Polaris xp 2013 eps Service Manual

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VEHICLE IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2

MODEL NUMBER DESIGNATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2

ENGINE DESIGNATION NUMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2

VEHICLE INDENTIFICATION NUMBER (VIN) DESIGNATION. . . . . . . . . . . . . . . . . . . . 1.2

VEHICLE AND ENGINE SERIAL NUMBER LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . 1.3

VEHICLE INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4

PUBLICATION NUMBERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4

REPLACEMENT KEYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4

SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5

GENERAL SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6

GENERAL: 2013 RANGER RZR XP 900 / EPS / INT'L . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6

DETAILED: 2013 RANGER RZR XP 900 / EPS / INT'L . . . . . . . . . . . . . . . . . . . . . . . . . . 1.7

GENERAL: 2013 RANGER RZR XP 4 900 / EPS / INT'L . . . . . . . . . . . . . . . . . . . . . . . . 1.8

DETAILED: 2013 RANGER RZR XP 4 900 / EPS / INT'L . . . . . . . . . . . . . . . . . . . . . . . . 1.9

MISC. SPECIFICATIONS AND CHARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.10

CONVERSION TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.10

STANDARD BOLT TORQUE SPECIFICATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.11

METRIC BOLT TORQUE SPECIFICATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.11

SAE TAP / DRILL SIZES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.12

METRIC TAP / DRILL SIZES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.12

DECIMAL EQUIVALENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.12

9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual

GENERAL INFORMATION

CHAPTER 1

1.1

Chapters

Table of Contents

Troubleshooting

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Page 2: Vehicle Identification
World Mfg. ID Individual Serial No. * Model Year: A = 2010; B = 2011; C = 2012; D = 2013 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 3: Vehicle And Engine Serial Number Location
GENERAL INFORMATION 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 left rear frame, behind the lower shock mounting location. Refer to Figure 1-1.
Page 4: Vehicle Information
9924107 9924109 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.
Page 5: Special Tools
Special tools may be required while servicing this vehicle. Some of the tools listed or depicted are mandatory, while other tools may be 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/...
Page 6: General Specifications
Do not use this vehicle for towing. Do not modify Hitch Tongue Capacity the vehicle by adding a hitch. 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 7: General: 2013 Ranger Rzr Xp 900 / Eps / Int'l
30 Amp: EFI (5000 - 12000) (1322982) (7043766) (3234452) Fuses (Power Fuse Holder) 30 Amp: Chassis 30 Amp: EPS (OPT) 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 8 Do not use this vehicle for towing. Do not modify Hitch Tongue Capacity the vehicle by adding a hitch. 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 9: Detailed: 2013 Ranger Rzr Xp 900 / Eps / Int'l
(5000 - 12000) (1322982) (7043805) (3234452) 30 Amp: EFI Fuses (Power Fuse Holder) 30 Amp: Chassis 30 Amp: EPS (OPT) 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 10: Misc. Specifications And Charts
°C to °F: °C x 9/5 + 32 = °F °F to °C: °F - 32 x 5/9 = °C 1.10 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 11: Standard Bolt Torque Specification
59 (80) 85 (115) 159 (215) 232 (315) 273 (370) 81 (110) 118 (160) 225 (305) 321 (435) 376 (510) 1.11 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 12: Sae Tap / Drill Sizes
GENERAL INFORMATION SAE Tap / Drill Sizes Decimal Equivalents Metric Tap / Drill Sizes 1.12 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 15: Periodic Maintenance Chart
 = SEVERE USE ITEM: See information provided above.  E = Emission Control System Service (California). NOTE: Inspection may reveal the need for replacement parts. Always use genuine Polaris parts. WARNING  Improperly performing the procedures marked could result in component failure and lead to serious injury or death.
Page 16: Pre-Ride - 50 Hour Maintenance Interval
Perform these procedures more often for vehicles subjected to severe use. E Emission Control System Service (California)  Have an authorized Polaris dealer perform these services. 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual...
Page 17: 50 - 500 Hour Maintenance Interval
Perform these procedures more often for vehicles subjected to severe use. E Emission Control System Service (California)  Have an authorized Polaris dealer perform these services. 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual...
Page 18: Maintenance Quick Reference
* More often under severe use, such as operated in water or under severe loads. 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 19: Maintenance Quick Reference, Continued
Add lubricant until it is Initial level check at 25 hours or Front Gearcase Polaris Demand Drive Plus visible at the fill hole threads 1 month; Change lubricant at 100 hours or every 12 months, Polaris AGL Plus...
Page 20: Grease Lubrication Points
Grease 2 fittings through Rear Torsion Bar the skid plate access holes Polaris All Season Grease Bushings on each side of the vehicle 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 21: Lubricants / Service Products
Premium U-Joint Lube (14 oz.) (10 Count) 2871329 Dielectric Grease (Nyogel™) Coolant 2871323 60/40 Coolant (Gallon) (6 Count) 2871534 60/40 Coolant (Quart) (12 Count) 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 22: General Vehicle Inspection And Maintenance
HIGH gear and cotter pins are in place. Refer to specific fastener torques PARK. listed in each chapter. 2.10 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 23: Fuel System And Air Intake
NOTE: Be sure to install the filter in the orientation shown in the previous photo. 2.11 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 24 Replace line if necessary. RZR XP Shown NOTE: Neither filter is servicable individually. Must replace the fuel pump as an assembly. 2.12 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 25: Throttle Pedal Inspection
Check throttle pedal freeplay periodically in accordance with the Periodic Maintenance Chart. Adjust the freeplay if necessary (see “Throttle Freeplay Adjustment”). 2.13 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 26: Throttle Freeplay Adjustment
6. Re-tighten the jam nut after final adjustment is made. 7. Slide the cable adjuster boot over the cable adjuster to its original position. 2.14 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 27: Engine Intake Pre-Filter Service
Pre-Filter 3. Pull cover rearward far enough to remove air filter (D). 2.15 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 28: Intake Baffle Box Drain Inspection
2. Check the drain to ensure it is not plugged with debris so it can drain properly. If needed, remove the drain from the baffle box during inspection. 2.16 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 29: Air Box / Air Filter Exploded View
Snap Bushing Drain Cap Grommet (2) Dual Round Throttle Body Boot Knob (5) Pivot Nut (5) Intake Tubes Clamp Clamps 2.17 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 30: Engine
SAFE range on dipstick. Do not Access the oil fill cap through the cargo box access panel. overfill (see NOTE below). Polaris recommends the use of PS-4 Plus Synthetic or PS-4 Extreme Duty Synthetic 4-Cycle Engine Oil. Maintain Oil Level In SAFE Range...
Page 31: Engine Oil And Filter Change
5. Remove the seats and engine service panel to access 12 ft-lbs (16 Nm) the oil filter and dipstick. 2.19 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 32: Engine Crankcase Breather Hose Inspection
20. Reinstall the cargo box access panel, engine service panel and seats. 21. Dispose of used oil and filter properly. 2.20 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 33: Valve Clearance Inspection
14. Remove the (4) bolts (J) that attach the rear cross member (K) and box support brackets (L) to the vehicle frame. 2.21 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 34 21. Repeat steps 18-20 until all (8) valves have been Exhaust Exhaust inspected. NOTE: Remove spark plugs to aid engine rotation. 2.22 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 35 PTO and MAG and should be installed Outer Clutch Cover Screws: to the corresponding cylinder. 45-50 in-lbs (5 Nm) 2.23 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 36: Exhaust - Spark Arrestor
5. Reinstall the arrestor and torque the retaining screw to 8 ft-lbs (11 Nm). Silencer Screen Arrestor Screw 8 ft-lbs (11 Nm) 2.24 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 37: Transmission And Front Gearcase
2. Remove the fill plug and check the lubricant level. 3. If lubricant level is not even with bottom threads, add recommended lubricant as needed. Do not overfill. 2.25 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 38: Front Gearcase Lubrication
3. If fluid level is not even with the bottom threads, add the recommended fluid as needed. Do not overfill. 2.26 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 39 4. Clean the drain plug magnetic surface. 5. Reinstall drain plug with a new O-ring and torque to specification. 2.27 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 40: Cooling System
With the engine at operating temperature, the coolant level should be between the upper and lower marks on the IMPORTANT: Polaris Premium 60/40 Antifreeze is coolant recovery bottle. If not, perform the following premixed and ready to use. Do not dilute with water.
Page 41: Cooling System Pressure Test / Hoses
Replace if necessary. 3. Check tightness and condition of all hose spring clamps. Replace if necessary. 2.29 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 42: Radiator Inspection / Cleaning
8. Refer to “Cooling System Bleeding Procedure” provided in Chapter 3. Recommended Coolant: Polaris Premium Pre-Mixed Antifreeze (PN 2871534) (Quart) (PN 2871323) (Gallon) 2.30 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 43: Pvt / Final Drive / Wheel And Tire
PVT system and has not been operated for a period of time, be sure to check the PVT system components for water damage. 2.31 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 44: Drive Shaft Boot Inspection
4. Elevate the appropriate side of the vehicle by placing a suitable stand under the frame. 5. Remove the wheel nuts and remove the wheel. 2.32 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 45: Tire Inspection
14 psi (96.5 kPa) RZR XP 4 Tire Pressure Inspection (Cold) Front Rear 14 psi (96.5 kPa) 16 psi (110.3 kPa) 2.33 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 46: Electrical And Ignition System
Battery Charging / Off Season Storage Refer to Chapter 10 “Electrical” for charging and off season storage procedures. 2.34 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 47: Battery Installation
5. Lift the battery out of the vehicle. RZR XP 4 6. Verify that cables are properly routed and reinstall the driver’s seat. 2.35 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 48: Engine / Chassis Electrical Ground
NOTE: Spark plug wells have drain holes built into the cylinder head to allow water to drain out. 2.36 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 49: Steering
WARNING Due to the critical nature of the procedures 7. Clean with electrical contact cleaner or a glass bead outlined in this chapter, Polaris recommends spark plug cleaner only. CAUTION: A wire brush or steering component repair and adjustment be coated abrasive should not be used.
Page 50: Tie Rod End / Wheel Hub Inspection
= In. / mm. Wheel Toe-Out: (A) - (B) = 1/8" to 3/16" (3.2 to 4.8 mm) 2.38 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 51: Wheel Toe Adjustment
• Shorten or lengthen the tie rod until alignment is as required to achieve the proper toe setting as specified in “Wheel Toe Alignment”. 2.39 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 52: Suspension (Fox™)
The increased suspension height will negatively impact vehicle stability when operating PN 2877408 without a load. Shock Spanner Wrench: PN 2877408 2.40 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 53: Shock Compression Adjustment
Compression Adjustment Table Setting Compression Damping Softest Full counter-clockwise position Factory 10 clicks from closed Firmest 2 clicks from closed 2.41 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 54: Suspension (Walker Evans™)
The increased suspension height will Shock Spanner / Clutch Spreader Tool: negatively impact vehicle stability when operating PN 2878925 without a load. 2.42 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 55: Shock Compression Adjustment
6 clicks from softest position Firmest Full clockwise position Decrease Increase Damping Damping Adjuster Knob Rear Shock Front Shock 2.43 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 56: Brake System
Check brake system hoses and fittings for cracks, deterioration, abrasion, and leaks. Tighten any loose fittings and replace any worn or damaged parts. 2.44 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 57: Parking Brake Cable Adjustment (Int'l)
Adjustment Procedure: Refer to Chapter 9 “Brakes” for complete adjustment procedure. 2.45 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 61: General Information
*Additional oil may be required after complete engine disassembly. Check level after filling and add oil as needed. 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 62: Oil Pressure Test
NOTE: Test results are based on the use of the recommended engine oil (Polaris PS-4 Plus or PS-4 Extreme Duty) at operating temperature, and may vary considerably if any other oil is used or if engine is not up to temperature.
Page 63: Engine Oil Flow Chart
Piston & small Piston spray jet 2 end bearings 2 Crank big end 2 Balancer bearing Main (PTO2) bearing 4 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 64: Engine Service Specifications
0.001" (0.025 mm) Cylinder Taper Limit 0.001" (0.025 mm) Cylinder to Piston Clearance 0.0009" - 0.0019" (0.025 - 0.050 mm) 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 65 Bearing Journal O.D. (Standard) 1.4939" - 1.4946" (37.946 - 37.962 mm) Balance Shaft Bearing Journal O.D. (Service Limit) 1.4921" (37.900 mm) 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 66: Engine Detail - Torque Values / Sequences / Assembly Notes
9 ft-lbs (12 Nm) 9 ft-lbs (12 Nm) 26 ft-lbs STATOR COVER SUMP COVER (35 Nm) TORQUE SEQUENCE TORQUE SEQUENCE 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 70 ENGINE / COOLING Spark Plugs / Starter / Thermostat Housing / Throttle Body / Valve Cover 3.12 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 71: Engine Cooling System
CAUTION: Using tap water in the cooling system will lead to a buildup of deposits which may restrict coolant flow and reduce heat dissipation, resulting in possible engine damage. Polaris Premium 60/40 Antifreeze/Coolant is recommended for use in all cooling systems and comes pre-mixed, ready to use.
Page 72: Pressure Cap Test
17 ft-lbs (20 Nm) 5. Disconnect cooling fan electrical connector. 6. Remove the upper radiator hose from the radiator. 3.14 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 73 10. Reverse this procedure for installation. Be sure to properly fill and bleed cooling system as outlined in this chapter. 3.15 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 74: Thermostat Replacement
7. Using an 8 mm swivel socket and long extension, remove the front bolt (C) retaining the thermostat cover. 3.16 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 75: Cooling System Exploded View
Recovery Bottle Radiator Engine Engine Oil Cooler Thermostat Housing Bypass (active when thermostat closed) Outlet (active when thermostat open) 3.17 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 76: Cooling System Bleeding Procedure
3. Remove the recovery bottle cap (A) and fill the bottle 10. Remove the pressure cap. Add the necessary amount to the MAX line. of Polaris Premium Antifreeze to the radiator filler neck. 11. Open the bleed screw to allow any trapped air to escape.
Page 77: Water Pump Removal / Installation
12. Remove water pump from engine by gently twisting and rocking the water pump housing while pulling Clean Surface outward. 3.19 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 78 NOTE: Install different bolt lengths as shown. Water Pump Mounting Bolts: 89 ± 9 in-lbs (10 ± 1 Nm) 3.20 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 79: Water Pump Service
7. Extract the mechanical seal and the oil seal from the water pump housing. 3.21 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 80 ™ Loctite O-Rings Mechanical Washers Seal PU-50564 Water Pump Drive Tab Oil Seal Shaft Impeller Water Pump Housing Washer 3.22 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 81: Engine Service
Use care when supporting vehicle so that it does not tip or fall. Serious injury may occur if vehicle tips or falls. 3.23 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 82 15. Remove (-) negative cable from the starter mounting bolt. IMPORTANT: Be sure to use the correct Drive Clutch Puller (PN 2872085) to prevent damage to crankshaft. 3.24 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 83 IMPORTANT: The spark plug wires are marked with MAG and PTO. Note during installation procedure. 3.25 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 84 28. With the help of an assistant and the engine hoist, raise the engine vertically out of the vehicle frame. 3.26 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 85: Engine Installation
PU-50562 PU-50625 Starter Motor Bolts: 7 ft-lbs (10 Nm) Trans Joint Bracket Bolts: 44 ft-lbs (60 Nm) PW-47054 PU-50624 3.27 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 86 The pictures below show the tool (PU-50658) properly installed. Drive Clutch Bolt Installed 3.28 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 87 14. Torque the (4) front engine mount fasteners to specification. specification. Exhaust Head Pipe Bolts: Front Engine Mount Fasteners: 18 ft-lbs (24 Nm) 40 ft-lbs (54 Nm) 3.29 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 88 24. Install the throttle body assembly and connect fuel lines as outlined in the EFI Chapter (see Chapter 4). 37. Add approximately 2.5 quarts (3.3 L) of Polaris PS-4 Install throttle cable retaining clip. Plus or PS-4 Extreme Duty Synthetic Engine Oil to the engine.
Page 89: Engine Mounting And Torque Values
CAUTION Oil Capacity * Approx. 2.5 Quarts (2.4 L) Use only Polaris PS-4 Plus or PS-4 Extreme Duty Synthetic 4-Cycle Engine Oil. Oil Filter Wrench PU-50105 or 2.5” (64 mm) Never substitute or mix oil brands.
Page 90: Engine Disassembly / Inspection - Top End
3. Remove the spark plugs (D). Stuff spark plug holes with shop towels to prevent anything from falling into the combustion chamber. 3.32 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 91 Remove 6. Rotate the engine using the flywheel and remove the remaining bolt from each camshaft sprocket (I). 3.33 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 92: Camshaft Sprocket Inspection
Compare to specification. Camshaft Journal O.D.: 0.9036" - 0.9055" (22.954 - 22.999 mm) Service Limit: 0.9033" (22.944 mm) 3.34 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 93 = In. / mm. Camshaft Carrier Bore I.D.: 0.9055" - 0.9063" (23.000 - 23.021 mm) Service Limit: 0.9072" (23.044 mm) 3.35 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 94: Cylinder Head Removal
If warp exceeds the service limit, replace the cylinder head. = In. / mm. Cylinder Head Warp Limit: 0.0039" (0.10 mm) 3.36 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 95: Cylinder Head Disassembly
6. Lift up the cylinder head and push the valve (M) out, keeping it in order for reassembly in the same valve guide. 3.37 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 96: Valve Inspection
Valve Stem Diameter: Intake: 0.2155" - 0.2161" (5.475 - 5.490 mm) Exhaust: 0.2147" - 0.2153" (5.455 - 5.470 mm) 3.38 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 97: Combustion Chamber Cleaning
The valve may overheat and warp, resulting in burnt valves. Combustion Area 3.39 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 100: Engine Disassembly / Inspection - Lower End
A blind bearing puller can also be used. Replace bearing if removed. 3.42 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 101: Water Pump Housing Removal
Inspect the shaft and bearing surfaces in the crankcase and stator cover for excessive wear. 3.43 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 102: Starter One-Way Clutch Inspection
6. Hold puller body and tighten the center bolt to remove the flywheel. Starter One-Way Clutch Disassembly PA-49316 1. Lift up to remove starter one-way gear. 3.44 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 103: Starter One-Way Clutch Assembly
Torque Limit Gear Asm. Screws 106 in-lbs (12 Nm) Starter Gear One-Way Clutch Asm Flywheel Bolt 133 ft-lbs (180 Nm) 3.45 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 104: Crankcase Disassembly / Inspection
2. Remove the crankcase drain plug (B) to drain any oil 7. Remove the sump cover (D) from the crankcase. remaining in the engine. 3. Remove the oil filter. 3.46 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 105 14. Remove the (11) M6 and (2) M8 upper crankcase Access the sprocket bolt by removing the case plug. bolts. 3.47 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 106: Balance Shaft Removal / Inspection
Carefully lift up and remove the lower crankcase half. 4. Inspect the balance shaft gear teeth for damage. 3.48 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 107: Crankshaft Removal / Inspection
(M). Remove the end caps from the crankshaft. 7. Inspect the crankshaft gear (S) and auxiliary sprocket (T) for broken or worn teeth. 3.49 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 108 (26.8 ± 0.1 mm) = In. / mm. Auxiliary Sprocket Installed Depth: 1.0551 ± .0039 in. (26.8 ± 0.1 mm) 3.50 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 110: Crankcase Inspection
(see “Engine Oil Flow Chart”). IMPORTANT: Always replace plain bearings when the crankcase connecting rods have been disassembled. Refer to “Bearing Selection Chart”. 3.52 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 111: Cylinder / Piston Removal
= In. / mm. Cylinder Warp Limit: .002" (0.05 mm) 2. Inspect cylinder for wear, scratches, or damage. 3.53 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 112: Piston Disassembly / Inspection
DO NOT apply heat to piston rings or a loss of Standard Bore Size: radial tension could result. 3.6614" ± .0003" (93 mm ± .008 mm) 3.54 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 113: Piston Ring Removal
= In. / mm. Piston Pin O.D.: 0.7873" - 0.7875" (20.000 - 20.005 mm) Service Limit: 0.7866" (19.98 mm) 3.55 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 114: Piston Ring To Groove Clearance Inspection
Service Limit: .035" (.90 mm) NOTE: Always check piston ring installed gap when installing new rings and/or a new cylinder. 3.56 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 115: Piston-To-Cylinder Clearance
3. Inspect the small end and big end of connecting rod (and matching rod cap) for damage, galling of surface or pitting. 3.57 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 116 “Connecting Rod Bearing Selection” compare to specifications. procedure in this chapter. Remove bearings when taking measurements 3.58 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 117: Engine Assembly - Lower End
Bearing Selection Identification Letters and Numbers Connecting Rod Bearing Identification Number Crankcase Bearing Identification Numbers 1-Number Crankshaft Bearing Identification Letters 3.59 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 118: Connecting Rod Bearing Selection
Blue Blue Green Blue Blue Green Case Blue Green Yellow Blue Green Yellow Green Yellow Yellow Green Yellow Yellow 3.60 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 119: Upper Crankcase Preparation
IMPORTANT: Ends must butt squarely together and must not overlap. 2. Install lower rail with end gap positioned on the intake side of piston. 3.61 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 120: Piston / Connecting Rod Assembly
2. Install a new circlip on one side of piston with gap at the top (12:00 position) or bottom (6:00 position). 12:00 6:00 3.62 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 121: Cylinder / Piston Installation
Toward Exhaust Side NOTE: Orientation arrow is also located on the bottom side of piston as an additional reference. 3.63 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 122: Crankshaft Installation
3. Align tab of new main bearing (A) with the slot in main bearing bore of crankcase. Press bearing insert firmly into place. Repeat for all main bearings. 3.64 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 123 5. Install oil drain diverter (C) into the upper crankcase. 9. Carefully lower the crankshaft into upper crankcase. Guide connecting rods onto the rod journals of crankshaft as necessary. 6. Apply Polaris PS-4 engine oil to each main and rod bearing journal of crankshaft. Apply Engine Oil 10.
Page 124: Balance Shaft Installation
13. Install new bolts and tighten evenly until snug. NEW Bolts 3. Rotate the crankshaft until the alignment dot (B) on the crankshaft MAG end gear is visible. 4. Apply Polaris PS-4 engine oil to both balance shaft journals. Apply Engine Oil 14.
Page 125: Lower Crankcase Preparation
(B) with the slot in each bearing bore of the lower crankcase. Press bearing inserts firmly into place. 3.67 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 126 ENGINE / COOLING 3. Apply Polaris PS-4 engine oil to the new bearings 8. Inspect crankcase mating surfaces to be sure they are installed in the lower crankcase half. joined properly. Investigate the cause of any gaps. 4. Clean crankcase mating surfaces to remove any oil.
Page 127 14. Rotate the engine so the cylinder is facing down. 15. Install a new seal on the oil pump. Oil Pump Mounting Bolts: 89 in-lbs (10 Nm) 3.69 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 128 22. Install the oil sump cover (G) onto the crankcase. Oil Sump Cover Bolts: M6 Bolts: 106 in-lbs (12 Nm) M8 Bolts: 26 ft-lbs (35 Nm) 3.70 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 129: Flywheel Installation
Head Installation”. Flywheel Retaining Bolt: 133 ft-lbs (180 Nm) 6. Install the starter torque limit gear as an assembly. 3.71 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 130: Stator Cover Installation
3. Install stator cover and (13) screws. Torque screws in sequence to specification. Stator Cover Screws: 106 ± 18 in-lbs (12 ± 2 Nm) 3.72 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 131: Engine Assembly - Top End
5. Dip the seat (C), valve spring (D) and retainer (E) in clean engine oil. 6. Install the valve spring seat (C). 3.73 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 132: Valve Sealing Test
The head gasket must be installed clean and dry, free from oil or grease. 3.74 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 133: Camshaft Installation / Timing
Crankshaft Position Sensor (CPS) mounting hole (B). This places the PTO cylinder at TDC for camshaft installation. IMPORTANT: Install new cylinder head bolts. 3.75 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 134 Exhaust Camshaft - PN 1204053 PU-50563 3. Lubricate all camshaft lobes and bearing journal surfaces with Polaris PS-4 engine oil prior to installation. 4. Carefully install the camshafts into the cylinder head. The PTO camshaft lobes should face out as shown.
Page 135 (D). Do not torque the bolts at this time. Install IMPORTANT: Use new sprocket retaining bolts upon assembly. 3.77 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 136 Camshaft Carrier Bolts: 89 ± 9 in-lbs (10 ± 1 Nm) 21. Apply Polaris PS-4 engine oil to the cam chain tensioner bore prior to assembly. Use a new tensioner sealing washer (G). 22. Install the hydraulic cam chain tensioner (H) into the cylinder and torque to specification.
Page 137: Camshaft Timing - Quick Reference
“I” mark. Only the “I” mark should be used as a TDC reference. 3.79 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 138: Valve Clearance Adjustment
Cam Lobe Up 2. Lubricate the camshaft bearing journal surfaces with Polaris PS-4 engine oil prior to installation. 3. Carefully install the camshafts into the cylinder head. Measure The PTO camshaft lobes should face out as shown.
Page 139 19. If all valve clearance measurements are now within specification, remove the camshaft carriers and proceed to “Camshaft Installation / Timing”. 3.81 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 140: Intake Valve Lash - Shim Selection Matrix
1.151-1.175 290 292 295 298 300 1.176-1.200 292 295 298 300 1.201-1.225 295 298 300 1.226-1.250 298 300 1.251-1.275 300 3.82 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 141: Exhaust Valve Lash - Shim Selection Matrix
1.301-1.325 290 292 295 298 300 1.326-1.350 292 295 298 300 1.351-1.375 295 298 300 1.376-1.400 298 300 1.401-1.425 300 3.83 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 142: Valve Cover Installation
6. Torque valve cover bolts to specification. Spark Plugs: 7 ft-lbs (10 Nm) Valve Cover Bolts: 89 in-lbs (10 Nm) 3.84 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 143: Troubleshooting
Engine Runs But Will Not Idle • Engine oil dirty or contaminated • Restricted fuel supply • Low compression • Crankcase breather restricted 3.85 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 144: Cooling System
• Faulty water pump mechanical seal (coolant leak) Sheared flywheel key • Faulty pump shaft oil seal (oil leak) 3.86 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 146: General Information
A USB to serial port adapter can be Digital Wrench® PU-47468 purchased through SPX Corporation (PU-50621) or SmartLink Module DSA at: www.diagsys.com SPX Corp: 1-800-328-6657 or http://polaris.spx.com/ 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 147 SmartLink Module PU-47468, Vehicle Interface Cable PU-47469 and PC Interface Cable PU-47470. This module kit is used on all 8 pin connector-based Polaris EFI systems. This kit is available to Polaris dealers through our tool supplier SPX at http://polaris.spx.com or (1-800-328- 6657).
Page 148: Efi Service Notes
• Never disconnect battery while engine is running. • Never use a battery boost-pack to start the engine. • Do not charge battery with key switch "on." 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 149: Efi System Exploded View
6. Dual Throttle Body Assembly 14. Ignition Coil 7. Fuel Injectors 15. Spark Plug Wires 8. Fuel Rail / Regulator 16. Spark Plugs 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 150: Efi System Component Locations
- Located between the air box assembly and rubber - Located on top of the stator cover. cylinder head adapters. Throttle Body 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 151 - RZR XP: Located under the passenger seat. - RZR XP 4: Located under right rear passenger seat. Fuel Pump Asm RZR XP Shown 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 152: Fuel Tank
Fuel Return Line Pressure Regulator Fuel Rail Fuel Injectors Fuel Tank Pressure Regulator Fuel Pump Assembly Fuel Supply Line Fuel Filters 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 153: Fuel Line Removal / Installation
Verify the connector tabs snap back into place. Rail Fitting 6. Be sure fuel line is routed and retained properly. 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 154: Fuel Tank Removal (Rzr Xp)
8. Remove the (2) bolts retaining the rear seat base assembly to the frame. Remove the rear seat base assembly from the vehicle. Remove Seat Base Asm 4.10 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 155: Fuel Tank Installation (Rzr Xp)
Seat Belt Mechanism Bolt: 40 ft-lbs (54 Nm) 7. Reinstall right-hand rocker panel and all previously removed fasteners. 4.11 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 156: Fuel Tank Removal (Rzr Xp 4)
4. Remove the fuel tank vent line (C) from the tank fitting. 5. Disconnect the fuel pump electrical harness (D). 4.12 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 157 13. Lift up on the rear of the fuel tank first. Then carefully pull the fuel tank out the side of the vehicle. 4.13 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 158: Fuel Tank Installation (Rzr Xp 4)
4. Reinstall the rear right-hand divider panel. Secure with screws and push rivets. 5. Reinstall the rear seat base assembly (F) and spacers (G). 4.14 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 159: Principal Components / Efi Operation Overview
4-stroke cycle. When the intake valve opens, the fuel/air mixture is drawn into the combustion chamber, ignited and burned. 4.15 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 160: Electronic Control Unit (Ecu)
If a problem is encountered, and you the ECU. Signals to the ECU include: ignition power (on/ determine the ECU to be faulty, contact the Polaris Service off), intake air temperature, manifold absolute pressure Department for specific handling instructions. Do not (load), engine coolant temperature, crankshaft position replace the ECU without factory authorization.
Page 161: Manifold Air Quality Sensor (Maqs)
Refer to “Throttle Body Removal” procedure. IMPORTANT: This sensor should only be tested using Digital Wrench® Diagnostic Software (dealer only). 4.17 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 162: Crankshaft Position Sensor (Cps)
CPS and flywheel encoder ring for stop running. damage. 4. If the resistance is incorrect, follow the “CPS Replacement” procedure. 4.18 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 163: Cps Replacement
O-ring to aid installation. 5. Torque the CPS retaining bolt to specification. CPS Retaining Bolt: 106 in-lbs (12 Nm) 4.19 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 164: Idle Air Control Valve (Iac)
60  ± 2.4  60  ± 2.4  1 - 3 4 - 6 6. Reinstall the cargo box access panel. 4.20 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 165: Engine Coolant Temperature Sensor (Ect)
ECT Sensor Refer to Chapter 3 and 10 for additional ECT sensor information. Polaris dealers can test the sensor by using Digital Wrench® Diagnostic Software (dealer only). 4.21 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual...
Page 166 13. Reinstall the cargo box access panel. 14. Add the required amount of coolant and bleed the system (see Chapter 3 “Cooling System Bleeding Procedure”). 4.22 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 167: Dual Throttle Body Assembly
Throttle Body Removal the throttle body using a 5 mm Allen wrench. 1. Remove the cargo box access panel (A). 4.23 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 168 NOTE: It is not necessary to disconnect fuel lines or the injector harnesses to perform this procedure. 4.24 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 169: Fuel Injectors
The ECU gathers fuel injection timing information from the Crankshaft Position Sensor (CPS) and the Manifold Air Quality Sensor (MAQS) to allow for sequential fuel injection. 4.25 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 170 Additives and higher grades of fuel can be used as a preventative measure if clogging has been a problem. 4.26 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 171: Fuel Injector Replacement
Remove air box assembly from vehicle. fuel rail to the throttle body using a 5 mm Allen wrench. Remove Remove 4.27 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 172 MAG injector to ensure proper engine operation. 11. Upon installation of the new fuel injectors, lightly lubricate the injector O-rings to aid installation. 4.28 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 173 • Be sure the lower air box post is placed properly the hose clamp. into the rubber grommet. 25. Reinstall the cargo box access panel. Rubber Grommet 4.29 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 174: Fuel Pump
When the key switch is turned to "ON", the ECU activates the fuel pump, which pressurizes the system for start-up. 4.30 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 175: Fuel Pump Test
NOTE: If the pump still does not operate, replace the on the tester to relieve the system pressure. fuel pump assembly. Normal Fuel Pressure: 43.5 ± 2 psi. 4.31 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 176: Fuel Pump Replacement
NOTE: Apply downward force on the fuel pump “Fuel Lines - Quick Connect Fittings” for specific flange while removing the fuel pump PFA nut. removal procedures). 4.32 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 177 13. Use cleaning wipes provided to clean fuel tank surface and threads. Remove all debris, grease and oil. Allow surfaces to dry completely. 4.33 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 178 Verify orientation marks are still aligned to prime the system. between fuel pump and fuel tank. 25. Install the passenger seat. 4.34 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 179: Ignition Coil
4. Install the new ignition coil and/or high tension lead(s). Ignition Coil Retaining Bolt: 75 in-lbs (8.5 Nm) 4.35 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 180: Efi Diagnostics
Manifold Absolute Pressure Sensor Voltage Too Low P0107 Voltage Too High P0113 Intake Air Temperature Sensor Voltage Too Low P0112 4.36 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 181 P0232 Driver Circuit Grounded P0231 Voltage Too High P16A2 ECU Output Supply Voltage 1 3597 Voltage Too Low P16A1 4.37 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 182 Idle Air Control Valve (IAC) Driver Circuit Short to B+ 520271 P1509 M17; IAC Stepper Pin 1 Driver Circuit Grounded P1508 4.38 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 183: Efi Troubleshooting
• Low compression (worn engine) • Injector failure • Spark plug(s) fouled • Spark plug wires loose or worn • Faulty electrical connection 4.39 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 184: Digital Wrench® Operation
IMPORTANT: Refer to Section 2, 3 and 4 in the Instruction Manual provided in the Digital Wrench® Diagnostic Kit to install the Polaris Digital Wrench® diagnostic software on your computer. The Digital Wrench® diagnostic software allows the technician to perform the following tests and observations: •...
Page 185: Digital Wrench® - Diagnostic Connector
1. Assemble the SmartLink Module and attach the PC Interface Cable to your laptop (see page 4.3). 2. Remove the protective cap from the Digital Wrench® 2. Proceed to http://polaris.diagsys.com to see if a connector. newer update is available. 3. Connect the Vehicle Interface Cable to the Digital Wrench®...
Page 188: Engine Controller Reprogramming (Reflash)
Wrench® Version and Update ID” on page 4.41. running in the background and make it harder for the diagnostic software to operate. 4.44 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 189 Authorization Key NOTE: Request Codes and Authorization Keys must be entered EXACTLY as they appear on the screen. 4.45 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 190 ‘Finish’ button on the screen. Verify the reflash was a success by starting the vehicle. 4.46 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 193: Torque Specifications
Mount Bracket Lower Steering Shaft to 30 ft-lbs (41 Nm) Gear Box Push Rivet Steering Gear Box 17 ft-lbs (23 Nm) 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 194: Cab Frame (Rzr Xp)
M8 screws and nuts on the bottom. Tighten to specification. M8 Screws: 16-18 ft-lbs (22-24 Nm) 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 196: Cab Frame (Rzr Xp 4)
Tighten tap screws to specification. M10x1.5 Bolts: 30 ft-lbs (41 Nm) M8x1.25 Tap Screws: 15 ft-lbs (20 Nm) 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 198: Body Exploded Views
BODY / STEERING / SUSPENSION BODY EXPLODED VIEWS Side Safety Nets (RZR XP) 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 199: Side Safety Nets (Rzr Xp 4)
Side Safety Nets (RZR XP 4) Strap Latch Washer Screw Screw Rear LH Net Washer Screw Washers Front LH Net Nyloc Nut 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 200: Dash Instruments / Controls
B. Headlight Switch or Hazard Switch (INT’L) E. Key Switch C. AWD/2WD Switch or AWD/2WD/TURF Switch (INT’L) F. Switch; Turn, Lights, Horn (INT’L) 5.10 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 201: Hood / Front Body Work
Hood / Dash T27 Screws Front RH Fender Flair Push Rivet Mud Shield T27 Screws Front Bumper Push Rivet Mud Shield 5.11 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 202: Seat Assembly
Shoulder Bolt Latch Plunger Washer 40 ft-lbs (54 Nm) 17 ft-lbs Rear 40 ft-lbs (23 Nm) Seat Base (54 Nm) 5.12 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 203: Seat Belts / Mounting (Rzr Xp 4)
Rear Seat Support 40 ft-lbs (54 Nm) 3 Point Seat Belts 40 ft-lbs (54 Nm) 17 ft-lbs (23 Nm) 5.13 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 204: Floor / Rocker Panels (Rzr Xp)
Screws Close Off Panel U-Type Nuts Push Rivets Upper Floor Torx Screws Screws RH Rocker Self-Tapping Screws Lower Floor 5.14 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 205: Floor / Rocker Panels (Rzr Xp 4)
Self-Tapping Torx Screws Seal Block Off Flap U-Type Nuts Self-Tapping Screw Screws Lower Floor Close Off Upper Floor Panel 5.15 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 206: Rear Cargo Box / Fenders (Rzr Xp)
Intake Grill Grommet Heat Shield Foam Filter Cover Divider Panel Screws Heat Shield Engine Service Panel Rear RH Divider Panel 5.16 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 207: Rear Cargo Box / Fenders (Rzr Xp 4)
Foam Filter 1/4 Turn Latch Screws Divider Panel Heat Shield Cover Rear RH Grommet Divider Panel Engine Service Panel 5.17 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 208: Chassis / Main Frame (Rzr Xp)
40 ft-lbs (54 Nm) Front Bumper Support Screws Skid Plate 17 ft-lbs (23 Nm) Washer Screws 6.5 ft-lbs (8.5 Nm) 5.18 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 209: Chassis / Main Frame (Rzr Xp 4)
(23 Nm) 38 ft-lbs (52 Nm) Screws 17 ft-lbs (23 Nm) Washers Front Skid Plate Screws 6.5 ft-lbs (8.5 Nm) 5.19 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 210: Front / Rear Bumper
Winch Pocket Spring Headlight Screw Cover Rear Bumper Rear Bumper Bulb Socket Screws Speed Tail Light Nuts Rear Bumper Support 5.20 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 211: Body Component Removal
3. Remove rear bumper from vehicle. RZR XP Shown 3. Lift the panel upward and towards the front of the vehicle to remove it. 5.21 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 212: Hood And Front Body Work
1. Remove the (6) T27 Torx screws and remove fender flairs from the dash assembly. Remove Fender Flare RZR XP Shown 5.22 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 213: Rear Fender Flair / Box Side Removal
10. Loosen the hose clamp (H) and remove the clutch intake hose from the inner clutch cover. 5.23 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 214: Rocker Panels, Console And Floor
5. Remove the Torx screws retaining the rear portion of the floor and remove the lower floor from the vehicle. 5.24 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 215: Decal Replacement
9. Remove the Torx screws retaining the rear floor. 10. Disconnect the 12V outlet connector. 11. Remove the rear floor from the vehicle. 5.25 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 216: Steering Assembly
Boot 17 ft-lbs 17 ft-lbs (23 Nm) (23 Nm) 12-14 ft-lbs (16-19 Nm) Tie Rod Cotter Pin Rod End 5.26 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 217: Steering Wheel Removal (Non-Eps Models)
5. Refer to steps 11-13 of the “Steering Shaft Bearing Replacement” procedure for installation. 5.27 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 218: Steering Shaft Bearing Replacement
16. Install steering wheel cap and field test steering ® NOTE: Use care not to allow any of the Loctite operation. get in the bearing. 5.28 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 219: Electronic Power Steering Assembly
Boot 17 ft-lbs 17 ft-lbs (23 Nm) (23 Nm) 12-14 ft-lbs (16-19 Nm) Rod End Tie Rod Cotter Pin 5.29 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 220: Upper Steering Shaft Removal (Eps Models)
3. Remove the fastener retaining the upper portion of the steering wheel tilt shock to the pivot tube. Swing the shock down out of the way. Remove 5.30 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 221: Steering Wheel Removal (Eps Models)
2. Disconnect the (2) electrical harnesses from the power steering unit. Remove 4. Place the assembly in a vise. 5.31 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 222 Remove 5. Carefully remove the power steering unit and mount bracket from the vehicle as an assembly. 5.32 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 223 Steering Shaft Pinch Bolt Gear Box Asm. 5. Lift up on the shaft and remove it through the floor panel. 5.33 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 224: Power Steering Unit Installation
3. Place the power steering mount bracket over the top of the brake pedal mount studs and finger tighten the (4) nuts. 5.34 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 225: Upper Steering Shaft Installation (Eps Models)
23 ft-lbs (31 Nm) 3. Install the tilt shock and torque fastener to specification. Upper Tilt Shock Fastener: 7 ft-lbs (10 Nm) 5.35 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 226: Front A-Arms
14. Attach shock to A-arm with fastener (A). Torque lower Front Shock Mounting Bolts: shock bolt to specification. 45 ft-lbs (61 Nm) 5.36 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 227 45 ft-lbs (61 Nm) 40 ft-lbs (54 Nm) 40 ft-lbs (54 Nm) 45 ft-lbs (61 Nm) 44 ft-lbs (60 Nm) 5.37 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 228: Ball Joint Service
A-arm to gain enough clearance to install ball joint tool (PU-50506) on the lower ball joint. Ball Joint Removal 5.38 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 229: Ball Joint Installation
Front Caliper Mounting Bolts: 40 ft-lbs (54 Nm) Wheel Nuts (Alum): 30 ft-lbs (41 Nm) + 90° (1/4 turn) Wheel Nuts (Steel): 27 ft-lbs (37 Nm) 5.39 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 230: Front Stabilizer Bar (Int'l)
The clamps should be flush with the end of the stabilizer bar. P-Clamp 5.40 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 231: Exploded View
Stabilizer Grease Zerk Clamp Bushings Nuts Linkage 40 ft-lbs Linkage (54 Nm) 43 ft-lbs (58 Nm) Spacer Upper A-Arm 5.41 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 232: Rear Radius Rods
Outer: 45 ft-lbs (61 Nm) WARNING RZR XP Shown Upon radius rod installation, test vehicle at low speeds before putting into service. 5.42 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 233: Rear Trailing Arm
8. Remove the bearing carrier from the rear drive shaft down. Discard the nut. and trailing arm. RZR XP Shown 5.43 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 234 Upon rear trailing arm installation, test vehicle at 18. Torque all fasteners to specification. low speeds before putting into service. 5.44 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 235: Trailing Arm Spherical Bearing Replacement
40 ft-lbs Ring (54 Nm) Bushing Bearing Carrier 70 ft-lbs 31-34 ft-lbs Spherical (95 Nm) (42-46 Nm) O-Ring Bearing 5.45 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 236: Rear Stabilizer Bar
Stabilizer Bar Bushings 10 ft-lbs (13.5 Nm) 31-34 ft-lbs (42-46 Nm) Locating Clamps Grease Fitting Link 31-34 ft-lbs (42-46 Nm) 5.46 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 237: Shocks / Springs / Fasteners
Retainer gap fasteners to specification. should be 180° from spring end 70 ft-lbs (95 Nm) O-Rings Guard RZR XP Shown 5.47 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 238: Fox™ Shock Exploded Views (Rzr Xp)
Bumper Valving Asm. Bearing, Spherical Lock Nut Retaining Ring Reservoir Retaining Ring Piston Asm, Floating (IFP) Shock Oil (2870995) 5.48 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 239: Fox™ Shock Service (Rzr Xp)
IFP Location 3.40” (86.4 mm) Piston Orifice: 2x 0.070 Nitrogen Pressure 200 psi +/- 5% Gas Shock Oil 2870995 (qt.) 5.49 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 240: Rear Shock Service Information
0.950 x 0.010 Gas Shock Oil 2870995 (qt.) 0.950 x 0.010 1.570 x .128 Top-Out Piston Orifice: 1x 0.098 5.50 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 241: Fox™ Shock Rebuild Information
6. Slowly loosen nylon ball retainer from reservoir cap and allow nitrogen to completely escape. 7. Remove the nylon ball retainer. 5.51 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 242 (C). Remove the retaining ring from the shock body. 23. Inspect the valve shims for kinks, waves, pits or foreign material. 5.52 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 243: Fox™ Shock Body And Reservoir Service
3. Use a spanner or strap wrench to remove the shock body tube and reservoir from the body cap. DSC: 35 ft-lbs (47 Nm) LSC: 14 ft-lbs (19 Nm) 5.53 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 244: Fox™ Shock Component Rebuild
1. Use a small pick to remove the U-cup seal (C), internal (D) and external (E) O-rings from the bearing assembly. 5.54 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 245: Fox™ Shock Assembly
4. Lubricate the shock rod and the Shock Seal Protector Sleeve with new shock oil. 5.55 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 246 21. Pass a small heating torch over the shock body to remove any air bubbles from the oil. 10. Lubricate and install the rebound valve stack. 5.56 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 247 30. Install the bearing assembly retaining ring and clean excess shock oil. Properly dispose of shop towel. 5.57 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 249: Walker Evans™ Shock Exploded Views (Rzr Xp 4)
Spring Adjustment Nut Washer (1.50" x 0.125" x 0.348") Shaft, Chrome Crimp Nut (7/16") 2-Piece Piston Asm. Snap Ring 5.59 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 250: Walker Evans™ 2.5" Rear Shock
Snap Ring Retention Nut O-Ring Adjuster Knob Piston Wear Band (2.125" OD) Shaft, Chrome Seal Head Asm. Shock Body 5.60 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 251: Walker Evans™ Shock Service (Rzr Xp 4)
Extended Length 22.87” IFP Location 3.375” (85.7 mm) Nitrogen Pressure 200 psi +/- 5% Gas Shock Oil 2874124 (qt.) 5.61 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 252: Rear Shock Service Information
0.800 x 0.015 Gas Shock Oil 2874124 (qt.) 0.700 x 0.015 1.500 x .100 Top-Out Piston Bleed Orifice: 0.073 5.62 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 253: Walker Evans™ Shock Rebuild Information
The face of the piston with the greater number of relief ports will always face the rebound valve stack. = Relief Port Faces Rebound Stack Faces Compression Stack 5.63 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 254: Walker Evans™ Shock Disassembly
Rear Shock Body Holding Tool: PU-50938 4. Remove the valve cap from the valve fitting on the top of the reservoir. 5.64 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 255 14. Using an 11/16" socket, remove the nut retaining the 10. Remove and properly dispose of the oil from the shock valve stack and piston. body. 5.65 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 257: Walker Evans™ Shock Assembly
IMPORTANT: If unsure of the valve stack order, refer to “Shock Valving” under the “Shock Service Information” provided earlier in this section. 5.67 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 258 • Be sure to bottom out piston in the reservoir body. • Allow time for the bubbles to dissipate. • Repeat the process until all air has been removed. 5.68 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 259 NOTE: Apply grease to the end of the Allen wrench so the bleed screw sticks to it during installation. 5.69 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 260 34. Continue filling until the shaft has fully extended and the reservoir pressure is at 200 psi. Nitrogen Pressure (Front and Rear): 200 psi (1379 kPa) +/- 5% 5.70 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 262: Special Tools And Supplies
PVT Outer Cover Screws 45-50 in-lbs (5-5.6 Nm) clutch upshift and backshift. During the development of the Polaris vehicle, the PVT system is matched first to the Spider Jam Nut 250 ft-lbs (339 Nm) engine power curve; then to average riding conditions and (Apply 263 Loctite) the vehicle’s intended usage.
Page 263: Drive Clutch Operation
PVT system and also to prevent water and other contaminants from entering the PVT area. This is especially critical on units subjected to frequent water forging. 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 264: Overheating / Diagnosis
PVT system. position for more than 10 seconds. Clutch seals should be inspected for damage if repeated leaking occurs. Clutch component inspection should be performed by a Polaris MSD certified Clutch malfunction. technician. Fouled spark plugs, foreign material in fuel tank, restricted fuel lines, or faulty Poor engine performance.
Page 265: Pvt System Service
5. Remove the lower mounting bolt and nut from the left rear shock. Discard the nut. 6. Swing shock outward toward the front of the vehicle. 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 267: Pvt Assembly
15. Remove the (7) bolts that retain inner clutch cover to engine and transmission. Remove inner clutch cover. Hose / Battery Cables / Throttle Cable 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 268 Lower: 70 ft-lbs (95 Nm) Wheel Nuts: 30 ft-lbs (41 Nm) + 90° (1/4 turn) 19. Install engine service panel and both seats. 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 269: Drive Belt
PVT operation. See the Troubleshooting Chart at the end of this chapter for possible causes. 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 270: Belt Installation
“Engine Break-In Period” for break-in example). Pull only light loads. Avoid aggressive acceleration and high speed operation during the break-in period. 6.10 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 271: Drive Clutch Service
Jam Nut 20 in-lbs Bolt (2.3 Nm) Apply 263 Loctite 250 ft-lbs (339 Nm) Moveable Sheave Washers Stationary Sheave 6.11 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 272: Drive Clutch Disassembly / Inspection
DO NOT reassemble the drive clutch without the remove cover plate. limiter spacer. Belt life will be greatly reduced. 6.12 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 273: Drive Clutch Spring Inspection
RZR XP 4: Drive Clutch Spring Specifications Part Number 7043805 Color Purple Free Length 2.865” (72.771 mm) Check Bolt For Wear 6.13 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 274: Button To Tower Clearance Inspection
Clutch Spider Removal / Installation Tool (PN 2870341). 2870341 2871358-A Spider Removal / Installation Tool: PN 2870341 Clutch Holding Fixture: PN 2871358-A 6.14 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 276: Moveable Sheave Bushing Inspection
Replace if worn or damaged. = In. / mm. Thrust Washer Thickness: Standard: .030” (.76 mm) Service Limit: .025” (.64 mm) 6.16 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 277: Bushing Service
7. Install removal tool (Item A, B) into center of sheave bushing bore prior to installing new bushing. with “A side” toward sheave. 6.17 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 278 6. Remove nut from puller rod. Take installation tool and clutch cover off rod. 9. Remove sheave from puller. 10. Remove installation tool. 6.18 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 279: Drive Clutch Assembly
7. Apply Loctite® 263™ to the threads of the spider jam Stationary Sheave nut. Install spider jam nut onto stationary shaft threads. 6.19 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 280 12. Install cover bolts and torque in a cross pattern evenly to specification. Drive Clutch Cover Bolts: 100 in-lbs (12 Nm) 6.20 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 281: Driven Clutch Service
3. Remove the four screws that secure the cam (helix) assembly using a T25 Torx driver. 6.21 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 282 (H). Inspect the rollers for wear; replace if worn. 9. Remove the clutch assembly from the holding tool. 6.22 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 283: Bushing Service
Clean all residual Loctite™ from Inspect Sheave Surface bushing bore prior to installing new bushing. 6.23 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 284 9. Remove installation tool and clutch sheave from puller. 9. Remove adapters from puller. 10. Remove bushing and removal tool from adapters. Discard bushing. 6.24 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 285: Clutch Assembly
4. Install the roller (A) onto the roller pin (B) on both sides. NOTE: Press only on the outer race of the bearing during installation to prevent damaging the bearing. 6.25 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 286 8. Install the clutch rollers (D) onto each side of the outside spider. Install the washers (E) and E-clips (F) to secure the rollers. The rollers should spin freely. 6.26 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 287 Once the spider passes the retaining ring notch on the shaft, install the retaining ring. Helix Retaining Screws: 42-52 in-lbs (4.75 - 5.88 Nm) 6.27 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 288: Exploded View
Ring Moveable Sheave Outer Roller Spider Spider Insert Clutch Shaft Slotted Spring Pin Retaining Ring Stationary Ball Sheave Bearing 6.28 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 289: Troubleshooting
-Dragging brake -Inspect brake system. spots  -Slow, easy clutch engagement -Fast, effective use of throttle for efficient engagement. 6.29 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 290 -Replace belt. Refer to belt burnt troubleshooting Engagement and instruct operator. erratic or stabby -Drive clutch bushings stick -Inspect and repair clutches. 6.30 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 292: Special Tools
45 ft-lbs (61 Nm) Bearing Carrier Bolts Rear Brake Caliper 40 ft-lbs. (54 Nm) Mounting Bolts Cone Castle Nut Washers Cotter Pin 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 293: Bearing Replacement
12. Replace bearing if moisture, dirt, corrosion, or roughness is evident. 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 294: Bearing Carrier Installation
Wheel 6. Install new brake caliper mounting bolts and torque to specification. Front Caliper Mounting Bolts: 40 ft-lbs (54 Nm) 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 295 30 ft-lbs (41 Nm) + 90° (1/4 turn) 11. Rotate wheel and check for smooth operation. Tie Rod End Fastener: 42.5 ft-lbs (58 Nm) 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 296: Front Drive Shaft
CAUTION: Do not hang the caliper by the brake line. Use wire to hang caliper to prevent damage to the brake line. 5. Remove the front wheel hub assembly. 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 297: Drive Shaft Installation
3. Install drive shaft into the front bearing carrier. 4. Install the upper and lower ball joint ends into the front bearing carrier. 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 298 Wheel Nuts: 30 ft-lbs (41 Nm) + 90° (1/4 turn) 11. Rotate wheel and check for smooth operation. 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 299: Propshaft Service
4. Remove the (4) bolts retaining the front gearcase. 5. Carefully move the gearcase forward to remove the front propshaft from the gearcase input shaft. 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 300: Front Propshaft Removal (Rzr Xp 4)
4. Remove the (4) bolts retaining the front gearcase. 5. Carefully move the gearcase forward to remove the front propshaft from the gearcase input shaft. 7.10 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 301: Front Propshaft Installation
5. Carefully move the gearcase forward to slide the front propshaft off the rear propshaft. Front Gearcase Mounting Bolts: 30 ft-lbs (41 Nm) 7.11 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 302 9. Pull the rear propshaft towards the front of the vehicle as an assembly. and position it as shown. 12. Proceed to “Rear Propshaft Installation”. 7.12 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 303: Rear Propshaft Removal (Rzr Xp 4)
10. Pull the rear propshaft towards the front of the vehicle. 7.13 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 304: Rear Propshaft Installation
Torque bolts to specification. Front Gearcase Mounting Bolts: 30 ft-lbs (41 Nm) 7.14 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 305: Support Bearing Replacement
IMPORTANT: Do not attempt to separate the bearing from the rubber isolated support assembly upon installation. 7.15 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 306: Propshaft U-Joint Service
2. Tighten vise to force bearing caps in. 3. Support U-joint in vise as shown and drive inner yoke down to remove remaining bearing caps. 7.16 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 307 If the joint is stiff or binding, tap the yoke lightly to center the joint until it pivots freely. 7.17 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 308: Front Gearcase / Centralized Hilliard
Cover Screws, M6 (T30 Torx) Armature Plate Cover Plate Assembly AWD Coil Gearcase Housing Fill Plug Clutch Housing (Ring Gear) Drain Plug, Magnetic 7.18 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 309: All Wheel Drive Operation
If AWD is engaged while the wheels are & Rollers spinning, severe drive shaft and front Armature gearcase damage could result. Plate Torsion Ring Spring Gear 7.19 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 311 2. Remove the (7) cover screws and remove the cover plate assembly. Vent Line Retaining Dart 7. Remove the (4) bolts securing the front gearcase to the frame. 7.21 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 312 4. Remove and inspect the armature plate. Refer to Remove as “AWD Diagnosis” for detailed inspection process. an assembly Armature Plate 7.22 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 313 13. Inspect clutch housing / ring gear (C) for a consistent wear pattern. Inspect the ring gear for chipped, broken, or missing teeth. Inspect 7.23 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 314: Front Gearcase Assembly
RH Output Hub Surface Spacer 16. Clean and inspect all remaining front gearcase components. Check each for excessive wear or damage. 7.24 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 315 10. Carefully install the ring gear and roll cage assembly into the gearcase housing. Align during installation 7.25 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 316: Front Gearcase Installation
5. Install the vent line. Install Vent Line Cover Plate Screws: 7-11 ft-lbs (10-15 Nm) 30 ft-lbs (41 Nm) 7.26 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 317: Rear Bearing Carrier
5. Remove the lower radius rod outer mounting bolt, nut and washer from the bearing carrier. Swing radius rod down. Discard the nut. RZR XP Shown 7.27 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 318 Discard the nuts. 9. Remove the bearing carrier from the rear drive shaft and trailing arm. 7.28 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 319: Bearing Replacement
4. Inspect the bearing carrier housing for scratches, wear or damage. Replace rear bearing carrier if damaged. 7.29 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 320: Bearing Carrier Installation
40 ft-lbs (54 Nm) Radius Rod to Bearing Carrier Bolts: 45 ft-lbs (61 Nm) 3. Apply anti-seize to drive shaft splines. 7.30 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 321: Rear Drive Shaft
CAUTION: Do not hang the caliper by the brake line. Use wire to hang caliper to prevent damage to the brake line. Remove RZR XP Shown 7.31 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 322: Drive Shaft Installation
3. Swing the rear trailing arm assembly outward and upward until the rear axle can be inserted into the bearing carrier. Support the trailing arm from underneath. 7.32 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 323 Wheel Nuts: 30 ft-lbs (41 Nm) + 90° (1/4 turn) Rear Wheel Hub Castle Nut: 80 ft-lbs (108 Nm) 7.33 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 324: Drive Shaft Cv Joint / Boot Replacement
5. Make sure circlip is on the shaft and not left in the joint. Circlip Actual boot clamp may differ from what is shown 7.34 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 326: Inner Plunging Joint / Boot Replacement
Brass Drift Shown Axle Boot Clamp Tool: PU-48951 CV Boot Clamp Pliers: 8700226 7.36 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 328: Drive Shaft Exploded View
Drive shaft design may differ from what is shown Axle Boot Clamp Tool: PU-48951 CV Boot Clamp Pliers: 8700226 7.38 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 329: Wheel Hubs
Wheel Cap Bolts Wheel Nuts Brake Disc 30 ft-lbs (41 Nm) + 90° (1/4 turn) Cone Washers Cotter Pin 7.39 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 334: Shift Cable
Shift Cable shift cable is properly adjusted. If transmission still ratchets after cable adjustment, the transmission will require service. Dust Boot 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 335: Transmission Removal
10. Remove the outer clutch cover, drive belt, drive clutch, driven clutch, inner clutch cover and clutch outlet duct (see Chapter 6). 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 336 Reinstall the lower shock bolts to hold the trailing arms up during the rest of the removal procedure. Reinstall Shock Bolts 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 337 21. Remove the (2) rear exhaust springs securing the muffler to the rear transmission mounting bracket. 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 338: Transmission Installation
7. Align front transmission mounting holes with transmission joint bracket mounting holes on engine. Rear Mount Bracket to Transmission Bolts: 15-20 ft-lbs (20-27 Nm) 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 339 17 ft-lbs (23 Nm) Step 3: 5 ft-lbs (7 Nm) Step 4-7: 44 ft-lbs (60 Nm) 11. Remove the clutch center distance tool. 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 340 16. Install and properly route the vent hose. 17. Lubricate the transmission splines and mid propshaft joint splines with Polaris All Purpose Grease. Install the propshaft onto the transmission output shaft (see Chapter 7). 23. Install the stabilizer bar link mounting bolts and new nuts.
Page 341 (see Chapter 5). 28. Connect the (-) negative battery cable. 29. Install the engine service panel, console cover and seats. 30. If transmission lubricant was drained, fill the transmission with the specified amount of Polaris Plus (see Chapter “Transmission Lubrication”).
Page 342: Transmission Service
6. Remove the compression spring (H). Do not pry on case sealing surfaces. Use only the designated pry points on the transmission. 8.12 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 343 18. Remove all seals from the gearcase halves and clean the cases in preparation for assembly. 8.13 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 344 Use caution when disassembling the shift rail. The compressed springs on the shift rail may pop off causing eye or face injury. 8.14 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 345 30. Remove the snap ring (A) and shim (B) retaining the bearing in the snorkel tube. PA-50231 8.15 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 346: Gear / Shaft / Bearing Inspection
Inspect all bearings for signs of wear or damage. If replacement is required, use a standard bearing puller or an arbor press. 8.16 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 347: Snorkel Gear Backlash Procedure
Seize on the threads of the snorkel tube. cover must be installed on the shaft before installing the 46T gear. Grease Threads 8.17 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 349: Transmission Assembly
2. Assemble the reverse shaft assembly and input shaft assembly previously disassembled (see illustrations). Snorkel Locking Screw: 8-10 ft-lbs (11-14 Nm) 8.19 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 350 NOTE: Both shift forks need to be orientated the same way, so that the shift fork pins are both offset to the same side of the rail. 8.20 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 352 Install and torque the bolts to specification. Sector Cover Bolts: 9-12 ft-lbs (12-16 Nm) 8.22 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 353: Transmission Service (Int'l)
Female Side Gear Assembly Planet Gear Bearing Assembly Male Side Gear Engagement Dog Assembly Ring Gear Assembly Planetary Differential Assembly 8.23 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 354: Transmission Disassembly
6. Remove the compression spring (H). CAUTION Do not pry on case sealing surfaces. Use only the designated pry points on the transmission. 8.24 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 356 Use caution when disassembling the shift rail. The compressed springs on the shift rail may pop off causing eye or face injury. 8.26 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 357 33. Remove the snap ring (A) and shim (B) retaining the bearing in the snorkel tube. PA-50231 8.27 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 358: Planetary Differential Disassembly
3. Remove the (6) planet gears and each side gear assembly from the ring gear. Planet Gears Side Gears 8.28 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 359: Planetary Differential Bushing Replacement
3. Press the new bushing into the planet gear until it is flush on each end. Repeat this procedure for the remaining planet gears. Bushing 8.29 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 360 3. Press the new bushing into the side gear until it bottoms out. 4. Install the bushing to the specified depth as shown. 8.30 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 361: Planetary Differential Assembly
Inspect all bearings for signs of wear or damage. If replacement is required, use a standard bearing puller or an arbor press. 8.31 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 362: Snorkel Gear Backlash Procedure
Seize on the threads of the snorkel tube. cover must be installed on the shaft before installing the 46T gear. Grease Threads 8.32 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 364: Transmission Assembly
8-10 ft-lbs (11-14 Nm) Shift Fork Screws: 7-10 ft-lbs (10-14 Nm) 4. Slide engagement dog (U) onto retaining pins of shift fork. 8.34 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 365 NOTE: Both shift forks need to be orientated the same way, so that the shift fork pins are both offset to the same side of the rail. 8.35 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 367 18. Install the spacer onto the shift drum shaft. Spacer Park Brake Disc Mounting Bolt: 18-22 ft-lbs (24-30 Nm) 8.37 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 368 Install and torque the bolts to specification. Sector Cover Bolts: 9-12 ft-lbs (12-16 Nm) 8.38 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 369: Troubleshooting
(rounding) or damage. Inspect all bearings, circlips, thrust washers and shafts for wear. 8.39 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 371 Cover, Sector Gears Bearing, Ball Case, RH Spring, Wave Case, LH Bracket, Wire Harness Drum, Shift Collar Sleeve, Input Shaft 8.41 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 373 Ring Gear, 53T Gear, Sector 16T 108. Bearing, Plain Gear, Sector 31T 109. Collar Sleeve, Input Shaft Pawl, Detent 8.43 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 376 Park Brake Assembly Bolts Park Brake Disc Mounting Bolt 18-22 24-30 Park Brake Lever Mount Bolts Park Brake Mount Bracket to Transmission Bolts 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 377: Brake System Service Notes
If noise does not change when brake is applied check Noise is from other source (axle, hub, disc or wheel) other sources. Inspect and repair as necessary 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 378: Hydraulic Brake System Operation
BRAKES HYDRAULIC BRAKE SYSTEM OPERATION The Polaris brake system consists of the following components or assemblies: brake pedal, master cylinder, hydraulic brake lines, brake calipers, brake pads, and brake discs, which are secured to the drive line. When the foot activated brake lever is applied it applies pressure on the piston within the master cylinder. As the master cylinder piston moves inward it closes a small opening (compensating port) within the cylinder and starts to build pressure within the brake system.
Page 379: Brake System Exploded View
15 ft-lbs (20 Nm). All Caliper Bleed Screws: 47 in-lbs (5.3 Nm) All Flare Style Fittings: 12-15 ft-lbs (16-20 Nm) 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 380: Rzr Xp 4
15 ft-lbs (20 Nm). All Caliper Bleed Screws: Seals 47 in-lbs (5.3 Nm) All Flare Style Fittings: Front Caliper 12-15 ft-lbs (16-20 Nm) 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 381: Master Cylinder
Brake fluid will damage finished surfaces. Brake Pedal Freeplay: Do not allow brake fluid to come in contact .090” (2.28 mm) with finished surfaces. 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 382: Brake Bleeding / Fluid Change
Be sure the hose fits tightly on fitting. 11. Install master cylinder reservoir cover. 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 383 With pedal firmly applied, pedal reserve should be no less than 1/2"(1.3 cm). 13. Check brake system for fluid leaks. 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 384: Parking Brake (Int'l Model)
16 ft-lbs 37 ft-lbs (22 Nm) (50 Nm) Clevis Clip 14 ft-lbs (19 Nm) Bolts Clevis Tie Strap Cable 9.10 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 385 Reconnect the connector as soon as practicable and parking brake switch. adjust the parking brake cable to proper tension. 9.11 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 386: Parking Brake Caliper Service (Int'l Model)
NOTE: Be sure the parking brake is not engaged. Bracket 3. Lift the parking brake caliper off the brake disc and remove it from the vehicle. 9.12 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 387: Caliper Disassembly / Inspection
Inboard Pad Thickness New 0.250” (6.35 mm) New 0.300” (7.62 mm) Limit: 0.190” (4.83 mm) Limit: 0.240” (6.10 mm) 9.13 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 388: Caliper Installation
Torque the mounting bolt to specification. Disc Bolt Washer Parking Brake Disc Mounting Bolt: 18-22 ft-lbs (24-30 Nm) 9.14 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 389: Front Brake Pads
Service Limit: .180" (4.6 mm) reservoir when piston is pushed back into caliper. Remove excess fluid from reservoir as required. 9.15 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 390: Pad Assembly / Installation
Repeat this procedure 10 times. Do not make more Front Caliper Mount Bolt: than 3 stops per 1 mile (1.6 km). 40 ft-lbs (54 Nm) 9.16 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 391: Front Caliper Service
Use care when supporting vehicle so that it does not tip or fall. Severe injury may occur. 3. Clean caliper area before removal. Remove Brake Line 9.17 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 392: Caliper Disassembly
1. Remove both brake pads from the caliper (see “FRONT BRAKE PADS - Pad Removal”). 2. Remove mount bracket assembly and dust boots. 9.18 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 393 Grooves O-Rings = In. / mm. Front Caliper Piston Bore I.D.: 2. Coat pistons with clean Polaris DOT 4 Brake Fluid. Std: 1.373” (34.87 mm) Install pistons with a twisting motion while pushing Service Limit: 1.375” (34.93 mm) inward. Piston should slide in and out of bore smoothly, with light resistance.
Page 394: Caliper Installation
40 ft-lbs (54 Nm) NOTE: If new pads are installed, refer to “FRONT BRAKE PADS - Brake Burnishing Procedure”. 9.20 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 395: Front Brake Disc
Replace disc if worn beyond service limit. Measure Thickness Front Disc 9.21 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 396 Make sure the brake is not dragging when pedal is released. If the brake drags, re-check assembly and installation. 9.22 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 398 40 ft-lbs (54 Nm) Rear Brake Pad Thickness: .298” ± .007” (7.57 mm ± .178 mm) Service Limit: .180” (4.6 mm) 9.24 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 399: Brake Burnishing Procedure
8. Install wheel and torque wheel nuts to specification. Wheel Nuts: 30 ft-lbs (41 Nm) + 90° (1/4 turn) 9.25 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 401 40 ft-lbs (54 Nm) Front Brake Pad Thickness New: .298 ± .007” (7.56 ± .178 mm) Service Limit: .180” (4.6 mm) 9.27 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 402: Brake Burnishing Procedure
7. Verify fluid level in reservoir is up to the MAX line inside reservoir and install reservoir cap. Master Cylinder Fluid Up to MAX line inside reservoir 9.28 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 403: Rear Caliper Service (Rzr Xp)
Severe injury may occur. 2. Remove the (4) wheel nuts and rear wheel. Clean caliper area before removal. 9.29 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 404: Caliper Disassembly
5. Clean the caliper body, piston, and retaining bracket with brake cleaner or alcohol. NOTE: Be sure to clean caliper body seal grooves. Clean Components 9.30 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 405 Replace if damage is evident or if worn beyond may drag upon assembly. service limit. 2. Coat piston with clean Polaris DOT 4 Brake Fluid (PN 2872189). Install piston (D) with a twisting motion = In. / mm. while pushing inward. Piston should slide in and out of bore smoothly with light resistance.
Page 406: Caliper Installation
30 ft-lbs (41 Nm) + 90° (1/4 turn) NOTE: If new pads are installed, refer to “REAR BRAKE PADS - Brake Burnishing Procedure”. 9.32 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 407: Rear Caliper Service (Rzr Xp 4)
Severe injury may occur. 2. Remove (4) wheel nuts and rear wheel. 3. Clean caliper area before removal. Remove Brake Line 9.33 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 408: Caliper Disassembly
IMPORTANT: Do not remove the caliper pistons with a standard pliers. The piston sealing surfaces will become damaged if a standard pliers is used. 9.34 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 409: Caliper Inspection
Std: 1.186” (30.12 mm) Service Limit: 1.184” (30.07 mm) 3. Inspect the brake disc and pads as outlined in this chapter. 9.35 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 410 (54 Nm) Seal Grooves O-Rings 2. Coat pistons with clean Polaris DOT 4 Brake Fluid. Install pistons with a twisting motion while pushing Rear Caliper Mount Bolt: inward. Piston should slide in and out of bore 40 ft-lbs (54 Nm) smoothly, with light resistance.
Page 411 30 ft-lbs (41 Nm) + 90° (1/4 turn) NOTE: If new pads are installed, refer to “REAR BRAKE PADS - Brake Burnishing Procedure”. 9.37 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 413: Troubleshooting
Brakes Lock • Alignment of caliper to disc • Caliper pistons sticking • Improper assembly of brake system components 9.39 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 417: General Information
• For resistance readings, isolate the component to be tested. Disconnect it from the wiring harness or power supply. 10.3 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 418: Instrument Cluster
Do not use alcohol to clean the instrument cluster. Do not allow insect sprays to contact the lens. Immediately clean off any gasoline that splashes on the instrument cluster. 10.4 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 419: Rider Information Display
The odometer can not be reset. switch is in the TURF position (INT’L Model Only). 10.5 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 420 Engine temperature can be displayed in ° F or ° C. Refer to “Units of Measurement” to change the format. 10.6 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 421 4. Press and hold the MODE button to save the setting and advance to the next display option. 5. Repeat the procedure to change remaining display settings. 10.7 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 422: Diagnostic Mode
MODE button to toggle until “CK ENG” displays on the information display area. 2. Press and hold the MODE button to enter the diagnostics code menu. 10.8 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 423 NOTE: If there is a diagnostic problem with the power steering system, the power steering MIL will illuminate and blink in place of the check engine MIL. 10.9 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 424 Only remove the rubber mount if necessary. The bezel is a snap-on assembly and is a serviceable part. 10.10 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 425: Switches / Controls
4. For switch replacement, refer to Chapter 9 “Brakes”. NOTE: Pins 7 and 8 provide power and ground to light the switch lamp. 10.11 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 426: Ignition Key Switch
• Turn the ignition key to START. There should be continuity between pins A and B; C and D; E and 10.12 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 427: Awd / 2Wd Switch
• Move the switch to TURF. There should be continuity between switch pins 1 and 2; 4 and 5. 10.13 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 429: Parking Brake Switch (Int'l Model)
1500 RPM until the parking brake is released. This feature has been added to prevent drive-away with the parking brake applied. 10.15 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 430: Throttle Release Switch (Trs)
11.7k Ohms +/-5% Replace sensor if Replace sensor if reading is more than: reading is less than: 2.26k Ohms 11.1k Ohms 10.16 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 432: Rear Diff Solenoid (Int'l)
Do not power the solenoid with 12 Volts for more than 1 second, or damage may occur to solenoid. 10.18 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 433: Vehicle Speed Sensor
80% of all electrical issues are caused by bad/failed connections and grounds. 10.19 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 434: Head Lights
NOTE: The front bumper can be removed and placed face down on a suitable workbench to ease headlamp replacement (see Chapter 5). 10.20 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 435: Headlamp Installation
6. Connect headlamp electrical connector to the headlamp assembly. 7. Perform the “Headlight Adjustment” procedure as shown in this chapter. 10.21 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 437: Coolant Temperature Sensor
Replace the fuel pump assembly malfunctions the radiator fan will default to 'ON' (see Chapter 4). while the engine is running. 10.23 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 438: Fuse Box: Fuses / Relays / Circuit Breaker
20-amp circuit breaker protects the fan motor circuit. Two separate relays located under the dash operate the headlights and the “flash to pass” function on INT’L models. 10.24 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 439: Fuse Box Detail
IMPORTANT: All relays (PN 4011283) located in fuse box are the same and can be swapped out to help diagnose electrical problems. 10.25 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 440: Relay Operation
20-Amp fuse protected 12 Vdc Red / White constant battery voltage. Provides 12 Vdc power for EFI Red / Dark Blue system circuits. 10.26 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 441 Key switch input to enable relay. Brown Relay coil ground. Relay switched power to operate Yellow / Dark Green the Headlights. 10.27 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 442: Charging System
7. Repeat test, observing ammeter and tachometer. With lights on, charging should occur at or below 2000 RPM. 10.28 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 443: Charging System Stator (Alternator) Tests
Battery Charge Coil to Ground (Infinity) NOTE: Any measurement other than Infinity (open) will indicate a failed or shorted stator leg. 10.29 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 446: Battery Service
Refer to OCV table (see “OCV - Open Circuit Voltage Test”). 3. Charge the battery as recommended (see “Charging Procedure”). 10.32 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 447: Battery Testing
NOTE: Battery charge can be maintained by using a conducted whenever poor battery performance is Polaris battery tender charger or by charging once a encountered. month to make up for normal self-discharge. Battery...
Page 448: Battery Conductance Analyzer
NOTE: Charge the battery using an automatic charger that will not exceed 14.6 Vdc. An automatic Authorized Polaris dealers/distributors are required to use charger will signal when charging is complete. the conductance analyzer when testing 12V Polaris batteries.
Page 449: Starting System
/ stud. Torque nut to specification. Voltage should not exceed .1 DC volts per connection Starter Mounting Bolts and Nut: 7 ft-lbs (10 Nm) 10.35 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 450 12V power to reach the starter motor. NOTE: See “ELECTRICAL SYSTEM BREAOUTS: Starter-Interlock” provided in this chapter for starter solenoid operation. 10.36 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 451: Starting System Testing Flow Chart
If all of these indicate a good condition, yet the starter still fails to turn, the starter must be removed for static testing and inspection. 10.37 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 452: Electronic Power Steering (Eps)
The system is READ BEFORE YOU REPLACE THE EPS UNIT! Polaris Digital Wrench® compatible for simplified IMPORTANT: Verify the EPS unit has the latest diagnostics and system troubleshooting through the software version and calibration loaded before vehicle’s diagnostic port.
Page 454: Eps Troubleshooting (Eps Non-Functional With Mil On)
ELECTRICAL EPS Troubleshooting (Power Steering Non-Functional with MIL ON) 10.40 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 455: Eps Troubleshooting (Eps Non-Functional With Mil Off)
ELECTRICAL EPS Troubleshooting (Power Steering Non-Functional with MIL OFF) 10.41 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 456: Eps Troubleshooting (Using Digital Wrench®)
* These Error Codes must have multiple occurrences or you must be able to duplicate the condition before replacing the EPS unit. 10.42 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 457: Electrical System Breakouts
ELECTRICAL ELECTRICAL SYSTEM BREAKOUTS Vehicle Speed Sensor 10.43 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 463 2013 RANGER RZR XP...
Page 464 2013 RANGER RZR XP...
Page 465 2013 RANGER RZR XP (EPS)
Page 466 2013 RANGER RZR XP (EPS)
Page 467 2013 RANGER RZR XP INT’L...
Page 468 2013 RANGER RZR XP INT’L...
Page 469 2013 RANGER RZR XP 4...
Page 470 2013 RANGER RZR XP 4...
Page 471 2013 RANGER RZR XP 4 (EPS)
Page 472 2013 RANGER RZR XP 4 (EPS)
Page 473 2013 RANGER RZR XP 4 INT’L...
Page 474 2013 RANGER RZR XP 4 INT’L...
Page 475 2013 RANGER RZR XP / RZR XP 4 (CARGO BOX)
Page 476 2013 RANGER RZR XP INT’L / RZR XP 4 INT’L (CARGO BOX)

Polaris xp 2013 eps Service Manual

General Information Chapter

Chapter 2 Maintenance 2

Chapter 3 Engine / Cooling

Chapter 4 Electronic Fuel Injection

Chapter 5 Body / Steering / Suspension

Clutching (Pvt) Chapter 6 Clutching (Pvt)