Page 1: Table Of Contents
DETAILED: 2013 RANGER RZR S / INT’L........
Page 2: Vehicle Identification
World Mfg. ID Individual Serial No. * Model Year: A = 2010; B = 2011; C = 2012; D = 2013 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 3: Vehicle And Engine Serial Number Locations
Vehicle and Engine Serial Number Locations Whenever corresponding about a Polaris ORV, refer to the vehicle identification number (VIN) and engine serial number. The VIN can be found stamped on the rear upper frame rail, behind the left rear fender, near the air box (see Figure 1-1).
Page 4: Vehicle Information
9924099 9924106 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
Capacity (Payload) and trailer tongue weight) Hitch Towing Capacity 1500 lbs. / 680 kg Hitch Tongue Capacity 150 lbs. / 68 kg 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 7 EFI: 20 Amp 1500-3700 23-62 Green Fuses (Power Fuse Holder) (5000 - 12000) (5632337) (7043789) (3234452) Chassis / EPS: 30 Amp 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 8 Capacity (Payload) and trailer tongue weight) Hitch Towing Capacity 1500 lbs. / 680 kg Hitch Tongue Capacity 150 lbs. / 68 kg MODEL: 2013 RANGER RZR S INT’L MODEL NUMBER: R13VE76FI, FX ENGINE NUMBER: 1204670 Category Dimension / Capacity Length 104 in.
Page 9 GENERAL INFORMATION MODEL: 2013 RANGER RZR S / INT’L Drivetrain Transmission Type Polaris Automatic PVT MODEL NUMBER: R13VE76AD, AI, AS, AW Drive Ratio - Front 3.82:1 MODEL NUMBER: R13VE76FI, FX Drive Ratio - Final 3.70:1 ENGINE NUMBER: 1204670 Shift Type...
Page 11 Fuses (Fuse/Relay Box) Lights / EFI / Accessory: 20 Amp EFI: 20 Amp Fuses (Power Fuse Holder) Chassis / EPS: 30 Amp 1.11 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 13: Standard Bolt Torque Specification
59 (80) 85 (115) 159 (215) 232 (315) 273 (370) 81 (110) 118 (160) 225 (305) 321 (435) 376 (510) 1.13 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 14: Sae Tap / Drill Sizes
GENERAL INFORMATION SAE Tap / Drill Sizes Decimal Equivalents Metric Tap / Drill Sizes 1.14 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 17: 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 18: 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. 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 19: 100 - 300 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. 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual...
Page 20: Maintenance Quick Reference
* More often under severe use, such as operated in water or under severe loads. 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 21: Maintenance Quick Reference, Continued
Lube Rec. Method Frequency* Add lubricant until it is visible Initial level check at 25 hours; Front Gearcase Polaris Demand Drive Plus at the fill hole threads change according to intervals Polaris ATV Angle Drive Add lubricant until it is visible Initial level check at 25 hours;...
Page 22: Grease Lubrication Points
A-arm Pivot Bushings Polaris Premium U-Joint Grease miles (800 km). thoroughly washing or Stabilizer Bar Bushings submerging the vehicle. 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 23: 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) 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 24: General Vehicle Inspection And Maintenance
• Excessive gear lash (noise) require service. • Gear selector moving out of desired range 2.10 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 25: Fuel System And Air Intake
2. Be sure vent lines are routed properly and secured with cable ties. IMPORTANT: Ensure lines are not kinked or pinched. 2.11 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 26: Throttle Pedal Inspection
Check throttle pedal freeplay periodically in accordance with the Periodic Maintenance Chart. Adjust the freeplay if necessary (see “Throttle Freeplay Adjustment”). 2.12 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 27: Air Filter Service
Do not attempt to clean the air filter, the filter should of freeplay is achieved at the throttle pedal. be replaced. 2.13 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 28 Intake Seal Seal Breather Filter Fitting Breather Hose Boot Clip (3) Filter Ring Air Box Can Clamps Seal Air Filter 2.14 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 29: Engine
8. Reinstall the dipstick and lock the lever. 5. Lift the lever lock, remove dipstick and wipe dry with a clean cloth. 2.15 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 30: Engine Oil And Filter Service
5. Place a drain pan beneath engine crankcase and remove the drain plug. 2.16 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 31: Engine Breather Hose Inspection
Periodically inspect engine and transmission mounts for cracks or damage. Refer to Chapter 3 “Engine Assembly and Installation” for mounting fastener torque values. 2.17 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 32: Exhaust - Spark Arrestor
4. Reinstall the arrestor and torque the screw to specification. Screen Arrestor Silencer Retaining Screw Spark Arrestor Screw: 40 in-lbs (4.5 Nm) 2.18 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 33: Transmission And Gearcases
4. Add the recommended fluid through the fill plug hole until it begins to flow out the level check plug hole. 2.19 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 34 2. Place a drain pan under the main gearcase drain plug. 3. Remove the drain plug and allow to drain completely. 2.20 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 35 6. Reinstall the fill / level plug and torque to specification. Fill / Level Plug: 40-50 ft-lbs (54-68 Nm) 7. Check for leaks. Dispose of used lubricant properly. 2.21 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 36: Front Gearcase Lubrication
Front Gearcase Specifications Fill Plug: 8-10 ft-lbs (11-14 Nm) Specified Lubricant: Polaris Demand Drive Plus (PN 2877922) Lubricant Change: Capacity: 6.75 oz. (200 ml) The drain plug is located on the bottom of the gearcase. Fill Plug: 8-10 ft-lbs (11-14 Nm)
Page 38 30-45 in-lbs (3-5 Nm) 6. Add the recommended lubricant. Maintain the fluid level even with the bottom threads of the fill plug hole. 2.24 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 39: Cooling System
Coolant Level Inspection funnel. The pressure cap and recovery bottle are located under 8. Fill recovery bottle to MAX level with Polaris 60/40 the front hood of the vehicle. The coolant level must be premix Anti Freeze/Coolant or 50/50 or 60/40 mixture...
Page 41: Radiator
Drain Here impair the radiators effectiveness. Use of a high- pressure washer is not recommended. 5. Allow coolant to completely drain. 2.27 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 42: Final Drive / Wheel And Tire
6. If hub removal is required, remove the hub nut and of nut goes into taper on wheel. washers. 2.28 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 43: Tire Inspection
If the boots exhibit any of these symptoms, they should be replaced. Refer to Chapter 7 for drive shaft boot replacement. Front Boots Rear Boots 2.29 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 44: Electrical And Ignition System
Charge battery according to “Charging Procedure” provided in Chapter 10. Do not use the vehicle’s stator/alternator to charge a new battery. 2.30 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 45: Battery Installation
Battery Charging (Maintenance Free) the electrodes. Inspect electrode for Refer to Chapter 10 “Electrical” for charging procedure. wear and buildup 2.31 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 46: Engine To Frame Ground
Champion RC7YC3 12. Install the plug caps to the appropriate cylinder by referencing the MAG and PTO spark plug cap decals. 2.32 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 47: Steering
WARNING Due to the critical nature of the procedures outlined in this chapter, Polaris recommends steering component repair and adjustment be performed by an authorized Polaris MSD certified technician. • Replace any worn steering components. Steering Use only genuine Polaris replacement parts.
Page 48: Wheel Toe Alignment Inspection
Wheel Toe-Out: specified in “Wheel Toe Alignment”. (A) - (B) = 1/8 to 1/4" (.3 to .6 cm) 2.34 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 49: Suspension (Standard)
4. Each notch of the adjustment will add 6% - 8% more preload to the spring over the primary position. 2.35 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 50: Suspension (Fox™)
3. Once you have obtained the correct preload, hold the lower adjustment ring while tightening the upper adjustment ring to lock them in place. Shock Spanner Wrench (PN 2870803) 2.36 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 51: Shock Compression Adjustment
Factory 10 clicks from closed Firmest 2 clicks from closed Increase Decrease Damping Damping Clicker Adjuster RZR 4 L.E. Shown 2.37 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 52: 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. 2.38 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 56: Stator Cover / Starter / Water Pump / Lubrication System
ENGINE / COOLING Stator Cover / Starter / Water Pump / Lubrication System Exploded View 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 58: Engine Efi Sensors / Valve Cover / General Components
Engine EFI Sensors / Valve Cover / General Components Exploded View NOTE: See chapter 4 for more information on the EFI System 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 59: Engine Torque Specifications
Water Pump Impeller Nut 8 mm 108 ± 3 (12 ± 0.35) NOTE: * See exploded views for notes or torque sequences. 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 60: 800 Efi Engine Service Specifications
1.735" (46.069 mm) Valve Spring  Intake - 1.4638" (37.18 mm) Valve Spring Overall Length - Installed Height Exhaust - 1.4736" (37.43 mm) 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 61 Side Clearance Connecting Rod Big End  0.0015" 0.0006" (0.038  0.015 mm) Radial Clearance Crankshaft Crankshaft Runout Limit 0.00236" (0.060 mm) 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 62: Special Tools
PA-45401 WATER PUMP SEAL SAVER 2870975 MITY VAC™PRESSURE TEST TOOL PU-45778 OIL SYSTEM PRIMING TOOL SPX Corporation: 1-800-328-6657 or http://polaris.spx.com/ 3.10 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 63: Engine Cooling System
Pressure Cap damage. Polaris Premium 60/40 Antifreeze/Coolant is recommended for use in all cooling systems and comes pre-mixed, ready to use. Cooling System Pressure Test 1.
Page 64: Cooling System Exploded View
To Top Fitting on Filler Neck Coolant Flow Diagram Filler Neck Engine Water Pump Radiator Recovery Bottle Engine Cylinder Head Bypass Engine Thermostat Housing 3.12 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 65: Radiator Removal
6. Remove the front bumper (see Chapter 5). Engine Inlet Hose 7. Remove the upper engine outlet hose and recovery hose from the top of the radiator. 3.13 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 66: Cooling System Bleeding Procedure
The coolant may be hot and could cause severe injury or burns. 3.14 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 67 NOTE: If there is air in the system you will see air bubbles forming through the radiator filler neck. 10. Add Polaris Premium Antifreeze to the radiator filler neck if the level goes down. If no bubbles are seen at the filler neck, the system should be purged of air.
Page 68: General Engine Service
• Crankshaft Main Bearings 3. Start engine and allow it to reach operating • Crankcase temperature, while monitoring the gauge. NOTE: Use only Polaris PS-4 PLUS or Extreme Duty Synthetic 4-Cycle Engine Oil. Oil Pressure at 6000 RPM (Engine Hot): Minimum: 27 PSI...
Page 69: Oil Flow Chart
MAG side crankshaft journal and also to the front balance shaft journal and onto the crankcase sump. 3.17 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 70: Engine Removal
8. Remove the (2) screws (A) from the rear of the center console (RZR / RZR S only). Because of its design configuration and fastener torque requirements, Polaris recommends removing the engine, transmission and rear gearcase as one assembly. Use the following procedure when engine removal is required.
Page 71 Outlet Duct PVT Cover Ignition 15. Remove the (8) screws that retain the PVT cover and Coil remove cover. PVT Duct 3.19 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 72 26. Mark the fuel injector harnesses to identify MAG and PTO harness connections to aid during reassembly. Disconnect the fuel injector harnesses. 3.20 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 73 (see Chapter 2 “Shift Cable Inspection / Adjustment”). 30. Disconnect the transmission gear indicator switch harness. Gear Switch Connector 3.21 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 74 36. Remove the through-bolt that attaches the upper A- arm to the rear hub on both sides of the vehicle. Speed Sensor Connector 3.22 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 75 43. Remove the (+) positive battery cable from the starter motor terminal and (-) negative battery cable from the starter motor engine mount. 3.23 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 76 NOTE: Have an assistant help guide the engine in and out of the vehicle while using an engine hoist to prevent personal injury or damage to vehicle components. 3.24 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 77: Engine / Transmission Separation
1. Remove the drive belt, drive clutch and driven clutch (see Chapter 6). 5. Carefully separate the engine and perform the required service (see “Engine Disassembly and Inspection”). 3.25 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 78: Engine Disassembly And Inspection
Retainer Locks (keepers) Push Rods Spring Retainers Springs Valve Seals (2) Valve Spring Seats (2) Coolant Bleeder Cylinder Head Hydraulic Lifters 3.26 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 79: Cylinder Head Removal
Push rods can also be checked with a dial indicator or rolled across a flat surface to check for straightness. 3.27 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 80: Cylinder Head Inspection / Warp
3. Remove spring retainer and spring. 4. The valve seals are now serviceable. 3.28 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 81: Cylinder Head Disassembly
Valve Spring Free Length = In. / mm. Valve Spring Free Length: Std: 1.735" (44.069 mm) 3.29 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 82: Valve Inspection
(0.087  0.025 mm) NOTE: The valve guides cannot be replaced. Be sure to measure each guide and valve combination individually. 3.30 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 83: Combustion Chamber / Valve Seat Reconditioning
1. Install pilot into valve guide. Valve Seat Reconditioning 2. Apply cutting oil to valve seat and cutter. NOTE: Polaris recommends that the work be done  by a local machine shop that specializes in this area. 3. Place 46 cutter on the pilot and make a light cut.
Page 84 Rinse and dry with compressed air. re-check contact point on the valve face and seat width after each cut. 3.32 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 85: Cylinder Head Reassembly
NOTE: To prevent damage to the valve seals, do not compress the valve spring more than necessary to install the keepers. 3.33 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 87: Piston Removal
*By hand: Placing both thumbs as shown, spread the ring open and push up on the opposite side. Do not scratch the ring lands. 3.35 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 88: Cylinder Inspection
Standard Bore Size Cylinder Warp: .004" (0.1 mm) Max. (Both Cylinders): 3.1496" (80 mm) 3. Inspect cylinder for wear, scratches, or damage. 3.36 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 89: Cylinder Hone Selection And Honing Procedure
Using a common spring loaded glaze breaker for honing is not advised for nicasil cylinders. Example of Cross Hatch Pattern Polaris recommends using a rigid hone or arbor honing machine. IMPORTANT: Clean the cylinder after honing Honing To Deglaze...
Page 90: Piston-To-Cylinder Clearance
See “800 EFI Engine Service Specifications” on page 3.8 Piston Pin Bore: See “800 EFI Engine Service Specifications” on page 3.8 3.38 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 91: Piston Ring Installed Gap
IMPORTANT: A difference in end gap indicates cylinder taper. The cylinder should be measured for excessive taper and out of round. 3.39 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 92: Flywheel / Stator Removal / Inspection
(A). CAUTION Do not thread the puller bolts into the flywheel more than 1/4" or stator coils may be damaged. 3.40 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 93 1/4" or stator coils may be damaged. 7. Note the position of the gears in the photo. Camshaft Gear 2871043 Crank Gear Counterbalance Gear 3.41 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 94 13. With a white marking pen, accent the timing mark on the gear that contains the springs. Accent Timing Marks 3.42 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 95 Push the gears back together, using both hands and hold securely. Align Timing Marks PU-45497-1 3.43 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 96 2871043 PU-45497-2 NOTE: For ease installing Gear Alignment Tool (PU-45497-2), use a twisting motion when pushing down on the tool. 3.44 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 97 Measure the gap between the two rotor 2871043 tips as shown below. The clearance should not exceed 0.006" (0.15 mm). Max Tip Clearance 0.006” (0.15 mm) 3.45 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 98 (dowel) in first. If the valve is installed incorrectly, oil pressure and oil priming problems will occur. Press Off Bearing 3.46 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 100: Camshaft Inspection
Exhaust (Std.): for abnormal wear. It is recommended to replace 1.342” (34.096 mm) the bearings anytime the engine is disassembled. 3.48 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 101: Engine Reassembly
NOTE: Replace the engine crankcase assembly if camshaft journal bores are damaged or worn excessively. 3.49 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 102 6. Apply Crankcase Sealant (PN 2871557) to the top half of the crankcase. NOTE: Do not apply sealant to cam relief hole (E). 3.50 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 103 12 O'clock position. 1. Top Ring 2. Second Ring 3. Oil Ring Piston Pin Cirlcip in 12 O’clock position 3.51 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 104 Loctite Primer N (commercially available) to remove any debris. This will ensure proper sealing when installing bolts and new Loctite™. 3.52 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 105 “This Side Out”. This indicates the side of the gear that faces outward or away from the case. 3.53 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 107 45543) and the Main Seal Installer (PA-45483) to seat the crankshaft seal into place. PU-45543 PU-45658 PA-45483 3.55 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 108 NOTE: Before assembly, clean the bolts and bolt holes with Loctite Primer N (commercially available) to remove any debris. This will ensure proper sealing when installing bolts. 3.56 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 109 NOTE: There are thrust washers on both sides of starter drive. Water Pump Impeller Nut: 108  6 in-lbs (6.8  0.68 Nm) 3.57 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 110: Flywheel / Stator Installation
1. Install the head gasket (A) on the cylinder (B). flywheel nut to specification. 65 ± 7 ft-lbs (88 ± 9.50 Nm) 3.58 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 112: Oil Pump Priming
Failure to perform this procedure may 84  8 in-lbs (9.5  0.9 Nm) cause internal engine damage on initial start-up. 3.60 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 113: Engine Installation
1. After the engine is completely assembled and ready for installation, the engine must be properly primed with engine oil. Fill the oil filter 3/4 full with Polaris PS- Engine Assembly and Installation 4 PLUS or PS-4 Extreme Duty Synthetic Engine Oil.
Page 114: Engine Break-In Period
CAUTION 17 ft-lbs (23 Nm) Use only Polaris PS-4 PLUS or Extreme Duty Synthetic 4-Cycle engine oil or an equivalent. 17 ft-lbs Never substitute or mix oil brands. (23 Nm) Serious engine damage and voiding of warranty can result.
Page 115: Troubleshooting
Engine Runs But Will Not Idle • Engine oil dirty or contaminated • Restricted fuel supply • Low compression • Crankcase breather restricted 3.63 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 116 Ignition timing incorrect • Faulty water pump mechanical seal (coolant leak) Sheared flywheel key • Faulty pump shaft oil seal (oil leak) 3.64 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 118: General Information
PU-47470 PC Interface Cable 328-6657. Digital Wrench™ PU-47469 Vehicle Interface Cable Digital Wrench™ PU-47468 SmartLink Module SPX Corp: 1-800-328-6657 or http://polaris.spx.com/ 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 119 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 120: Service Notes
• Always unplug ECU from the wire harness before performing any welding on the unit. 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 121: Efi System Exploded View
7. Fuel Rail 8. Engine Coolant Temperature Sensor (ECT) 9. Throttle Position Sensor (TPS) 10. Throttle Body 11. Ignition Coil 12. Spark Plugs 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 122: Efi System Component Locations
- Located under the passenger seat (RZR / RZR S) or under the right rear passenger seat (RZR 4). Fuel Pump Assembly T-MAP RZR / RZR S Shown 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 123 TPS. 11. Ignition Coil - Located behind the rear service panel just above the outer PVT cover. Throttle Body Ignition Coil 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 124: Fuel Tank
Exploded View Fuel Flow Fuel Injectors Fuel Rail Fuel Tank Pressure Regulator Fuel Pump Assembly Fuel Filters Quick Connect Fuel Line 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 125: Fuel Line Removal / Installation
4. Snap the fuel line back over the nipple and slide the locking mechanism back into place. Verify the connector tabs snap back into place. 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 126 At the engine, fuel is fed through the fuel rail and into the injectors, which inject into the intake ports. 4.10 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 127: Electronic Control Unit (Ecu)
No internal servicing or readjustment may be performed. If a problem is encountered, and you RZR / RZR S determine the ECU to be faulty, contact the Polaris Service - Located behind driver’s seat Department for specific handling instructions. Do not replace the ECU without factory authorization.
Page 128: Temp / Manifold Absolute Pressure Sensor (T-Map)
The ECU aid installation of the new sensor. calculates engine speed from the time interval between the consecutive pulses. 4.12 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 129 CPS Resistance Specification: mounting bracket to the transmission. Retain the Yellow to White: 560  10% bolts, washers, and spacers for installation. 4.13 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 130 O-ring to aid installation. 11. Torque the CPS retaining bolt to specification. CPS Retaining Bolt: 25 in-lbs (2.8 Nm) 4.14 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 131 2. Reinstall mounting bracket and hand tighten the (7) bolts. 3. Torque ALL mounting bracket bolts to specification. Mount Bracket Bolt: 23-27 ft-lbs (31-37 Nm) 4.15 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 132 Check with the manufacturer of your torque wrench to see if it can be used to tighten left-hand threaded bolts. 4.16 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 133: Fuel Injectors
Additives and higher grades of fuel can be used as a preventative measure if clogging has been a problem. 4.17 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 134 NOTE: Be sure to connect like colored fuel injector connectors for proper engine function (PTO = GRAY, MAG = BLACK). 4.18 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 135 9. Lubricate O-rings lightly with oil to aid installation. Torque the fuel rail mounting screw to specification. Fuel Rail Mounting Screw: 216 ± 24 in-lbs (24 Nm) 4.19 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 136: Fuel Pump
When the key switch is turned to "ON", the ECU activates the fuel pump, which pressurizes the system for start-up. 4.20 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 137: Fuel Pump Test
Turn the key switch off and depress the valve button fuel pump assembly. on the tester to relieve the system pressure. 4.21 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 138: Fuel Pump Replacement
Properly drain fuel into a suitable container. NOTE: Apply downward force on the fuel pump flange while removing the fuel pump PFA nut. 4.22 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 139 11. Use cleaning wipes provided to clean fuel tank surface and threads. Remove all debris, grease and oil. Allow surfaces to dry completely. 4.23 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 140 22. Test the fuel pump by turning on the key and listening for the pump to activate. Cycle the key several times to prime the system. 4.24 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 141: Fuel Tank Removal (Rzr / Rzr S)
(see Chapter 5). 4. Disconnect the fuel pump electrical harness. Disconnect Here Remove RH Rocker Panel 4.25 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 143: Fuel Tank Removal (Rzr 4)
Reinstall fuel tank cap once rocker panel is removed. 4. Remove the rocker panel from the vehicle. 4.27 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 144 NOTE: A small amount of fuel may come out of the fuel line or tank. Properly drain fuel into a suitable container. 4.28 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 145: Fuel Tank Installation
Check for leaks. 12. Finally, install the rear service panel along with the seats. 4.29 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 147: Throttle Position Sensor (Tps)
If the stop screw is repositioned or adjusted, the throttle body assembly must be replaced. 4.31 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 148: Tps Replacement
1. Remove the seats, rear service panel and the rear cargo box (see Chapter 5). 2. Loosen the hose clamps retaining the throttle body. 4.32 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 149 8. Reinstall cargo box, rear service panel and seats (see 10. Reinstall cargo box, rear service panel and seats (see Chapter 5). Chapter 5). 4.33 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 150: Camshaft Phase Sensor
50 ± 5 in-lbs (5.65 ± .55 Nm) NOTE: Use Digital Wrench™ Diagnostic Software (dealer only) if you suspect this sensor is faulty. 4.34 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 151: Engine Coolant Temperature Sensor (Ect)
ELECTRONIC FUEL INJECTION ENGINE COOLANT TEMPERATURE Refer to Chapter 3 and 10 for additional ECT sensor information. Polaris dealers can test the sensor by using SENSOR (ECT) the Digital Wrench™ Diagnostic Software (dealer only). ECT Sensor Resistance Readings Operation Overview Temperature F (C)
Page 152: Ignition Coil
4. Install the new ignition coil and/or high tension lead(s). Ignition Coil Retaining Bolt: 75 in-lbs (8.5 Nm) 4.36 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 153: Efi Diagnostics
Manifold Absolute Pressure Sensor (T-MAP) Voltage Too Low P0107 Voltage Too High P0113 Intake Air Temperature (T-MAP) Voltage Too Low P0112 4.37 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 154 Driver Circuit Short to B+ 520207 P1835 (AWD) Driver Circuit Grounded P1834 Steering Over Current Shut Down Current Above Normal or Grounded 520221 C1050 4.38 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 155 Idle Air Control Valve (IAC) Driver Circuit Short to B+ 520271 P1509 M17; IAC Stepper Pin 1 Driver Circuit Grounded P1508 4.39 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 156: Efi Troubleshooting
• TPS setting incorrect • Throttle stop screw set incorrectly (out of sync with • Injector failure ECU) • Faulty electrical connection 4.40 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 157: 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 158: 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 161: Engine Controller Reprogramming (Reflash)
Wrench™ Version and Update ID” on page 4.42. running in the background and make it harder for the diagnostic software to operate. 4.45 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 162 Copy Request Code to obtain Authorization Key NOTE: Request Codes and Authorization Keys must be entered EXACTLY as they appear on the screen. 4.46 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 167: Torque Specifications
RZR 4 38 ft-lbs (52 Nm) M10 Bolts Outer Frame Coupler RZR 4 17 ft-lbs (23 Nm) M8 Bolts Push Rivet 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 168: Cab Frame (Rzr / Rzr S)
(3/8-16 x 1 1/4) screws and (3/ 8-16 Nyloc) nuts. Tighten screws to specification. Screws: 25-28 ft-lbs (34-38 Nm) 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 170: Assembly / Removal
16 x 1 1/4) bolts and (3/8-16 Nyloc) nuts. Tighten bolts to 25-28 ft-lbs (34-38 Nm). Bolts: 25-28 ft-lbs (34-38 Nm) 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 173: Dash Instruments / Controls / Glovebox
C. AWD/2WD or AWD/2WD/TURF Switch D. 12 Volt Accessory Receptacle E. Key Switch F. Hazard Switch (INT’L) G. Switch; Turn, Lights, Horn (INT’L) 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 174: Hood / Front Body Work
Front LH Fender Flair Front RH Fender Flair T27 Screws Push Rivets Front Bumper Push Rivet Winch Pocket Cover T27 Screws 5.10 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 175: Rear Bumper
BODY / STEERING / SUSPENSION Rear Bumper LH Tail Light RH Tail Light Screw Speed Screws Nuts Rear Bumper Screws 5.11 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 176: Seat Assembly
Seat Belt Seat Belt 40 ft-lbs (54 Nm) Latch Plunger Rear Seat Base 40 ft-lbs 40 ft-lbs (54 Nm) (54 Nm) 5.12 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 177: Seat Belts / Mounting (Rzr 4)
Seat Support Rubber Bumpers Latch Plunger Front Seat Base 40 ft-lbs (54 Nm) 3 Point Seat Belts 40 ft-lbs (54 Nm) 5.13 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 178: Floor / Rocker Panels (Rzr / Rzr S)
Push Rivets U-Type Nuts Close Off Torx Panel Screws Screws Plastic Dart Front Self-Tapping Support Bracket Screws RH Rocker Lower Floor 5.14 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 179: Floor / Rocker Panels (Rzr 4)
Screw Torx Screws RH Rocker U-Type Nuts Front Support Bracket Upper Floor Screw Self-Tapping Screws Lower Floor Close Off Panel 5.15 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 180: Rear Cargo Box / Fenders (Rzr / Rzr S)
Service Panel Push Bolts Rivets Sound Cover Foam Foil Heat Shield Rear RH Panel Divider Screws Push Rivet Cargo Box Supports 5.16 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 181: Rear Cargo Box / Fenders (Rzr 4)
Screws Screws Bolts Torx Screws Rear RH Fender Flair Push Rivet Foil Rear RH Floor Heat Shield Cargo Box Supports 5.17 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 182: Chassis / Main Frame (Rzr / Rzr S)
Rear Bumper Support Main Frame 15 ft-lbs 17 ft-lbs (20 Nm) (23 Nm) Skid Plate Washer 6-8 ft-lbs (8-11 Nm) 5.18 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 183: Chassis / Main Frame (Rzr 4)
Skid Plate Fuel Tank Front Frame Skid Plate Bracket Washers Self-Tapping Screws Front Skid Plate Coupler 6-8 ft-lbs (8-11 Nm) 5.19 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 184: Body Component Removal
3. Disconnect the front head lamp connectors and remove the front bumper from the vehicle. 5.20 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 185: Rear Bumper
Rivets 2. Tilt the hood back to disengage the front tabs and Torx remove the hood from the vehicle. Screws 5.21 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 186: Rear Fender, Flair And Tie Down Removal
Remove the fender from the vehicle. 5. Remove the (4) fasteners that retain the tie-down brackets to the cargo box and remove from vehicle. Remove 5.22 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 187: Cargo Box Assembly Removal
5. Remove the Torx screws retaining the rear portion of the floor and remove the lower floor from the vehicle. 5.23 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 188 9. Remove the Torx screws retaining the rear floor. 10. Disconnect the 12V outlet and ECU connector. 11. Remove the rear floor from the vehicle. 5.24 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 189: Steering Assembly
(58 Nm) Boot 17 ft-lbs 17 ft-lbs (23 Nm) (23 Nm) 12-14 ft-lbs (16-19 Nm) Tie Rod Cotter Pin Rod End 5.25 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 190: Steering Wheel Removal (Non-Eps Models)
5. Refer to steps 11-13 of the “Steering Shaft Bearing Replacement” procedure for installation. 5.26 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 191: Steering Shaft Bearing Replacement
NOTE: Use care not to allow any of the Loctite 16. Install steering wheel cap and field test steering get in the bearing. operation. 5.27 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 192: Electronic Power Steering Assembly
(58 Nm) Boot 17 ft-lbs 17 ft-lbs (23 Nm) (23 Nm) 12-14 ft-lbs (16-19 Nm) Rod End Tie Rod Cotter Pin 5.28 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 193: 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 5.29 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 194: Steering Wheel Removal (Eps Models)
Power Steering Fault. 2. Disconnect the (2) electrical harnesses from the power steering unit. Remove 4. Place the assembly in a vise. 5.30 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 195: Lower Steering Shaft Removal (Eps Models)
5. Carefully remove the power steering unit and mount bracket from the vehicle as an assembly. 3. Remove the power steering unit (see “Power Steering Unit Removal” procedure). 5.31 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 196: Lower Steering Shaft Installation (Eps Models)
Torque the mounting bolts to specification. 17 ft-lbs (23 Nm) Power Steering Unit Mount Bracket Nuts: 17 ft-lbs (23 Nm) 5.32 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 197: Upper Steering Shaft Installation (Eps Models)
(2) Torx-head fasteners. Opening 8. Turn the key switch on and test EPS operation. Skip-Tooth 5.33 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 198: Front A-Arms
(F) and remove lower A-arm from the vehicle. 17. Examine A-arm bushings and pivot tube (see “Exploded View”). Replace if worn. Discard hardware. Standard RZR Shown 5.34 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 199: Exploded View (Rzr)
A-arm Grease Zerk Grease Zerk Pinch Bushing Pinch Bolts Bolts Ball Joint CV Shield CV Shield Screws Ball Joint Screws 5.35 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 200: Ball Joint Service
A-arm to gain enough clearance to install ball joint tool (PU-50506) on the lower ball joint. Ball Joint Removal 5.36 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 201: Ball Joint Installation
Front Caliper Mount Bolts: 31-34 ft-lbs (42-46 Nm) Wheel Nuts (Alum): 30 ft-lbs (41 Nm) + 90° (1/4 turn) Wheel Nuts (Steel): 27 ft-lbs (37 Nm) 5.37 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 202: Front Stabilizer Bar (Rzr / Rzr S Int'l)
Screws Frame Nuts Bumper Recovery Support Bottle NOTE: Properly support the bumper support and Filler wires that are attached. Neck 5.38 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 203 11. Reverse the procedure for installation. Torque the linkage fasteners to specification (see “Exploded View”). 5.39 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 204 Screws Washer Bracket Grease Clamp Zerk Bushings Nuts Bracket 30 ft-lbs (41 Nm) Linkage Spacer Mounts 37 ft-lbs (50 Nm) 5.40 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 205: Rear A-Arms
4. Remove the (2) fasteners (E) attaching the lower A- View” on page 5.40). Replace if worn. Discard arm to the frame. Remove the A-arm from the vehicle. hardware. 5.41 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 206: Installation
5. Examine bushings and pivot tubes (see “Exploded RZR S / RZR 4: 40 ft-lbs (54 Nm) View”). Replace if worn. Discard hardware. 5.42 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 207: Exploded View (Rzr)
Lower Tube A-arm Bushings Bearing Pivot Carrier Tube Screws Lower Shield Pivot Fastener Tube Screws Bearing Carrier Lower Shield Fastener 5.43 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 208: Rear Stabilizer Bar (Rzr)
4. Remove the stabilizer bar and bracket from the frame as an assembly. Stabilizer Mounting Bolts: 18 ft-lbs (24 Nm) 5.44 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 209: Rear Stabilizer Bar (Rzr S / Rzr 4)
4. Remove the stabilizer bar from the bracket (bracket can remain attached to the frame). Stabilizer Mounting Bolts: 18 ft-lbs (24 Nm) 5.45 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 210: Shocks / Springs / Fasteners
Retainer gap decal surface to eliminate any air bubbles during the should be 180° application. from spring end 5.46 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 211: Exploded View (Rzr 4)
3. Reverse the procedure to reinstall the shock. Torque new fasteners to specification (refer to exploded views). 5.47 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 212: Fox™ Podium Piggyback Shock Service
Retaining Ring, Wire Piston Asm, Floating (IFP) Damping Adjust Asm., Piston Valving Asm. Damping Adjust Asm., Concentric Bearing Asm. Screw Asm. Bumper 5.48 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 213: Fox™ 1.5 Podium 'Piggyback - General Service Information
1.125 x .093 Top-Out 0.900 x 0.015 Piston Orifice: 0.098 0.800 x 0.015 1.125 x .093 Top-Out Piston Orifice: 0.081 5.49 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 214: Fox™ 2.0 Podium 'Piggyback' Shock (Rzr 4 L.e. Models)
Bearing Asm. Bumper Valving Asm. Bearing, Spherical Lock Nut Retaining Ring Reservoir Retaining Ring Piston Asm, Floating (IFP) Shock Oil (2870995) 5.50 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 215: Fox™ 2.0 Podium 'Piggyback - General Service Information
0.750 x .100 Back-Up 1.230 x .082 Top-Out Piston Orifice: 2x 0.070 0.750 x .100 Back-Up Piston Orifice: 2x 0.070 5.51 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 216: Fox™ Podium 'Piggyback' Rebuild Information
6. Slowly loosen nylon ball retainer from reservoir cap and allow nitrogen to completely escape. 7. Remove the nylon ball retainer. 5.52 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 217 22. A tie strap can be used to keep the shims in the proper expose the retaining ring (C). Remove the retaining order. ring from the shock body. 5.53 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 218: Fox™ Podium 'Piggyback' Body And Reservoir Service
3. Use a spanner or strap wrench to remove the shock LSC: 14 ft-lbs (19 Nm) body tube and reservoir from the body cap. 5.54 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 219: Fox™ Podium 'Piggyback' 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. 5.55 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 220: Fox™ Podium 'Piggyback' Assembly
(PU-50939) onto the shaft threads. 4. Lubricate the shock rod and the Shock Seal Protector Sleeve with new shock oil. 5.56 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 221 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. 5.57 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 222 30. Install the bearing assembly retaining ring and clean excess shock oil. Properly dispose of shop towel. 5.58 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 224: Fox™ Podium Top Fill Shock Service
Spiral Retaining Ring Bearing Cap Asm. Shock Oil (2870995) Bearing Asm. Valving Asm. Lock Nut Piston Asm. Floating Preload Ring 5.60 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 225: Fox™ 2.0 Podium Top Fill - General Service Information
1.230 x 0.082 Top-Out 1.570 x 0.128 Top-Out 1.230 x 0.082 Top-Out 0.750 x 0.100 Back-Up 0.750 x 0.100 Back-Up 5.61 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 226: Fox™ 2.0 Podium Top Fill Disassembly
Dry the shock assembly with compressed air, if available, or use clean towels. 5.62 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 227 NOTE: If the shock has been rebuilt several times, body cap assembly replacement is recommended as the air valve assembly is not servicable. 5.63 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 228 22. Remove the piston/wear band (if still attached). Discard wear band. Note the orientation of the rebound and compression sides of the piston. 5.64 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 229: Fox™ 2.0 Podium Top Fill Reassembly
29. Clean all parts with solvent and use compress air to dry. Place clean parts on a lint-free towel/shop rag. Figure 13 5.65 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 230 (Fig. 18). Figure 16 Figure 18 Compression Port 9. Install the compression valve shim stack onto the shock shaft. 5.66 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 231 17. Handle the shock body with care after setting the IFP depth. Do not move the IFP after initial setting is established. 5.67 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 232 Figure 25 Polaris Gas Shock Oil - 5 wt. 24. Carefully and slowly push the bearing down just past PN 2870995 - qt. the retainer groove in the shock body. Install the PN 2872279 - 2.5 gal.
Page 233 NOTE: After installation, be sure to RIDE SLOWLY initially to ensure the shock and the vehicle’s suspension is performing correctly. 5.69 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 236: Special Tools And Supplies
(initial vehicle movement), clutch upshift and backshift. During the development of the Polaris vehicle, the PVT system is matched first to the engine power curve; then to average riding conditions and the vehicle’s intended usage. Therefore, modifications or...
Page 237: Drive Clutch Operation
Rather than vary throttle position, as a conventional governor does, the PVT system changes engine load requirements by either upshifting or backshifting. 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 238: Overheating / Diagnosis
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.
Page 239: Pvt System Service
Boot Outlet Duct Cover Screws Clamp Clamps Bolt & Washer Inner Clutch Cover Retainer Outer Screws Outer Cover Seal Clutch Cover 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 240: Pvt Disassembly
Remove driven clutch offset spacers from the transmission input shaft if present. Keep Spacers In Order (Note Thickness) Retaining Seat Base Bolt 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 241: Pvt Assembly
Torque to specification (see next page). 11. Clean end of taper on crankshaft and the taper bore inside drive clutch. 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 242: Clutch Offset Procedure
Mounting Bolts: 40 ft-lbs (54 Nm) • .030" Offset Washer - PN 7556454 • .060" Offset Washer - PN 7556120 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 243 7. Install the outer clutch cover and torque the cover screws to specification. Cover Screws: 45-50 in-lbs (5-5.6 Nm) 8. Install the clutch cover outlet duct and tighten the clamps. 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 244: Drive Belt (Non-Ebs)
5. Install outer PVT cover as described in “PVT SYSTEM SERVICE - PVT Assembly”. 6. See “PVT Break-In (Drive Belt / Clutches)” on page 6.3. 6.10 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 245: Drive Belt (Ebs)
5. Walk the belt out of the driven clutch and drive clutch. page 6.3. Remove the belt from the vehicle. 6.11 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 247: Clutch Disassembly
Replace the cover bushing if more brass than Teflon™ is visible on the bushing. Refer to bushing replacement in this chapter. 6.13 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 248: Drive Clutch Spring Inspection
See “Roller, Pin and Thrust Washer Inspection”. Color Neon Green Free Length 2.72 in. (6.90 cm) 6.14 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 249: Button To Tower Clearance Inspection
Teflon™ is visible on the bushing. Refer to bushing replacement in this chapter. 2871358-A Clutch Holding Fixture: PN 2871358-A Spider Removal Tool: PN 2870341 6.15 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 250: Roller, Pin, And Thrust Washer Inspection
3. Lift bearing (C) and PTFE washers (D) off the shaft. Replace as an assembly if worn, damaged, or if problems were noted. 6.16 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 251: Moveable Sheave Bushing Inspection
Replace if worn or damaged. = In. / mm. PTFE Washer Thickness Standard: .030” (.76 mm) Service Limit: .025” (.64 mm) 6.17 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 252: 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. 6.18 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 253 8. Remove nut from puller rod and set aside. clutch cover off rod. 9. Remove sheave from puller. 10. Remove installation tool. 6.19 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 254: Clutch Assembly
9. Torque cover bolts evenly to specification. Spider Cover Screw: 90 in-lbs (10.4 Nm) Bearing 6.20 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 255: Driven Clutch Service (Non-Ebs)
This aids in reassembly and maintains clutch balance after reassembly. Outer Spring Retainer NOTE: Spring is compression only and has no torsional wind. 6.21 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 256 8. Check the rollers in the stationary sheave for wear. If rollers are worn, a new driven clutch assembly may be needed. Check Rollers for Wear 6.22 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 257: Clutch Assembly
Assemble Sheaves 3. Install the spring into the inner retainer. 4. Install the spacer over the shaft. 6.23 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 258 Compressor PU-50518. 7. Apply and hold downward pressure on the outer spring retainer. Carefully install the snap ring. Snap Ring 6.24 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 259: Driven Clutch Service (Ebs)
Press down reassembly. on spider 3. Remove the four screws that secure the cam (helix) assembly using a T25 Torx driver. 6.25 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 260 8. Remove the E-clips (F), washers (G), and the clutch rollers (H). Inspect the rollers for wear; replace if worn. 9. Remove the clutch assembly from the holding tool. 6.26 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 261: Bushing Service
 each bushing. Clean all residual Loctite from Inspect Sheave Surface bushing bore prior to installing new bushing. 6.27 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 262 9. Remove installation tool and clutch sheave from puller. 9. Remove adapters from puller. 10. Remove bushing and removal tool from adapters. Discard bushing. 6.28 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 263: 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. 6.29 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 264 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. 6.30 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 265 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) 6.31 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 266: Exploded View
Retaining Ring Moveable Sheave Outer Roller Spider Spider Insert Clutch Shaft Slotted Spring Pin Retaining Ring Stationary Ball Sheave Bearing 6.32 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 267: Troubleshooting
Belt burnt, thin -Dragging brake -Inspect brake system. spots  -Slow, easy clutch engagement -Fast, effective use of throttle for efficient engagement. 6.33 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 268 -Replace belt. Refer to belt burnt troubleshooting Engagement and instruct operator. erratic or stabby -Drive clutch bushings stick -Inspect and repair clutches. 6.34 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 270: Special Tools
27 ft-lbs (37 Nm) Cone Washers Cotter Pin 5. Remove the fastener retaining the steering tie rod end to the front bearing carrier. 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 271: Bearing Replacement
The bearings should turn smoothly and quietly, with no detectable up and down movement and minimal movement sideways between inner and outer race. 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 272: Bearing Carrier Installation
Install washers with bearing carrier. domed side out. Cone Washers Wheel RZR / RZR S Shown 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 273 11. Rotate wheel and check for smooth operation. Bend both ends of cotter pin around end of spindle in different directions. RZR 4 Tie Rod End Shown 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 274: 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. 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 275: Drive Shaft / Cv Joint Handling Tips
CV joint from the drive shaft. NOTE: If using a brass drift, be sure to tap on the inner race of the joint only. 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 278: Drive Shaft Installation
Cone Washers Wheel RZR / RZR S Shown 4. Install the upper ball joint end into the front bearing carrier. 7.10 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 279: Propshaft Service
NOTE: You may have to loosen the front gearcase different directions. mounting bolts to allow for propshaft removal. 7.11 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 280: Removal / Installation (Rzr 4)
4. Remove the retaining screw and the gear selector 8. Slide the front portion of the propshaft back and away handle. from the front gearcase to remove it. 7.12 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 281: Support Bearing Replacement (Rzr 4)
Support Bearing Fasteners: 16-18 ft-lbs (22-24 Nm) 14. When installing the front portion of the propshaft, use a NEW roll pin. 7.13 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 282: Propshaft U-Joint Service
10. Install the front portion of the propshaft onto the front gearcase and install a NEW roll pin. 11. Reinstall the center console, selector handle and front seats. 7.14 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 283: Assembly
If the joint is stiff or binding, tap the yoke lightly to center the joint until it pivots freely. 7.15 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 284: Front Gearcase / Centralized Hilliard
Gearcase Housing Fill Plug Clutch Housing (Ring Gear) Drain Plug, Magnetic Roll Cage Retaining Ring, External Hub / Race Assembly 7.16 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 285: All Wheel Drive Operation
Centers Roll Cage and Rollers in Ring Gear Output Hubs Ring Gear Torsion Roll Cage Spring & Rollers 7.17 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 287 6. Remove the (4) bolts securing the front gearcase to frame. Remove Vent Line Disconnect Harness Gearcase image is for reference only. Remove 4 Bolts 7.19 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 288 4. Remove and inspect the armature plate. Refer to Remove as “AWD Diagnosis” for detailed inspection process. an assembly Armature Plate 7.20 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 289 13. Inspect clutch housing ring gear (C) for a consistent wear pattern. Inspect the ring gear for chipped, broken, or missing teeth. Inspect 7.21 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 290: Gearcase Assembly
Check each for excessive wear or damage. 5. Carefully install the rollers into the roll cage assembly while installing the assembly into the clutch housing. 7.22 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 291 10. Carefully install the ring gear and roll cage assembly into the gearcase housing. Align during installation 7.23 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 292: Gearcase Installation
30 ft-lbs (41 Nm) Cover Plate Screws: 7-11 ft-lbs (10-15 Nm) Front Gearcase Mounting Bolts: 30 ft-lbs (41 Nm) 7.24 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 293 Chapter 2 for fluid fill and change information. Polaris Demand Drive Plus (PN 2877922) Front Housing Capacity 6.75 fl. oz. (200 ml) 7.25 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 294: Rear Bearing Carrier
9. Rotate bearing by hand and check for smooth rotation. Visually inspect bearing for moisture, dirt, or corrosion. Replace bearing if any of these things are evident. 7.26 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 295: Bearing Replacement
4. Inspect the bearing carrier housing for scratches, Bushing wear or damage. Replace rear bearing carrier if damaged. Control Arm Pivot Tube Bushing 7.27 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 296: Bearing Carrier Installation
RZR: 38 ft-lbs (52 Nm) RZR S / RZR 4: 40 ft-lbs (54 Nm) 3. Apply grease to drive shaft axle splines. 7.28 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 297: Rear Drive Shaft
Wear eye protection when removing bearings and seals. 2. Remove the (4) wheel nuts and remove rear wheel. 7.29 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 298: Outer Cv Joint / Boot Replacement
Brass Drift Shown IMPORTANT: Tap on inner race only! 9. Inspect axle splines and CV boots for any damage. 7.30 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 300 Axle Boot Clamp Tool: PU-48951 CV Boot Clamp Pliers: 8700226 Axle Boot Clamp Tool: PU-48951 CV Boot Clamp Pliers: 8700226 7.32 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 302 16. Pull on the joint to test that the circlip is seated and CV Boot Clamp Pliers: 8700226 that the joint is securely fastened to the shaft. 7.34 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 303: Drive Shaft Exploded View
Boot Kit Grease Pack Large Clamp Spring Ring CV Joint 3. Slide the rear drive shaft into the rear bearing carrier. 7.35 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 304 Wheel Nuts: Steel Wheels: 27 ft-lbs (37 Nm) Aluminum Wheels: 30 ft-lbs + 90° (1/4 turn) 18 ft-lbs 24 (Nm) 7.36 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 305: Rear Gearcase
Remove Remove Suspension Plate Remove 6. Remove the (4) fasteners and remove the rear mount from the rear gearcase. Remove 7.37 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 306: Gearcase Disassembly
2. Remove remaining cover screws from rear gearcase. 3. Remove the ring gear/axle spool assembly. The bearings are a slip-fit and will slide off the axel spool. 7.38 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 307 NOTE: In the event damage to the gears, pinion bearings or housing requires replacement, the entire assembly must be replaced. 7.39 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 308: Gearcase Assembly
(2871557) to gearcase mating surfaces upon cover installation. WARNING Wear the appropriate safety equipment while installing bearing races to reduce the risk of injury. 7.40 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 309: Gearcase Installation
6. Install the gearcase cover. Install the cover screws onto the rear gearcase. Torque to specification. 2. Add Polaris ATV Angle Drive Fluid to rear gearcase. Refer to maintenance information in Chapter 2 for more details. Torque drain and fill plugs to specification.
Page 310: Gearcase Exploded View
Screw, Flange Head Assembly, Rear Housing, RH Screw Dowel Assembly, Tapered Roller Bearing Plug, Drain w/O-Ring Shim Plug, Fill w/O-Ring 7.42 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 311: Rear Gearcase (Rzr S Int'l)
Shift Yoke powered and the Clutch Gear plunger extends to disengage the clutch gear and unlock the differential. Differential - Lock 7.43 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 312: Gearcase Removal
4. Remove the (2) rear gearcase mount bracket IRS Axle fasteners and mount bolt and remove bracket from Unlocked vehicle. Axle Shaft Axle Shaft 7.44 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 313: Gearcase Disassembly
9. Remove the vent line and lift the rear gearcase upward and on its side to remove it from the vehicle. 7.45 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 314 Be sure to keep the shims together for reassembly. wear or damage. If bearing replacement is required, use standard bearing puller tools to remove the bearing races. 7.46 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 315 Inspect the pinion gear for chipped, worn, or broken teeth. If damaged, replace the gearcase assembly. 7.47 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 316 OEM tooling in order to properly reassemble. If there is any damage to the pinion gear, bearings or case, the gearcase assembly must be replaced. 7.48 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 317: Differential Disassembly
6. With the roll pin removed, slide the cross pin out and 3. Remove the upper differential gear. remove the remaining differential gears. 7.49 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 318: Differential Assembly
6. Install the ring gear and torque the retaining bolts to specification. 2. Install the lower differential gear and thrust washer. Ring Gear Bolts: 70-80 ft-lbs (95-108 Nm) 7.50 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 319: Gearcase Assembly
Install the bearings by hand as they are a slip-fit. 7. If previously removed; assembly the shift lever (A), NOTE: Grease all seals with Polaris All Season shift lever spring (B), shift return springs (C), shift yoke Grease (PN 2871322) upon assembly.
Page 320 13. If previously removed, install the differential solenoid. Torque the solenoid to 30-40 ft-lbs (41-54 Nm). 30-40 ft-lbs (41-54 Nm) 7.52 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 321: Gearcase Installation
Refer to the “Installation” procedure listed on page 4.14. Special Tool PA-48873 2. Add Polaris ATV Angle Drive Fluid to rear gearcase. Refer to maintenance information in Chapter 2 for more details. Torque drain and fill plugs to specification.
Page 322: Gearcase Exploded View
Thrust Washer, Side Gear Cover Asm., Rear Case, Diff Half Screw Pin, Diff, Cross Seal, Oil Pin, Spring Screw, Flanged 7.54 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 323: Wheel Hubs
+ 90° (1/4 turn) Ring Brake Disc Studs Castle Nut 80 ft-lbs Wheel Nuts (108 Nm) 27 ft-lbs (37 Nm) Rear Rim (Steel) 7.55 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 326: Torque Values / Specifications
(shifter, cable, console, shift knob). 2. Tighten the shift cable nut to specification. Shift Cable Nut: 130-155 in-lbs (14.7-17.5 Nm) 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 327: Shift Cable Inspection / Adjustment
4. Adjust the shift cable so there is the same amount of cable travel when shifting slightly past the detents of HIGH (H) gear and PARK (P). 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 328: Transmission Service
7. Remove the screws from the transfer case cover and remove the cover (note position of the longest screw #4). Transfer Case Transmission Gearcase Drain Plug Drain Plug 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 329 12. Output shaft bearing cup is a slip-fit. Remove and record number and thickness of shims and set aside. Note the alignment dowels (circled) for installation. 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 331: Transfer Case Reassembly
6. Place transmission upright with the output shaft facing up. Rotate output shaft 5-10 times both clockwise and counter-clockwise. 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 332 10. Remove the slip fit bearing race and shim(s). Shim(s) Installed Below Bearing Race Output Pinion Shaft Bracket Bearing Race 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 334 Output Shaft transfer case cover. Coating shim(s) and bearing race 23mm, 12 Point with Polaris All Purpose Grease may be necessary to hold the assembly together during installation. 28. Apply a thin coat of sealant to the case mating surfaces.
Page 335: Transmission Shift Housing Disassembly
B) If the torque required to rotate the output shaft is within specification, no adjustment is needed and the transfer case reassembly is complete. 8.11 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 336 4. Remove the reverse clutch gear assembly from the housing. Inspect these components and replace if needed. 8.12 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 337 Removing the detent sleeve first will allow the detent ball and spring to fall into the shift housing. Neutral 8.13 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 338 16. Inspect the ball bearing channels on both ends of the shift collar for excessive wear or damage. 17. Remove the sliding shoes from the clutch yoke. 8.14 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 339 Inspect the shaft bearing and replace if bearing. required using a shop press. Inspect the gears for damage and/or wear. Replace the shaft if required. 8.15 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 340: Transmission Shift Housing Reassembly
6. Install the pivot pin set screw and torque to specification. NOTE: Install new bearings and seals by pressing on the inner race only. 8.16 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 341 8. Install the clutch shaft into the transmission housing. Install First 9. Install the sliding shoes onto the clutch yoke. Detent Sleeve Assembly: 40-45 ft-lbs (54-61 Nm) 8.17 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 343 Apply lubricant to both seal case screws to the front of the transmission. Torque lips. to specification. Shift Housing Screws: 23-27 ft-lbs (31-37 Nm) 8.19 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 344: Troubleshooting
(rounding), damage. Inspect all bearings, circlips, thrust washers and shafts for wear. 8.20 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 345: Transmission Exploded View
TRANSMISSION TRANSMISSION EXPLODED VIEW Shift Housing / Transfer Case Exploded View 8.21 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 348 Front Brake Disc to Hub Bolts Rear Brake Disc to Hub Bolts Brake Switch 12-15 16-20 Master Cylinder to Frame Brake Pedal Mounting Bracket to Frame 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 349: Brake System Service Notes
Noise is from other source (axle, hub, disc or wheel) other sources. Inspect and repair as necessary Wrong pad for conditions Change to a softer or harder pad 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 350: Hydraulic Brake System Operation
MAX LEVEL line! When servicing Polaris brake systems use only Polaris DOT 4 Brake Fluid (PN 2872189). WARNING: Once a bottle is opened, use what is necessary and discard the rest in accordance with local laws. Do not store or use a partial bottle of brake fluid.
Page 351: Brake System Exploded View
All Caliper Bleed Screws: Brake Line 47 in-lbs (5.3 Nm) 15 ft-lbs All Flare Style Fittings: (20 Nm) 12-15 ft-lbs (16-20 Nm) 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 352: Master Cylinder
.090” (2.28 mm) Brake fluid will damage finished surfaces. Do not allow brake fluid to come in contact with finished surfaces. 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 353: Brake Bleeding / Fluid Change
Attach a clean, clear hose to fitting and place the other end in a clean container. Be sure the hose fits tightly on fitting. 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 355: Pad Inspection
RZR 4: .297 ± .007" (7.5 ± .178 mm) RZR 4 Service Limit: .180” (4.6 mm) Shown 31-34 ft-lbs (42-46 Nm) Front Caliper Mount Bolt: 31-34 ft-lbs (42-46 Nm) 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 356: Brake Burnishing Procedure
Repeat this procedure 10 times. Do not make more than 3 stops per 1 mile (1.6 km). 9.10 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 357: Front Caliper Service
D. Boots E. Square O-rings  F. Pistons  G. Caliper Mount H. Brake Pads I. Brake Scraper J. Bolts 9.11 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 359: Caliper Disassembly
Clean Components RZR 4 NOTE: Be sure to clean seal grooves in caliper body. 9.13 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 360: Caliper Inspection
2. Inspect piston for nicks, scratches, pitting or wear. Measure piston diameter and replace if damaged or worn beyond service limit. 9.14 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 361: Caliper Assembly
(42-46 Nm) Shown O-Rings Front Caliper Mount Bolt: 2. Coat pistons with clean Polaris DOT 4 Brake Fluid. 31-34 ft-lbs (42-46 Nm) Install pistons with a twisting motion while pushing inward. Piston should slide in and out of bore smoothly, with light resistance.
Page 362: Front Brake Disc
2. Use a 0-1” micrometer and measure disc thickness at eight different points around the pad contact surface. Replace disc if worn beyond service limit. Measure Thickness Front Disc 9.16 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 363: Disc Replacement
4. Clean the wheel hub mating surface and install new disc on wheel hub. 5. Install new bolts and torque to 18 ft-lbs (24 Nm). 18 ft-lbs (24 Nm) 9.17 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 364: Rear Brake Pads
NOTE: When removing caliper, be careful not to damage brake line. Support caliper so as not to kink or bend brake line. 9.18 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 365: Pad Inspection
Repeat this procedure 10 times. Do not make more than 3 stops per 1 mile (1.6 km). 9.19 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 366: Rear Caliper Service
4. Place a container below the caliper to catch the brake fluid. Remove brake line from caliper. Remove Brake Line 9.20 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 368: Caliper Assembly
Torque mounting bolts to specification. 18 ft-lbs (24 Nm) 2. Coat piston with clean Polaris DOT 4 Brake Fluid (PN 2872189). Install piston (D) with a twisting motion while pushing inward. Piston should slide in and out of bore smoothly with light resistance.
Page 369 Aluminum Wheels: 30 ft-lbs + 90° (1/4 turn) NOTE: If new pads are installed, refer to “REAR BRAKE PADS - Brake Burnishing Procedure”. 9.23 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 370: Rear Brake Disc
CAUTION Always use new brake disc mounting bolts. The bolts have a pre-applied locking agent which is destroyed upon removal. 9.24 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 371: Troubleshooting
• Operator riding brakes Brakes Lock • Alignment of caliper to disc • Caliper pistons sticking • Improper assembly of brake system components 9.25 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 375: General Information
• For resistance readings, isolate the component to be tested. Disconnect it from the wiring harness or power supply. 10.3 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 376: Headlamp Switch
1 and 2; 4 and 5. NOTE: Pins 7 and 8 provide power and ground to light the switch lamp. 10.4 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 377: Ignition Key Switch (Int'l)
• Turn the ignition key to START. There should be continuity between pins A and B; C and D; E and 10.5 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 378: Awd / 2Wd / Turf Switch (Int'l)
2. Test between the 5 sets of outputs (HI BEAM / LO BEAM / L-TURN / R-TURN / HORN). If any of the tests fail, replace the switch assembly. 10.6 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 379: Transmission (Gear Position) Switch
Gear Position when measured at terminals A and B 620  HIGH 300  160  75  24  PARK 10.7 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 380: Throttle Release Switch (Trs)
6.80k Ohms +/-5% Replace sensor if Replace sensor if reading is more than: reading is less than: 2.26k Ohms 6.46k Ohms 10.8 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 382: Vehicle Speed Sensor
CAUTION Do not power the solenoid with 12 Volts for more than 1 second, or damage may occur to solenoid. 10.10 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 383: All Wheel Drive Coil
80% of all electrical issues are caused by bad/failed connections and grounds. 10.11 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 384: 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. 10.12 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 385: Rider Information Display
11. TURF Indicator - Illuminated when the AWD / TURF traveled by the vehicle. The odometer can not be reset. switch is in the TURF position (INT’L Models Only). 10.13 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 386 Engine temperature can be displayed in ° F or ° C. Refer to “Units of Measurement” to change the format. 10.14 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 387 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. 10.15 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 388: Diagnostic Mode
5. If more than one code exists, press the MODE button to advance to the next trouble code. 10.16 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 389: Instrument Cluster Pinouts
Apply pressure on the bezel while pressing down on the instrument cluster. 10.17 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 390: Head Lights (Incandescent)
(INT’L Only) also located in the headlamp housing. NOTE: Make sure the tabs on the bulb locate properly in the housing. 10.18 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 391: Headlamp Housing Removal
3. Reconnect wire harness or re-insert bulb if previously removed. 4. Adjust headlights using the “Headlight Adjustment” procedure in this section. 10.19 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 392: Headlamp Replacement
NOTE: The headlights are different and electrical connectors cannot be interchanged. 7. Perform the “Headlight Adjustment” procedure as shown in this chapter. 10.20 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 393: Tail / Brake Lights
3. Connect the wire harness. 4. Test the tail light, brake light and turn signal (INT’L Only) to verify it is working properly. 10.21 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 395: Fan Control Circuit Operation / Testing
If none of the conditions exist, the fuel sender assembly is malfunctions the radiator fan will default to 'ON'. faulty. Replace the fuel pump assembly (see Chapter 4). 10.23 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 396: Fuse Box: Fuses / Relays / Circuit Breaker
20-amp circuit breaker protects the fan motor circuit. A separate relay located under the dash, operates the high beam and low beam headlights on INT’L models. 10.24 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 397: 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 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 398: Relay Operation
20-Amp fuse protected 12 Vdc operation. Red / White constant battery voltage. Provides 12 Vdc power for EFI Red / Dark Blue system circuits. 10.26 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 399 Key switch input to enable relay. Brown Relay coil ground. Relay switched power to operate Yellow / Dark Green the Headlights. 10.27 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 400: Charging System
7. Repeat test, observing ammeter and tachometer. With lights on, charging should occur at or below 2000 RPM. 10.28 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 401: Charging System 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 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 402: Regulator / Rectifier
If it turns off, verify the cooling fins are clean, free from debris and that adequate airflow is present. 10.30 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 404: Battery Service
Refer to OCV table (see “OCV - Open Circuit Voltage Test”). 3. Charge the battery as recommended (see “Charging Procedure”). 10.32 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 405: Battery Removal / Installation
NOTE: Battery charge can be maintained by using a Load Test Polaris battery tender charger or by charging once a month to make up for normal self-discharge. Battery CAUTION tenders can be left connected during the storage period, and will automatically charge the battery if the voltage drops below a pre-determined point.
Page 406: Battery Conductance Analyzer
Always watch charging times carefully. Stop charging if the battery becomes very warm to the Authorized Polaris dealers/distributors are required to use touch. Allow it to cool before resuming charging. the conductance analyzer when testing 12V Polaris batteries.
Page 407: Starting System
5. Remove starter from the engine. Use a soft, rubber • Faulty flywheel gear or loose flywheel hammer to aid in starter removal. 10.35 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 408: Starter Installation
8. Install seat base and connect the battery.  F. Stopper  G. Cover H. Spring Starter Motor Mounting Bolts: 7 ft-lbs (9.5 Nm) 10.36 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 409: Starter Solenoid Bench Test
• Once the pull-in coil is energized, the solenoid provides a current path for 12V power to reach the starter motor. 10.37 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 410: 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. 10.38 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 411: Electronic Power Steering (Eps)
EPS unit as the first step in diagnosing an mechanically coupled steering system. The system is EPS problem. Polaris Digital Wrench™ compatible for simplified diagnostics and system troubleshooting through the vehicle’s diagnostic port. With the engine off and the key on, the power steering unit will operate for up to five minutes.
Page 415: 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. 10.43 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc.
Page 417 2013 RANGER RZR 800...
Page 418 2013 RANGER RZR 800...
Page 419 2013 RANGER RZR 800 (EPS)
Page 420 2013 RANGER RZR 800 (EPS)
Page 421 2013 RANGER RZR S 800...
Page 422 2013 RANGER RZR S 800...
Page 423 2013 RANGER RZR S 800 INT’L...
Page 424 2013 RANGER RZR S 800 INT’L...
Page 425 2013 RANGER RZR 4 800...
Page 426 2013 RANGER RZR 4 800...
Page 427 2013 RANGER RZR 4 800 (EPS)
Page 428 2013 RANGER RZR 4 800 (EPS)
Page 429 2013 RANGER RZR / RZR S / RZR 4 (CARGO BOX)
Page 430 2013 RANGER RZR S 800 INT’L (CARGO BOX)

This manual is also suitable for:

2013 ranger rzr 4

Polaris 2013 RANGER RZR S Service Manual

General Information Chapter

Maintenance Chapter 2 Maintenance 2

Chapter 3 Engine / Cooling

Chapter 4 Electronic Fuel Injection

Chapter 5 Body / Steering / Suspension

Clutching Chapter 6 Clutching

Quick Links

Chapters

Troubleshooting

Related Manuals for Polaris 2013 RANGER RZR S

Summary of Contents for Polaris 2013 RANGER RZR S