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2013 RANGER RZR 4
Polaris 2013 RANGER RZR 4 Manuals
Manuals and User Guides for Polaris 2013 RANGER RZR 4. We have
3
Polaris 2013 RANGER RZR 4 manuals available for free PDF download: Service Manual, Owner's Manual
Polaris 2013 RANGER RZR 4 Service Manual (430 pages)
Brand:
Polaris
| Category:
Offroad Vehicle
| Size: 44.16 MB
Table of Contents
General Information Chapter
1
Table of Contents
1
Chapter 1
2
Engine Designation Number
2
Model Number Designation
2
Vehicle Identification
2
Vehicle Identification Number (Vin) Designation
2
Vehicle and Engine Serial Number Locations
3
Vehicle Information
4
Publication Numbers
4
Replacement Keys
4
Special Tools
5
General Specifications
6
Misc. Specifications and Charts
12
Conversion Table
12
Standard Bolt Torque Specification
13
Metric Bolt Torque Specification
13
Sae Tap / Drill Sizes
14
Metric Tap / Drill Sizes
14
Maintenance Chapter 2 Maintenance 2
15
Break-In Period / Maintenance Chart Key
17
Chapter 2
17
Periodic Maintenance Chart
17
Pre-Ride - 50 Hour Maintenance Interval
18
100 - 300 Hour Maintenance Interval
19
Maintenance Quick Reference
20
Maintenance Quick Reference, Continued
21
Grease Lubrication Points
22
Lubricants / Service Products
23
General Vehicle Inspection and Maintenance
24
Pre-Ride / Daily Inspection
24
Frame, Nuts, Bolts, and Fasteners
24
Shift Cable Inspection / Adjustment
24
Fuel System and Air Intake
25
Fuel Line / Fuel Pump / Fuel Filters
25
Vent Lines
25
Throttle Pedal Inspection
26
Throttle Freeplay Adjustment
26
Air Filter Service
27
Engine
29
Engine Oil Level
29
Engine Oil and Filter Service
30
Engine Breather Hose Inspection
31
Engine and Transmission Mounts
31
Compression and Leakdown Test
31
Exhaust - Spark Arrestor
32
Transmission and Gearcases
33
Transmission / Gearcase Specification Chart
33
Transmission Lubrication
33
Front Gearcase Lubrication
36
Rear Gearcase Lubrication
37
Cooling System
39
Cooling System Overview
39
Coolant Level Inspection
39
Coolant Strength / Type
40
Cooling System Pressure Test
40
Cooling System Hoses
40
Radiator
41
Coolant Drain
41
Final Drive / Wheel and Tire
42
Wheel and Hub Torque Table
42
Wheel Removal
42
Wheel Installation
42
Tire Inspection
43
Tire Pressure
43
Drive Shaft Boot Inspection
43
Electrical and Ignition System
44
Battery Maintenance
44
Battery Removal
44
Battery Installation
45
Battery off Season Storage
45
Battery Charging (Maintenance Free)
45
Spark Plug Service
45
Engine to Frame Ground
46
Steering
47
Steering Inspection
47
Steering Wheel Freeplay
47
Tie Rod End / Wheel Hub Inspection
47
Wheel Toe Alignment Inspection
48
Wheel Toe Adjustment
48
Suspension (Standard)
49
Spring Preload Adjustment
49
Suspension (Fox™)
50
Spring Preload Adjustment
50
Shock Compression Adjustment
51
Brake System
52
Brake Fluid Inspection
52
Brake Pad / Disc Inspection
52
Brake Hose and Fitting Inspection
52
Chapter 3 Engine / Cooling
53
Crankcase
54
Engine Specifications
54
Oil Pump / Gears / Engine Cover
55
Stator Cover / Starter / Water Pump / Lubrication System
56
Cylinder / Cylinder Head / Piston
57
Engine Efi Sensors / Valve Cover / General Components
58
Engine Torque Specifications
59
800 EFI Engine Service Specifications
60
Special Tools
62
Engine Cooling System
63
Cooling System Specifications / Pressure Test
63
Pressure Cap Test
63
Cooling System Exploded View
64
Radiator Removal
65
Cooling System Bleeding Procedure
66
General Engine Service
68
Engine Lubrication Specifications / Oil Pressure Test
68
Accessible Engine Components
68
Oil Flow Chart
69
Engine Removal
70
Engine / Transmission Separation
77
Engine Disassembly and Inspection
78
Cylinder Head Assembly Exploded View
78
Rocker Arms / Push Rods
78
Cylinder Head Removal
79
Cylinder Head Inspection / Warp
80
Valve Seal / Spring Service (on Engine)
80
Cylinder Head Disassembly
81
Valve Inspection
82
Combustion Chamber / Valve Seat Reconditioning
83
Cylinder Head Reassembly
85
Valve Sealing Test
86
Cylinder Removal
86
Valve Lifter Removal / Inspection
86
Piston Removal
87
Cylinder Inspection
88
Cylinder Hone Selection and Honing Procedure
89
Honing to Deglaze / Cleaning the Cylinder after Honing
89
Piston-To-Cylinder Clearance
90
Piston / Rod Inspection
90
Piston Ring Installed Gap
91
Starter Drive Bendix Removal / Inspection
91
Flywheel / Stator Removal / Inspection
92
Engine Crankcase Disassembly / Inspection
92
Camshaft Inspection
100
Engine Reassembly
101
Crankcase Reassembly
101
Flywheel / Stator Installation
110
Cylinder Head Reassembly
110
Oil Pump Priming
112
Engine Installation
113
Engine Assembly and Installation
113
Engine Break-In Period
114
Troubleshooting
115
Chapter 4 Electronic Fuel Injection
117
General Information
118
Special Tools
118
Service Notes
120
Efi System Exploded View
121
Efi System Component Locations
122
Fuel Tank
124
Exploded View
124
Fuel Line Removal / Installation
125
Electronic Fuel Injection
125
Electronic Control Unit (Ecu)
127
Crankshaft Position Sensor (Cps)
128
Temp / Manifold Absolute Pressure Sensor (T-Map)
128
Fuel Injectors
133
Fuel Injector Service
133
Fuel Pump
136
Fuel Sender Test
136
Fuel Pump Test
137
Fuel Pump Replacement
138
Fuel Tank Removal (Rzr / Rzr S)
141
Fuel Tank Removal (Rzr 4)
143
Fuel Tank Installation
145
Idle Air Control (Iac)
146
Throttle Position Sensor (Tps)
147
Tps Resistance Tests
147
Tps Tester / Regulator
147
Tps Replacement
148
Camshaft Phase Sensor
150
Engine Coolant Temperature Sensor (Ect)
151
Overview, Test and Replacement
151
Ignition Coil
152
Ignition Coil / Ht Lead Replacement
152
Ignition Coil Tests
152
Efi Diagnostics
153
Instrument Cluster Trouble Code Display
153
Efi Troubleshooting
156
Digital Wrench™ Operation
157
Digital Wrench™ Communication Errors
157
Digital Wrench™ - Diagnostic Connector
158
Digital Wrench™ Serial Number Location
158
Digital Wrench™ Version and Update ID
158
Digital Wrench™ Updates
159
Digital Wrench™ Feature Map
160
Engine Controller Reprogramming (Reflash)
161
Chapter 5 Body / Steering / Suspension
165
Special Tools
167
Torque Specifications
167
Cab Frame (Rzr / Rzr S)
168
Cab Frame (Rzr 4)
170
Body Exploded Views
172
Side Safety Nets
172
Dash Instruments / Controls / Glovebox
173
Hood / Front Body Work
174
Rear Bumper
175
Seat Assembly
176
Seat Belts / Mounting (Rzr / Rzr S)
176
Seat Belts / Mounting (Rzr 4)
177
Floor / Rocker Panels (Rzr / Rzr S)
178
Floor / Rocker Panels (Rzr 4)
179
Rear Cargo Box / Fenders (Rzr / Rzr S)
180
Rear Cargo Box / Fenders (Rzr 4)
181
Chassis / Main Frame (Rzr / Rzr S)
182
Chassis / Main Frame (Rzr 4)
183
Body Component Removal
184
Seats
184
Rear Service Panel (Rzr / Rzr S)
184
Rear Console Cover (Rzr 4)
184
Front Bumper
184
Rear Bumper
185
Hood and Front Body Work
185
Rear Fender, Flair and Tie down Removal
186
Cargo Box Assembly Removal
187
Rocker Panels, Console and Floor
187
Steering Assembly
189
Exploded View (Non-Eps Models)
189
Steering Wheel Removal (Non-Eps Models)
190
Steering Shaft Removal (Non-Eps Models)
190
Steering Shaft Bearing Replacement
191
Electronic Power Steering Assembly
192
Exploded View (Eps Models)
192
Upper Steering Shaft Removal (Eps Models)
193
Steering Wheel Removal (Eps Models)
194
Power Steering Unit Removal
194
Lower Steering Shaft Removal (Eps Models)
195
Lower Steering Shaft Installation (Eps Models)
196
Power Steering Unit Installation
196
Upper Steering Shaft Installation (Eps Models)
197
Front A-Arms
198
Removal / Replacement
198
Exploded View (Rzr)
199
Exploded View (Rzr S / Rzr 4)
199
Ball Joint Service
200
Service Preparation
200
Ball Joint Removal
200
Ball Joint Installation
201
Front Stabilizer Bar (Rzr / Rzr S Int'l)
202
Stabilizer Bar Linkage Removal
202
Stabilizer Bar Removal
202
Exploded View
202
Rear A-Arms
205
Installation
206
Exploded View (Rzr)
207
Exploded View (Rzr S / Rzr 4)
207
Rear Stabilizer Bar (Rzr)
208
Removal / Installation
208
Rear Stabilizer Bar (Rzr S / Rzr 4)
209
Removal / Installation
209
Shocks / Springs / Fasteners
210
Exploded View (Rzr / Rzr S)
210
Exploded View (Rzr S / Rzr S Int'l)
210
Exploded View (Rzr 4)
211
Shock Removal / Installation
211
Shock Replacement
211
Fox™ Podium Piggyback Shock Service
212
Fox™ 1.5 Podium 'Piggyback' Shock (Rzr S)
212
Fox™ 1.5 Podium 'Piggyback - General Service Information
213
Front Shock Service (Rzr S)
213
Rear Shock Service (Rzr S)
213
Fox™ 2.0 Podium 'Piggyback' Shock (Rzr 4 L.e. Models)
214
Fox™ 2.0 Podium 'Piggyback - General Service Information
215
Front Shock Service (Rzr 4 L.e Models)
215
Rear Shock Service (Rzr 4 L.e. Models)
215
Fox™ Podium 'Piggyback' Rebuild Information
216
Fox™ Podium 'Piggyback' Special Tools
216
Fox™ Podium 'Piggyback' Disassembly
216
Fox™ Podium 'Piggyback' Body and Reservoir Service
218
Fox™ Podium 'Piggyback' Component Rebuild
219
Fox™ Podium 'Piggyback' Assembly
220
Fox™ Podium Top Fill Shock Service
224
Fox™ 2.0 Podium Top Fill Shock (Rzr 4 Base Models)
224
Fox™ 2.0 Podium Top Fill - General Service Information
225
Front Shock Service (Rzr 4 Base Models)
225
Rear Shock Service (Rzr 4 Base Models)
225
Fox™ 2.0 Podium Top Fill Disassembly
226
Fox™ 2.0 Podium Top Fill Reassembly
229
Clutching Chapter 6 Clutching
235
Chapter 6
236
High Altitude Clutch Charts
236
Pvt System Overview
236
General Operation
236
Drive Clutch Operation
237
Driven Clutch Operation
237
Pvt Break-In (Drive Belt / Clutches)
237
Maintenance / Inspection
237
Overheating / Diagnosis
238
Ranger Rzr / Rzr S / Rzr 4
236
Ranger Rzr Eps (Ebs)
236
Special Tools and Supplies
236
Torque Specifications
236
Pvt System Service
239
Pvt Covers and Ducting Components
239
Pvt Disassembly
240
Pvt Assembly
241
Clutch Offset Procedure
242
Drive Belt (Non-Ebs)
244
Drive Belt (Ebs)
245
Drive Clutch Service
246
Exploded View
246
Shift Weights
246
Clutch Disassembly
247
Bearing Inspection
247
Drive Clutch Spring Inspection
248
Shift Weight Inspection
248
Button to Tower Clearance Inspection
249
Spider Removal
249
Roller, Pin, and Thrust Washer Inspection
250
Clutch Inspection
250
Moveable Sheave Bushing Inspection
251
Bushing Service
252
Clutch Assembly
254
Driven Clutch Service (Non-Ebs)
255
Exploded View
255
Clutch Disassembly / Inspection
255
Clutch Assembly
257
Driven Clutch Service (Ebs)
259
Clutch Disassembly
259
Bushing Service
261
Clutch Assembly
263
Exploded View
266
Troubleshooting
267
Chapter 7 Final Drive
269
Bearing Carrier Inspection / Removal
270
Final Drive
270
Front Bearing Carrier
270
Special Tools
270
Torque Specifications
270
Bearing Replacement
271
Bearing Carrier Installation
272
Front Drive Shaft
274
Drive Shaft Removal
274
Drive Shaft / CV Joint Handling Tips
275
Outer CV Joint / Boot Replacement
275
Inner Plunging Joint / Boot Replacement
276
Drive Shaft Installation
278
Propshaft Service
279
Removal / Installation (Rzr / Rzr S)
279
Removal / Installation (Rzr 4)
280
Support Bearing Replacement (Rzr 4)
281
Propshaft U-Joint Service
282
Disassembly
282
Assembly
283
Front Gearcase / Centralized Hilliard
284
Centralized Hilliard Exploded View
284
All Wheel Drive Operation
285
Awd Diagnosis
286
Gearcase Assembly
290
Gearcase Installation
292
Rear Bearing Carrier
294
Bearing Carrier Inspection / Removal
294
Bearing Replacement
295
Bearing Carrier Bushing Replacement
295
Bearing Carrier Installation
296
Rear Drive Shaft
297
Drive Shaft Removal
297
Outer CV Joint / Boot Replacement
298
Inner Plunging Joint / Boot Replacement
301
Drive Shaft Exploded View
303
Rear Gearcase
305
Gearcase Removal
305
Gearcase Disassembly
306
Gearcase Assembly
308
Gearcase Installation
309
Gearcase Exploded View
310
Rear Gearcase (Rzr S Int'l)
311
General Operation
311
Gearcase Removal
312
Gearcase Disassembly
313
Differential Disassembly
317
Differential Assembly
318
Gearcase Assembly
319
Gearcase Installation
321
Gearcase Exploded View
322
Wheel Hubs
323
Transmission Chapter 8 Transmission
325
Chapter 8
326
Installation
326
Removal
326
Shift Lever
326
Torque Values / Specifications
326
Shift Cable Inspection / Adjustment
327
Transmission Service
328
Transmission Removal / Service Notes
328
Transfer Case Disassembly
328
Transfer Case Reassembly
331
Transmission Shift Housing Disassembly
335
Transmission Shift Housing Reassembly
340
Troubleshooting
344
Transmission Exploded View
345
Brakes Chapter 9 Brakes
347
Brake Noise Troubleshooting
349
Brake System Service Notes
349
Hydraulic Brake System Operation
350
Brake System Exploded View
351
Chapter 9
351
Rzr / Rzr S / Rzr S Int'l
351
Rzr 4
351
Brake Pedal Lever
352
Master Cylinder
352
Brake Bleeding / Fluid Change
353
Front Brake Pads
354
Pad Removal
354
Pad Inspection
355
Pad Assembly / Installation
355
Brake Burnishing Procedure
356
Front Caliper Service
357
Caliper Exploded View (Rzr / Rzr S / Rzr S Int'l)
357
Caliper Exploded View (Rzr 4)
357
Caliper Removal
358
Caliper Disassembly
359
Caliper Inspection
360
Caliper Assembly
361
Caliper Installation
361
Front Brake Disc
362
Disc Runout
362
Disc Inspection
362
Disc Replacement
363
Rear Brake Pads
364
Pad Removal
364
Pad Inspection
365
Pad Assembly / Installation
365
Brake Burnishing Procedure
365
Rear Caliper Service
366
Caliper Exploded View
366
Caliper Removal
366
Caliper Disassembly
367
Caliper Inspection
367
Caliper Assembly
368
Caliper Installation
368
Rear Brake Disc
370
Disc Inspection
370
Disc Replacement
370
Troubleshooting
371
Brakes Squeal / Poor Brake Performance
371
Pedal Vibration
371
Caliper Overheats (Brakes Drag)
371
Brakes Lock
371
Advertisement
Polaris 2013 RANGER RZR 4 Service Manual (418 pages)
Brand:
Polaris
| Category:
Offroad Vehicle
| Size: 39.29 MB
Table of Contents
General Information Chapter 1 1
6
Table of Contents
6
Chapter 1
7
Engine Designation Number
7
General Information
7
Model Identification
7
Model Information
7
Vehicle and Engine Serial Number Location
7
Vin Identification
7
Special Tools
8
Vehicle Information
8
Publication Numbers
8
Replacement Keys
8
General Specifications
9
Misc. Specifications and Charts
15
Conversion Table
15
Standard Torque Specifications
16
Sae Tap / Drill Sizes
17
Metric Tap / Drill Sizes
17
Glossary of Terms
18
Maintenance Chapter 2 Maintenance 2
20
Break-In Period / Maintenance Chart Key
22
Chapter 2
22
Periodic Maintenance Chart
22
Pre-Ride - 25 Hour Maintenance Interval
23
50 - 500 Hour Maintenance Interval
24
Maintenance Quick Reference
25
Maintenance Quick Reference, Continued
26
Grease Lubrication Points
27
Lubricants / Service Products
28
General Vehicle Inspection and Maintenance
29
Pre-Ride / Daily Inspection
29
Frame, Nuts, Bolts, and Fasteners
29
Shift Cable Inspection / Adjustment
29
Fuel System and Air Intake
30
Fuel Line / Fuel Pump / Fuel Filters / Vent Lines
30
Throttle Pedal Inspection
31
Throttle Freeplay Adjustment
31
Air Filter Service
32
Engine
34
Engine Oil Level
34
Engine Oil and Filter Service
35
Engine Breather Hose Inspection
36
Engine and Transmission Mounts
36
Compression and Leakdown Test
36
Exhaust - Spark Arrestor
36
Transmission and Gearcases
37
Transmission Lubrication
37
Front Gearcase Lubrication
39
Rear Gearcase Lubrication
40
Cooling System
41
Coolant Level Inspection
41
Coolant Strength / Type
41
Cooling System Pressure Test
42
Cooling System Hoses / Radiator
42
Coolant Drain / Radiator Removal
42
Wheel Installation
43
Final Drive / Wheel and Tire
43
Wheel and Hub Torque Table
43
Wheel Removal / Installation
43
Tire Inspection / Pressure
44
Drive Shaft Boot Inspection
44
Electrical and Ignition System
45
Battery Maintenance
45
Battery Removal
45
Battery Installation
46
Battery off Season Storage
46
Battery Charging (Maintenance Free)
46
Spark Plug Service
46
Engine to Frame Ground
47
Steering
47
Steering Inspection / Steering Wheel Freeplay
47
Tie Rod End / Wheel Hub Inspection
48
Wheel Toe Alignment Inspection
48
Wheel Toe Adjustment
49
Suspension (Fox™)
50
Shock Compression Adjustment
51
Suspension (Standard)
50
Spring Preload Adjustment
50
Suspension (Walker Evans™)
52
Spring Preload Adjustment
52
Shock Compression Adjustment
52
Brake System
53
Brake Fluid / Pad / Disc Inspection
53
Brake Hose and Fitting Inspection
53
Brake Fluid Inspection
53
Maintenance Log
54
Chapter 3 Engine
56
Crankcase
57
Engine Specifications
57
Oil Pump / Gears / Engine Cover
58
Stator Cover / Starter / Water Pump / Lubrication System
59
Cylinder / Cylinder Head / Piston
60
Engine Efi Sensors / Valve Cover / General Components
61
Engine Torque Specifications
62
800 EFI Engine Service Specifications
63
Special Tools
65
Engine Cooling System
66
Cooling System Specifications / Pressure Test / Cap Test
66
Cooling System Exploded View
67
Cooling System Bleeding Procedure
68
General Engine Service
69
Engine Lubrication Specifications
69
Accessible Engine Components / Oil Pressure Test
69
Oil Flow Chart
70
Engine Removal
71
Engine / Transmission Separation
78
Engine Disassembly and Inspection
79
Cylinder Head Assembly Exploded View
79
Rocker Arms / Push Rods
80
Cylinder Head Removal
80
Cylinder Head Inspection / Warp
81
Valve Seal / Spring Service (on Engine)
81
Cylinder Head Warp
81
Cylinder Head Disassembly
82
Valve Inspection
83
Combustion Chamber
84
Valve Seat Reconditioning
84
Cylinder Head Reassembly
86
Valve Sealing Test
87
Cylinder Removal
87
Valve Lifter Removal / Inspection
87
Piston Removal
88
Cylinder Inspection
89
Cylinder Hone Selection and Honing Procedure
90
Honing to Deglaze / Cleaning the Cylinder after Honing
90
Piston-To-Cylinder Clearance
91
Piston / Rod Inspection
91
Piston Ring Installed Gap
92
Starter Drive Bendix Removal / Inspection
92
Flywheel / Stator Removal / Inspection
93
Engine Crankcase Disassembly / Inspection
93
Camshaft Inspection
101
Engine Reassembly
102
Crankcase Reassembly
102
Flywheel / Stator Installation
111
Cylinder Head Reassembly
111
Oil Pump Priming
113
Engine Installation
114
Engine Assembly and Installation
114
Engine Break-In Period
115
Troubleshooting
116
Chapter 4 Electronic Fuel Injection
118
Electronic Fuel Injection
119
General Information
119
Special Tools
119
Service Notes
121
Efi System Exploded View
122
Efi System Component Locations
123
Fuel Tank
125
Fuel Lines - Quick Connect
126
Electronic Fuel Injection
126
Principal Components / Efi Operation Overview
126
Initial Priming / Starting Procedure
127
Electronic Control Unit (Ecu)
127
Temp / Manifold Absolute Pressure Sensor (T-Map)
128
Crankshaft Position Sensor (Cps)
129
Cps Test
129
Cps Replacement
130
Fuel Injectors
133
Fuel Injector Service
134
Fuel Injector Replacement
135
Fuel Pump
136
Fuel Sender Test
136
Fuel Pump Test
137
Fuel Pump Replacement
138
Fuel Tank Removal (Rzr / Rzr S)
141
Fuel Tank Removal (Rzr 4)
143
Fuel Tank Installation
145
Idle Air Control (Iac)
146
Throttle Position Sensor (Tps)
147
Tps Replacement
148
Camshaft Phase Sensor
150
Engine Coolant Temperature Sensor (Ect)
151
Overview, Test and Replacement
151
Ignition Coil
152
Efi Diagnostics
153
Instrument Cluster Trouble Code Display
153
Diagnostic Trouble Code Table
153
Efi Troubleshooting
156
Digital Wrench™ Operation
157
Digital Wrench™ Communication Errors
157
Digital Wrench™ - Diagnostic Connector
158
Digital Wrench™ Updates
159
Digital Wrench™ Feature Map
160
Engine Controller Reprogramming (Reflash)
161
Efi System Electrical Operation
165
Chapter 5 Body / Steering / Suspension
166
Special Tools
168
Torque Specifications
168
Cab Frame (Rzr / Rzr S)
169
Cab Frame (Rzr 4)
170
Body Exploded Views
171
Side Safety Nets
171
Dash Instruments / Controls / Glovebox
172
Hood / Front Body Work
173
Seat Assembly
175
Seat Belts / Mounting (Rzr / Rzr S)
175
Seat Belts / Mounting (Rzr 4)
176
Floor / Rocker Panels (Rzr / Rzr S)
177
Floor / Rocker Panels (Rzr 4)
178
Rear Cargo Box / Fenders (Rzr / Rzr S)
179
Rear Cargo Box / Fenders (Rzr 4)
180
Chassis / Main Frame (Rzr / Rzr S)
181
Chassis / Main Frame (Rzr 4)
182
Body Component Removal
183
Seats
183
Rear Service Panel (Rzr / Rzr S)
183
Rear Console Cover (Rzr 4)
183
Front Bumper
183
Rear Bumper
184
Hood and Front Body Work
184
Rear Fender, Flair and Tie down Removal
185
Cargo Box Assembly Removal
185
Rocker Panels, Console and Floor
186
Steering Assembly
187
Exploded View (Non-Eps Models)
187
Steering Wheel Removal (Non-Eps Models)
188
Steering Shaft Removal (Non-Eps Models)
188
Steering Shaft Bearing Replacement
189
Electronic Power Steering Assembly
190
Exploded View (Eps Models)
190
Upper Steering Shaft Removal (Eps Models)
191
Steering Wheel Removal (Eps Models)
192
Power Steering Unit Removal
192
Power Steering Unit Installation
194
Upper Steering Shaft Installation (Eps Models)
195
Front A-Arms
196
Removal / Replacement
196
Exploded View
197
Ball Joint Service
198
Removal
198
Installation
199
Front Stabilizer Bar (Rzr / Rzr S Int'l)
199
Sway Bar Linkage Removal
199
Stabilizer Bar Removal
199
Exploded View
200
Rear A-Arms
201
Removal
201
Installation
202
Exploded View
203
Rear Stabilizer Bar (Rzr)
204
Rear Stabilizer Bar (Rzr S / Rzr 4)
205
Decal Replacement
206
Shocks / Springs / Fasteners
206
Exploded View (Rzr / Rzr S)
206
Exploded View (Rzr S / Rzr S Int'l)
206
Exploded View (Rzr 4)
207
Fox™ Shock Exploded Views
208
Fox™ Podium X 'Piggyback' Shock (Rzr S)
208
Fox™ 2.0 'Piggyback' Shock (Rzr 4)
209
Fox™ Shock Service
210
General Service Information
210
Fox™ Shock Rebuild Information
212
Fox™ Shock Disassembly
213
Fox™ Shock Rebuild
215
Fox™ Shock Reassembly
216
Walker Evans™ Shock Exploded View
219
Walker Evans™ Compression Adjuster Reservoir Shock (Rzr L.e.)
219
Walker Evans™ Shock Service
220
Recommended Service Intervals
220
Walker Evans™ Shock Rebuild Information
221
Special Tools
221
Valve Shim Arrangement
221
Piston Orientation
221
Walker Evans™ Shock Disassembly
222
Walker Evans™ Shock Assembly
224
Clutching Chapter 6 Clutching
228
Chapter 6
229
Drive Clutch Operation
229
General Operation
229
Pvt System Overview
229
Special Tools and Supplies
229
Torque Specifications
229
Driven Clutch Operation
230
Maintenance / Inspection
230
Pvt Break-In (Drive Belt / Clutches)
230
Overheating / Diagnosis
231
Pvt System Service
232
Pvt Covers and Ducting Components
232
Pvt Disassembly
233
Pvt Assembly
234
Clutch Offset Procedure
235
Drive Belt
237
Pvt Break-In (Drive Belt / Clutches)
237
Drive Clutch Service
238
Spring Specifications
238
Shift Weights
239
Drive Clutch Exploded View
239
Clutch Disassembly
240
Spider Removal
240
Roller, Pin, and Thrust Washer Inspection
241
Button to Tower Clearance Inspection
242
Shift Weight Inspection
242
Bearing Inspection
242
Clutch Inspection
243
Moveable Sheave Bushing Inspection
244
Bushing Service
244
Clutch Assembly
246
Driven Clutch Service
248
Exploded View
248
Clutch Disassembly / Inspection
248
Clutch Assembly
250
Troubleshooting
251
Chapter 7 Final Drive
254
Bearing Carrier Inspection / Removal
255
Front Bearing Carrier
255
Special Tools
255
Torque Specifications
255
Bearing Replacement
256
Bearing Carrier Installation
257
Front Drive Shaft
259
Drive Shaft Removal
259
Drive Shaft / CV Joint Handling Tips
260
Outer CV Joint / Boot Replacement
260
Inner Plunging Joint / Boot Replacement
261
Drive Shaft Installation
263
Propshaft Service
264
Removal / Installation (Rzr / Rzr S)
264
Removal / Installation (Rzr 4)
265
Support Bearing Replacement (Rzr 4)
266
Propshaft U-Joint Service
267
Front Gearcase / Centralized Hilliard
269
Centralized Hilliard Exploded View
269
All Wheel Drive Operation
270
Awd Diagnosis
271
Gearcase Removal
272
Gearcase Assembly
275
Gearcase Installation
277
Rear Bearing Carrier
279
Bearing Carrier Inspection / Removal
279
Bearing Replacement
280
Bearing Carrier Bushing Replacement
280
Bearing Carrier Installation
281
Rear Drive Shaft
282
Drive Shaft Removal
282
Outer CV Joint / Boot Replacement
283
Inner Plunging Joint / Boot Replacement
286
Drive Shaft Exploded View
288
Rear Gearcase
290
Gearcase Removal
290
Gearcase Disassembly
291
Gearcase Assembly
293
Gearcase Installation
294
Gearcase Exploded View
295
Rear Gearcase (Rzr S Int'l)
296
General Operation
296
Gearcase Removal
297
Gearcase Disassembly
298
Differential Disassembly
302
Differential Assembly
303
Gearcase Assembly
304
Gearcase Installation
306
Gearcase Exploded View
307
Wheel Hubs
308
Transmission Chapter 8 Transmission
310
Shift Lever
311
Torque Values / Specifications
311
Chapter 8 Shift Cable Inspection / Adjustment
312
Transmission Service
313
Transmission Removal / Service Notes
313
Transfer Case Disassembly
313
Transfer Case Reassembly
316
Transmission Shift Housing Disassembly
318
Transmission Shift Housing Reassembly
322
Troubleshooting
327
Troubleshooting Checklist
327
Transmission Exploded View
328
Polaris 2013 RANGER RZR 4 Owner's Manual (148 pages)
Brand:
Polaris
| Category:
Offroad Vehicle
| Size: 3.84 MB
Table of Contents
Table of Contents
7
Introduction
8
Vehicle Identification Numbers
10
Safety
11
Safe Riding Gear
12
Safety Warnings
14
Protective Apparel
15
Operating on Pavement
17
Operating on Public Roads
17
Operating at Excessive Speeds
17
Improper Hill Climbing
18
Turning Improperly
18
Jumps and Stunts
18
Descending Hills Improperly
19
Crossing Hillsides
19
Stalling While Climbing a Hill
19
Improper Tire Maintenance
20
Operating in Unfamiliar Terrain
20
Operating on Slippery Terrain
20
Skidding or Sliding
21
Improper Cargo Loading
22
Operating a Damaged Vehicle
22
Handling Gasoline
23
Exposure to Exhaust
23
Hot Exhaust Systems
23
Age Warning
27
Features and Controls
32
Component Locations
33
Seat Removal
35
Steering Wheel
36
Fuel Cap
38
Seat Belt Inspection
39
Seat Belts
39
Auxiliary Outlet
40
Headlight Switch
41
Ignition Switch
41
Gear Selector
42
Brake Pedal
43
Throttle Pedal
43
Engaging Awd
44
Instrument Cluster
45
Mode Button
45
Indicator Lamps
46
Rider Information Center
47
Operation
54
Brake System Break-In
55
Safe Operation Practices
57
Starting the Engine
58
Stopping the Engine
58
Parking the Vehicle
59
Trail Etiquette
59
Driving with Passengers
62
Driving on Slippery Surfaces
63
Driving Uphill
64
Driving Downhill
65
Driving through Water
66
Driving over Obstacles
67
Driving in Reverse
68
Parking on an Incline
69
Hauling Cargo
70
Belt Life
71
Towing Loads
71
Crankcase Emission Control System
72
Emission Control Systems
72
Maintenance
73
Severe Use Definition
73
Maintenance Chart Key
74
Periodic Maintenance Chart
74
Lubrication Recommendations
78
Engine Oil
80
Oil Recommendations
80
Oil Check
81
Oil and Filter Change
82
Rear Gearcase
89
Spark Plugs
90
Spark Plug Condition
91
Cooling System
94
Radiator and Cooling Fan
95
Radiator Coolant Level
95
Coolant Level
96
Pvt Drying
98
Air Filter
99
Spark Arrester
100
Throttle Freeplay Inspection
101
Throttle System
101
Throttle Freeplay Adjustment
102
Brake Fluid
104
Brake Inspection
105
Steering Wheel Inspection
105
Suspension Settings
106
Tire Tread Depth
109
Wheel Installation
110
Wheel Removal
110
Headlight Lamp Replacement
111
Headlight High Beam Adjustment
112
Brake Lights
113
Vehicle Immersion
113
Battery Removal
115
Battery Installation
116
Battery Storage
117
Cleaning and Storage
120
Polishing the Vehicle
121
Washing the Vehicle
121
Storage Tips
123
Removal from Storage
125
Transporting the Vehicle
125
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