Polaris xp 2013 eps Manuals

Polaris xp 2013 eps Manuals

Manuals and User Guides for Polaris xp 2013 eps. We have 1 Polaris xp 2013 eps manual available for free PDF download: Service Manual

Polaris xp 2013 eps Service Manual

Polaris xp 2013 eps Service Manual (476 pages)

Brand: Polaris | Category: Utility Vehicle | Size: 39.45 MB

Table of Contents

General Information Chapter

1
Chapter 2 Maintenance 2

13
- Break-In Period / Maintenance Chart Key
  15
- Periodic Maintenance Chart
  15
- Pre-Ride - 50 Hour Maintenance Interval
  16
- 50 - 500 Hour Maintenance Interval
  17
- Maintenance Quick Reference
  18
- Maintenance Quick Reference, Continued
  19
- Grease Lubrication Points
  20
- Lubricants / Service Products
  21
- General Vehicle Inspection and Maintenance
  22
- Fuel System and Air Intake
  23
- Engine
  30
- Transmission and Front Gearcase
  37
  - Transmission Lubrication
    37
  - Front Gearcase Lubrication
    38
- Cooling System
  40
- Pvt / Final Drive / Wheel and Tire
  43
  - Drive Clutch / Driven Clutch / Belt Service
    43
  - Pvt Intake Pre-Filter Service
    43
  - Pvt Drying
    43
  - Drive Shaft Boot Inspection
    44
  - Wheel and Hub Torque Table
    44
  - Wheel Removal / Installation
    44
  - Tire Inspection
    45
  - Tire Pressure
    45
- Electrical and Ignition System
  46
  - Battery Maintenance
    46
  - Battery Charging / off Season Storage
    46
  - Battery Removal
    46
  - Battery Installation
    47
  - Engine / Chassis Electrical Ground
    48
  - Spark Plug Service
    48
- Steering
  49
  - Steering Inspection
    49
  - Steering Wheel Freeplay
    49
  - Tie Rod End / Wheel Hub Inspection
    50
  - Wheel Toe Alignment Inspection
    50
  - Wheel Toe Adjustment
    51
- Suspension (Fox™)
  52
  - Spring Preload Adjustment
    52
  - Shock Compression Adjustment
    53
- Suspension (Walker Evans™)
  54
  - Spring Preload Adjustment
    54
  - Shock Compression Adjustment
    55
- Brake System
  56
Chapter 3 Engine / Cooling

59
- General Information
  61
- Special Tools / Engine Lubrication Specifications
  61
- Oil Pressure Test
  62
- Engine Oil Flow Chart
  63
- Engine Service Specifications
  64
- Engine Detail - Torque Values / Sequences / Assembly Notes
  66
- Engine Cooling System
  71
- Engine Service
  81
  - Accessible Engine Components
    81
  - Top-End Service (Engine in Chassis)
    81
  - Engine Removal
    81
  - Engine Installation
    85
  - Engine Mounting and Torque Values
    89
  - Engine Break-In Period
    89
  - Engine Lubrication Specifications
    89
- Engine Disassembly / Inspection - Top End
  90
  - Valve Cover Removal
    90
  - Camshaft Removal
    90
  - Camshaft Sprocket Inspection
    92
  - Camshaft / Camshaft Bore Inspection
    92
  - Cylinder Head Removal
    94
  - Cylinder Head Warp Inspection
    94
  - Cylinder Head Disassembly
    95
  - Valve Inspection
    96
  - Combustion Chamber Cleaning
    97
  - Valve Seat Reconditioning
    97
- Engine Disassembly / Inspection - Lower End
  100
  - Stator Cover Removal / Inspection
    100
  - Water Pump Housing Removal
    101
  - Flywheel Removal
    101
  - Starter One-Way Clutch Inspection
    102
  - Starter One-Way Clutch Disassembly
    102
  - Starter One-Way Clutch Assembly
    103
  - Crankcase Disassembly / Inspection
    104
  - Balance Shaft Removal / Inspection
    106
  - Crankshaft Removal / Inspection
    107
  - Crankcase Inspection
    110
  - Cylinder / Piston Removal
    111
  - Cylinder Inspection
    111
  - Piston Disassembly / Inspection
    112
  - Piston Ring Removal
    113
  - Piston Ring to Groove Clearance Inspection
    114
  - Piston Ring Installed Gap
    114
  - Piston-To-Cylinder Clearance
    115
  - Connecting Rod Inspection
    115
- Engine Assembly - Lower End
  117
  - Bearing Selection Identification Letters and Numbers
    117
  - Connecting Rod Bearing Selection
    118
  - Crankshaft Main Bearing Selection
    118
  - Upper Crankcase Preparation
    119
  - Piston Ring Installation
    119
  - Piston / Connecting Rod Assembly
    120
  - Cylinder / Piston Installation
    121
  - Crankshaft Installation
    122
  - Balance Shaft Installation
    124
  - Lower Crankcase Preparation
    125
  - Crankcase Assembly
    125
  - Flywheel Installation
    129
  - Stator Cover Installation
    130
- Engine Assembly - Top End
  131
  - Cylinder Head Assembly
    131
  - Valve Sealing Test
    132
  - Cylinder Head Installation
    132
  - Camshaft Installation / Timing
    133
  - Camshaft Timing - Quick Reference
    137
  - Valve Clearance Adjustment
    138
  - Intake Valve Lash - Shim Selection Matrix
    140
  - Exhaust Valve Lash - Shim Selection Matrix
    141
  - Valve Cover Installation
    142
- Troubleshooting
  143
  - Engine
    143
  - Cooling System
    144
Chapter 4 Electronic Fuel Injection

145
- General Information
  146
- Special Tools
  146
- Efi Service Notes
  148
- Efi System Exploded View
  149
- Efi System Component Locations
  150
- Fuel Tank
  152
  - Fuel Line Removal / Installation
    153
  - Fuel Tank Removal (Rzr Xp)
    154
  - Fuel Tank Installation (Rzr Xp)
    155
  - Fuel Tank Removal (Rzr Xp 4)
    156
  - Fuel Tank Installation (Rzr Xp 4)
    158
- Electronic Fuel Injection
  158
  - Principal Components / Efi Operation Overview
    159
  - Initial Priming / Starting Procedure
    159
- Electronic Control Unit (Ecu)
  160
- Manifold Air Quality Sensor (Maqs)
  161
  - Maqs Test / Replacement
    161
- Crankshaft Position Sensor (Cps)
  162
  - Cps Test
    162
  - Cps Replacement
    163
- Idle Air Control Valve (Iac)
  164
- Engine Coolant Temperature Sensor (Ect)
  165
- Dual Throttle Body Assembly
  167
- Fuel Injectors
  169
  - Fuel Injector Replacement
    171
- Fuel Pump
  174
  - Fuel Sender Test
    174
  - Fuel Pump Test
    175
  - Fuel Pump Replacement
    176
- Ignition Coil
  179
  - Ignition Coil / Ht Lead Replacement
    179
  - Ignition Coil Tests
    179
- Efi Diagnostics
  180
  - Instrument Cluster Trouble Code Display
    180
  - Efi Troubleshooting
    183
- Digital Wrench® Operation
  184
Chapter 5 Body / Steering / Suspension

191
- Special Tools
  193
- Torque Specifications
  193
- Cab Frame (Rzr Xp)
  194
- Cab Frame (Rzr Xp 4)
  196
- Body Exploded Views
  198
- Side Safety Nets (Rzr Xp)
  198
- Side Safety Nets (Rzr Xp 4)
  199
- Dash Instruments / Controls
  200
- Hood / Front Body Work
  201
- Seat Assembly
  202
- Seat Belts / Mounting (Rzr Xp)
  202
- Seat Belts / Mounting (Rzr Xp 4)
  203
- Floor / Rocker Panels (Rzr Xp)
  204
- Floor / Rocker Panels (Rzr Xp 4)
  205
- Rear Cargo Box / Fenders (Rzr Xp)
  206
- Rear Cargo Box / Fenders (Rzr Xp 4)
  207
- Chassis / Main Frame (Rzr Xp)
  208
- Chassis / Main Frame (Rzr Xp 4)
  209
- Front / Rear Bumper
  210
- Body Component Removal
  211
  - Seats / Engine Service Panel
    211
  - Front / Rear Bumper
    211
  - Hood and Front Body Work
    212
  - Rear Fender Flair / Box Side Removal
    213
  - Cargo Box Assembly Removal
    213
  - Rocker Panels, Console and Floor
    214
- Decal Replacement
  215
- Steering Assembly
  216
- Electronic Power Steering Assembly
  219
- Front A-Arms
  226
- Ball Joint Service
  228
  - Ball Joint Removal
    228
  - Ball Joint Installation
    229
- Front Stabilizer Bar (Int'l)
  230
- Rear Radius Rods
  232
- Rear Trailing Arm
  233
- Rear Stabilizer Bar
  236
- Shocks / Springs / Fasteners
  237
  - Front / Rear Shock Exploded View
    237
- Fox™ Shock Exploded Views (Rzr Xp)
  238
  - Fox™ 2.0 'Piggyback' Shock
    238
- Fox™ Shock Service (Rzr Xp)
  239
  - General Service Information
    239
  - Front Shock Service Information
    239
  - Rear Shock Service Information
    240
  - Fox™ Shock Rebuild Information
    241
  - Special Tools
    241
  - Fox™ Shock Disassembly
    241
  - Fox™ Shock Body and Reservoir Service
    243
  - Fox™ Shock Component Rebuild
    244
  - Fox™ Shock Assembly
    245
- Walker Evans™ Shock Exploded Views (Rzr Xp 4)
  249
  - Walker Evans™ 2.0" Front Shock
    249
  - Walker Evans™ 2.5" Rear Shock
    250
- Walker Evans™ Shock Service (Rzr Xp 4)
  251
  - General Service Information
    251
  - Front Shock Service Information
    251
  - Rear Shock Service Information
    252
  - Walker Evans™ Shock Rebuild Information
    253
  - Special Tools
    253
  - Valve Shim Arrangement
    253
  - Piston Orientation
    253
  - Walker Evans™ Shock Disassembly
    254
  - Walker Evans™ Shock Assembly
    257
Clutching (Pvt) Chapter 6 Clutching (Pvt)

261
- 2013 Ranger Rzr Xp 4 900 / Eps / Int'l
  262
- 2013 Ranger Rzr Xp 900 / Eps / Int'l
  262
- Chapter 6
  262
- High Altitude Clutch Charts
  262
- Pvt System Overview
  262
  - General Operation
    262
  - Drive Clutch Operation
    263
  - Driven Clutch Operation
    263
  - Pvt Break-In (Drive Belt / Clutches)
    263
  - Maintenance / Inspection
    263
  - Overheating / Diagnosis
    264
- Special Tools and Supplies
  262
- Torque Specifications
  262
- Pvt System Service
  265
  - Pvt Covers and Ducting Components
    265
  - Pvt Disassembly
    265
  - Pvt Assembly
    267
- Drive Belt
  269
  - Belt Removal
    269
  - Belt Inspection
    269
  - Belt Installation
    270
  - Pvt Break-In (Drive Belt / Clutches)
    270
- Drive Clutch Service
  271
  - Drive Clutch Exploded View
    271
  - Drive Clutch Disassembly / Inspection
    272
  - Drive Clutch Spring Inspection
    273
  - Needle Bearing Inspection
    273
  - Shift Weight Inspection
    273
  - Button to Tower Clearance Inspection
    274
  - Spider Removal
    274
  - Roller, Pin, and Thrust Washer Inspection
    275
  - Clutch Inspection
    275
  - Moveable Sheave Bushing Inspection
    276
  - Bushing Service
    277
  - Drive Clutch Assembly
    279
- Driven Clutch Service
  281
  - Clutch Disassembly
    281
  - Bushing Service
    283
  - Clutch Assembly
    285
  - Exploded View
    288
- Troubleshooting
  289
Final Drive Chapter 7 Final Drive

291
- Bearing Carrier Inspection / Removal
  292
- Chapter 7
  292
- Front Bearing Carrier
  292
- Special Tools
  292
- Torque Specifications
  292
- Bearing Replacement
  293
- Bearing Carrier Installation
  294
- Front Drive Shaft
  296
  - Drive Shaft Removal
    296
  - Drive Shaft Installation
    297
- Propshaft Service
  299
  - Front Propshaft Removal (Rzr Xp)
    299
  - Front Propshaft Removal (Rzr Xp 4)
    300
  - Front Propshaft Installation
    301
  - Rear Propshaft Removal (Rzr Xp)
    301
  - Rear Propshaft Removal (Rzr Xp 4)
    303
  - Rear Propshaft Installation
    304
  - Support Bearing Replacement
    305
- Propshaft U-Joint Service
  306
- Front Gearcase / Centralized Hilliard
  308
  - Centralized Hilliard Exploded View
    308
  - All Wheel Drive Operation
    309
  - Awd Diagnosis
    310
  - Front Gearcase Assembly
    314
  - Front Gearcase Installation
    316
- Rear Bearing Carrier
  317
  - Bearing Carrier Inspection / Removal
    317
  - Bearing Replacement
    319
  - Bearing Carrier Installation
    320
- Rear Drive Shaft
  321
  - Drive Shaft Removal
    321
  - Drive Shaft Installation
    322
- Drive Shaft CV Joint / Boot Replacement
  324
- Wheel Hubs
  329
Transmission Chapter 8 Transmission

331
- Chapter 8
  332
- Lubrication
  332
- Special Tools
  332
- Specifications
  332
- Torque Specifications
  332
- Transmission Mounting and Torque Values
  332
- Shift Lever
  333
- Shift Cable
  334
- Transmission Removal
  335
- Transmission Installation
  338
- Transmission Service
  342
  - Transmission Disassembly
    342
  - Gear / Shaft / Bearing Inspection
    346
  - Snorkel Gear Backlash Procedure
    347
  - Transmission Assembly
    349
- Transmission Service (Int'l)
  353
  - Differential Operation
    353
  - Transmission Disassembly
    354
  - Planetary Differential Disassembly
    358
  - Planetary Differential Bushing Replacement
    359
  - Planetary Differential Assembly
    361
  - Gear / Shaft / Bearing Inspection
    361
  - Snorkel Gear Backlash Procedure
    362
  - Transmission Assembly
    364
- Troubleshooting
  369
- Transmission Exploded View
  370
- Transmission Exploded View (Int'l)
  372
Brakes Chapter 9 Brakes

375
- Brake Noise Troubleshooting
  377
- Brake System Service Notes
  377
- Hydraulic Brake System Operation
  378
- Brake System Exploded View
  379
- Chapter 9
  379
- Rzr Xp
  379
- Rzr Xp 4
  380
- Brake Pedal Lever
  381
- Master Cylinder
  381
- Brake Bleeding / Fluid Change
  382
- Parking Brake (Int'l Model)
  384
- Parking Brake Caliper Service (Int'l Model)
  386
  - Caliper Removal
    386
  - Caliper Disassembly / Inspection
    387
  - New Brake Pad Installation
    387
  - Caliper Installation
    388
- Parking Brake Disc (Int'l Model)
  388
- Front Brake Pads
  389
  - Pad Assembly / Installation
    390
  - Brake Burnishing Procedure
    390
- Front Caliper Service
  391
  - Caliper Removal
    391
  - Caliper Disassembly
    392
  - Caliper Installation
    394
- Front Brake Disc
  395
- Rear Brake Pads (Rzr Xp)
  397
  - Pad Removal
    397
  - Brake Burnishing Procedure
    399
- Rear Brake Pads (Rzr Xp 4)
  400
  - Pad Removal
    400
  - Brake Burnishing Procedure
    402
- Rear Caliper Service (Rzr Xp)
  403
  - Caliper Removal
    403
  - Caliper Disassembly
    404
  - Caliper Installation
    406
- Rear Caliper Service (Rzr Xp 4)
  407
  - Caliper Removal
    407
  - Caliper Disassembly
    408
  - Caliper Inspection
    409
- Rear Brake Disc
  412
- Troubleshooting
  413
Chapter 10 Electrical

415
- Electrical Service Notes
  417
- General Information
  417
- Special Tools
  417
- Under-Dash Components
  417
- Instrument Cluster
  418
  - Overview
    418
  - Rider Information Display
    419
  - Information Display Area
    419
  - Diagnostic Mode
    422
- Switches / Controls
  425
  - Brake Light Switch
    425
  - Headlamp Switch
    425
  - Ignition Key Switch
    426
  - Ignition Key Switch (Int'l)
    426
  - Awd / 2Wd Switch
    427
  - Awd / 2Wd / Turf Switch (Int'l)
    427
  - Turn Signal Switch (Int'l)
    428
  - Hazard Switch (Int'l)
    428
  - Transmission (Gear Position) Switch
    428
  - Parking Brake Switch (Int'l Model)
    429
  - Throttle Release Switch (Trs)
    430
- Rear Diff Solenoid (Int'l)
  432
- All Wheel Drive Coil
  433
- Vehicle Speed Sensor
  433
- Head Lights
  434
  - Headlight Adjustment
    434
  - Headlamp Replacement
    434
  - Headlamp Installation
    435
- Tail / Brake Lights
  435
  - Bulb Replacement
    435
- Cooling System
  436
  - Cooling System Break-Out Diagram
    436
  - Coolant Temperature Sensor
    437
- Efi Diagnostics
  437
- Fuel Sender
  437
- Fuse Box: Fuses / Relays / Circuit Breaker
  438
  - Overview / Operation
    438
  - Fuse Box Detail
    439
  - Relay Operation
    440
- Charging System
  442
  - Current Draw - Key off
    442
  - Charging System "Break Even" Test
    442
  - Charging System Stator (Alternator) Tests
    443
  - Stator (Alternator) Replacement
    443
  - Regulator / Rectifier
    444
  - Charging System Testing Flow Chart
    445
- Battery Service
  446
  - Battery Specifications
    446
  - General Battery Information
    446
  - Battery Testing
    447
  - Ocv - Open Circuit Voltage Test
    447
  - Load Test
    447
  - Battery Conductance Analyzer
    448
  - Charging Procedure
    448
- Starting System
  449
  - Troubleshooting
    449
  - Voltage Drop Test
    449
- Starting System Testing Flow Chart
  451
- Electronic Power Steering (Eps)
  452
- Electrical System Breakouts
  457
  - Awd
    457
  - Vehicle Speed Sensor
    457
  - Cooling Fan
    458
  - Chassis Power
    459
  - Starter-Interlock
    459
  - Key-On Battery Power
    460
  - Lights
    461
  - Charging System
    462

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