Polaris 2013 RANGER RZR Manuals

Polaris 2013 RANGER RZR Manuals

Manuals and User Guides for Polaris 2013 RANGER RZR. We have 2 Polaris 2013 RANGER RZR manuals available for free PDF download: Service Manual, Owner's Manual

Polaris 2013 RANGER RZR Service Manual

Polaris 2013 RANGER RZR Service Manual (430 pages)

Brand: Polaris | Category: Offroad Vehicle | Size: 44.16 MB

Table of Contents

General Information Chapter

1
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
- 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
- Transmission and Gearcases
  33
- 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
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
- General Engine Service
  68
- Engine Disassembly and Inspection
  78
- 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
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
- Electronic Power Steering Assembly
  192
- 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™ Podium Top Fill Shock Service
  224
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
- 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
- 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
Electrical Chapter 10 Electrical

373
- Chapter 10 Under-Dash Components
  375
- General Information
  375
- Switches / Controls
  375
  - Brake Light Switch
    375
  - Headlamp Switch
    376
  - Ignition Key Switch
    376
  - Ignition Key Switch (Int'l)
    377
  - Awd / 2Wd Switch
    377
  - Awd / 2Wd / Turf Switch (Int'l)
    378
  - Turn Signal Switch (Int'l)
    378
  - Transmission (Gear Position) Switch
    379
  - Throttle Release Switch (Trs)
    380
- Rear Diff Solenoid (Int'l)
  382
  - Differential Solenoid Overview
    382
  - Differential Solenoid Circuit Operation
    382
- Vehicle Speed Sensor
  382
  - Speed Sensor Location
    382
  - Speed Sensor Testing
    382
- All Wheel Drive Coil
  383
  - Operation Overview
    383
  - Diagnosing System Failures
    383
- Instrument Cluster
  384
  - Overview
    384
  - Rider Information Display
    385
  - Information Display Area
    385
  - Diagnostic Mode
    388
  - Instrument Cluster Pinouts
    389
  - Instrument Cluster Removal
    389
  - Instrument Cluster Installation
    389
- Head Lights (Incandescent)
  390
  - Headlight Adjustment
    390
  - Headlamp Bulb Replacement
    390
  - Headlamp Housing Removal
    391
  - Headlamp Housing Installation
    391
- Head Lights (Led)
  391
  - Headlight Adjustment
    391
  - Headlamp Replacement
    392
  - Headlamp Installation
    392
- Tail / Brake Lights
  393
  - Bulb Replacement
    393
- Cooling System
  394
- Efi Diagnostics
  395
- Fuel Sender
  395
- Fuse Box: Fuses / Relays / Circuit Breaker
  396
  - Overview / Operation
    396
  - Fuse Box Detail
    397
  - Relay Operation
    398
- Charging System
  400
  - Current Draw - Key off
    400
  - Charging System "Break Even" Test
    400
  - Charging System Alternator Tests
    401
  - Regulator / Rectifier
    402
  - Charging System Testing Flow Chart
    403
- Battery Service
  404
  - Battery Specifications
    404
  - General Battery Information
    404
  - Battery Removal / Installation
    405
  - Battery off Season Storage
    405
  - Battery Testing
    405
  - Ocv - Open Circuit Voltage Test
    405
  - Load Test
    405
  - Battery Conductance Analyzer
    406
  - Charging Procedure
    406
- Starting System
  407
  - Troubleshooting
    407
  - Voltage Drop Test
    407
  - Starter Motor Removal
    407
  - Starter Installation
    408
  - Starter Drive Bendix
    408
  - Starter Solenoid Bench Test
    409
  - Starter Solenoid Operation
    409
- Starting System Testing Flow Chart
  410
- Electronic Power Steering (Eps)
  411
  - Eps Operation
    411
  - Proper Eps System Diagnosing
    411
  - Eps System Breakout
    412
  - Eps Troubleshooting (Using Digital Wrench™)
    415

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Polaris 2013 RANGER RZR Owner's Manual

Polaris 2013 RANGER RZR 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
Specifications
126
POLARIS Products
130
Troubleshooting
131
Warranty
135
Maintenance Log
142
Index
144

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