushing Inspection
295
Bushing Service
295
Clutch Assembly
297
Driven Clutch Service (Non-Ebs)
299
Exploded View
299
Clutch Disassembly / Inspection
299
Clutch Assembly
301
Driven Clutch Service (Ebs)
302
Clutch Disassembly
302
Bushing Service
305
Clutch Assembly
306
Exploded View
310
Troubleshooting
311
Chapter 7 Final Drive
313
Special Tools
315
Torque Specifications
315
Front Bearing Carrier
316
Bearing Carrier Inspection / Removal
316
Bearing Replacement
317
Bearing Carrier Installation
318
Front Drive Shaft
320
Drive Shaft Removal
320
Drive Shaft / CV Joint Handling Tips
321
Outer CV Joint / Boot Replacement
321
Inner Plunging Joint / Boot Replacement
322
Drive Shaft Installation
324
Propshaft Service
326
Removal / Installation (Rzr 4)
327
Support Bearing Replacement (Rzr 4)
329
Propshaft U-Joint Service
330
Disassembly
330
Assembly
330
Front Gearcase / Centralized Hilliard
332
Centralized Hilliard Exploded View
332
All Wheel Drive Operation
333
Awd Diagnosis
334
Gearcase Removal
335
Gearcase Disassembly / Inspection
336
Gearcase Assembly
339
Gearcase Installation
342
Rear Bearing Carrier
343
Bearing Carrier Inspection / Removal
343
Bearing Replacement
344
Bearing Carrier Bushing Replacement
345
Bearing Carrier Installation
345
Rear Drive Shaft
347
Drive Shaft Removal
347
Outer CV Joint / Boot Replacement
348
Inner Plunging Joint / Boot Replacement
351
Drive Shaft Exploded View
354
Drive Shaft Installation
354
Rear Gearcase
356
Gearcase Removal
356
Gearcase Disassembly
357
Gearcase Assembly
360
Gearcase Installation
363
Rear Gearcase (Rzr S Int
363
General Operation
365
Gearcase Removal
366
Gearcase Disassembly
368
Differential Disassembly
372
Differential Assembly
373
Gearcase Assembly
374
Gearcase Installation
377
Gearcase Exploded View
378
Wheel Hubs
379
Front Hub Exploded View
379
Rear Hub Exploded View
379
Chapter 8 Transmission
381
Removal
382
Shift Lever
382
Torque Values / Specifications
382
Installation
383
Shift Cable Inspection / Adjustment
383
Transmission Service
384
Transmission Removal / Service Notes
384
Transfer Case Disassembly
384
Transfer Case Reassembly
388
Transmission Shift Housing Disassembly
394
Transmission Shift Housing Reassembly
398
Troubleshooting
404
Troubleshooting Checklist
404
Transmission Exploded View
405
Shift Housing / Transfer Case Exploded View
405
Chapter 9 Brakes
407
General Specifications
409
Special Tools
410
Torque Specifications
410
Brake System Service Notes
411
Brake Noise Troubleshooting
412
Hydraulic Brake System Operation
413
Brake System Exploded View
414
Rzr / Rzr S / Rzr S Int'l
414
Rzr 4
414
Master Cylinder
415
Removal
415
Installation
415
Brake Bleeding / Fluid Change
416
Brake Pedal Lever
416
Pedal Removal
416
Pedal Installation
416
Front Brake Pads
417
Pad Removal
417
Pad Inspection
419
Pad Assembly / Installation
419
Brake Burnishing Procedure
420
Front Caliper Service
421
Caliper Exploded View (Rzr / Rzr S / Rzr S Int
421
Caliper Exploded View (Rzr 4)
421
Caliper Removal
422
Caliper Disassembly
423
Caliper Inspection
424
Caliper Assembly
425
Caliper Installation
426
Front Brake Disc
427
Disc Runout
427
Disc Inspection
428
Disc Replacement
428
Rear Brake Pads
429
Pad Removal
429
Pad Inspection
430
Pad Assembly / Installation
431
Brake Burnishing Procedure
431
Rear Caliper Service
432
Caliper Exploded View
432
Caliper Removal
432
Caliper Disassembly
433
Caliper Inspection
434
Caliper Assembly
435
Caliper Installation
435
Rear Brake Disc
436
Disc Inspection
436
Disc Replacement
437
Troubleshooting
438
Pedal Vibration
438
Caliper Overheats (Brakes Drag)
438
Brakes Lock
438
Chapter 10 Electrical
439
Electrical Service Notes
441
General Information
441
Special Tools
441
Under-Dash Components
441
Switches / Controls
442
Brake Light Switch
442
Headlamp Switch
442
Ignition Key Switch
443
Awd / 2Wd Switch
444
Transmission (Gear Position) Switch
446
Throttle Release Switch (Trs)
446
Vehicle Speed Sensor
448
Speed Sensor Location
448
Speed Sensor Testing
448
Rear Diff Solenoid (Int'l)
449
Differential Solenoid Overview
449
Differential Solenoid Circuit Operation
449
All Wheel Drive Coil
450
Operation Overview
450
Diagnosing System Failures
450
Instrument Cluster
451
Overview
451
Rider Information Display
452
Information Display Area
452
Diagnostic Mode
455
Instrument Cluster Pinouts
456
Instrument Cluster Removal
456
Instrument Cluster Installation
456
Head Lights (Incandescent)
457
Headlight Adjustment
458
Headlamp Housing Removal
458
Headlamp Housing Installation
458
Head Lights (Led)
458
Headlamp Replacement
459
Headlamp Installation
460
Tail / Brake Lights
460
Bulb Replacement
460
Cooling System
461
Cooling System Break-Out Diagram
461
Fan Control Circuit Operation / Testing
462
Fan Control Circuit Bypass Test
462
Coolant Temperature Sensor
462
Efi Diagnostics
461
Efi Component Testing
461
Fuel Sender
462
Testing
462
Fuse Box: Fuses / Relays / Circuit Breaker
463
Overview / Operation
463
Fuse Box Detail
464
Relay Operation
465
Charging System
466
Current Draw - Key off
466
Charging System "Break Even" Test
466
Charging System Alternator Tests
467
Regulator / Rectifier
468
Charging System Testing Flow Chart
469
Battery Service
470
Battery Specifications
470
General Battery Information
470
Battery Removal / Installation
471
Battery off Season Storage
471
Battery Testing
471
Ocv - Open Circuit Voltage Test
471
Load Test
471
Battery Conductance Analyzer
471
Charging Procedure
472
Starting System
473
Troubleshooting
473
Voltage Drop Test
473
Starter Motor Removal
473
Starter Motor Installation
473
Starter Drive Bendix
474
Starter Solenoid Bench Test
474
Starter Solenoid Operation
474
Starting System Testing Flow Chart
475
Condition: Starter Fails to Turn over the Engine
475
Electronic Power Steering (Eps)
476
Eps Operation
476
Proper Eps System Diagnosing
476
Eps System Breakout
477
Eps Troubleshooting (Power Steering Non-Functional with Mil Off)
479
Eps Troubleshooting (Using Digital Wrench®)
480
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