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Polaris 2013 RANGER RZR S User Manual

Polaris 2013 RANGER RZR S
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GENERAL INFORMATION
1.1
CHAPTER 1
GENERAL INFORMATION
1
9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual
© Copyright 2012 Polaris Sales Inc.
VEHICLE IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
MODEL NUMBER DESIGNATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
ENGINE DESIGNATION NUMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
VEHICLE IDENTIFICATION NUMBER (VIN) DESIGNATION
. . . . . . . . . . . . . . . . . . . . . 1.2
VEHICLE AND ENGINE SERIAL NUMBER LOCATIONS. . . . . . . . . . . . . . . . . . . . . . . .1.3
VEHICLE INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4
PUBLICATION NUMBERS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4
REPLACEMENT KEYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5
GENERAL SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6
GENERAL: 2013 RANGER RZR / EPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.6
DETAILED: 2013 RANGER RZR / EPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.7
GENERAL: 2013 RANGER RZR S / INT’L. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8
DETAILED: 2013 RANGER RZR S / INT’L. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.9
GENERAL: 2013 RANGER RZR 4 / EPS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.10
DETAILED: 2013 RANGER RZR 4 / EPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.11
MISC. SPECIFICATIONS AND CHARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.12
CONVERSION TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.12
STANDARD BOLT TORQUE SPECIFICATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.13
METRIC BOLT TORQUE SPECIFICATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.13
SAE TAP / DRILL SIZES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.14
METRIC TAP / DRILL SIZES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.14
DECIMAL EQUIVALENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.14
PRELIMINARY VERSION

Table of Contents

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Polaris 2013 RANGER RZR S Specifications

General IconGeneral
BrandPolaris
Model2013 RANGER RZR S
CategoryOffroad Vehicle
LanguageEnglish

Summary

GENERAL INFORMATION

VEHICLE IDENTIFICATION

Details on identifying vehicle models, engine designations, and VIN.

VEHICLE INFORMATION

Information regarding publication numbers and replacement keys.

SPECIAL TOOLS

List and description of specialized tools recommended for servicing.

GENERAL SPECIFICATIONS

Key specifications for various RANGER RZR models including dimensions and capacities.

MISC. SPECIFICATIONS AND CHARTS

Includes conversion tables, bolt torque specifications, and tap/drill sizes.

MAINTENANCE

PERIODIC MAINTENANCE CHART

Overview of inspection, adjustment, and lubrication schedules for vehicle components.

GENERAL VEHICLE INSPECTION AND MAINTENANCE

Covers pre-ride inspections, fuel system, air intake, engine, transmission, and cooling systems.

STEERING

Procedures for steering inspection, wheel freeplay, and alignment.

SUSPENSION (STANDARD)

Details on adjusting spring preload for standard suspension components.

BRAKE SYSTEM

Covers brake fluid inspection, pad/disc inspection, and hose/fitting inspection.

ENGINE / COOLING

ENGINE SPECIFICATIONS

Detailed specifications for engine components including exploded views.

SPECIAL TOOLS

List of specialized tools required for engine and cooling system service.

ENGINE COOLING SYSTEM

Information on cooling system specifications, pressure tests, and component locations.

GENERAL ENGINE SERVICE

Covers engine lubrication, oil pressure tests, and accessible engine components.

ENGINE REMOVAL

Step-by-step procedure for removing the engine assembly from the vehicle.

ENGINE / TRANSMISSION SEPARATION

Procedure for separating the engine from the transmission assembly.

ENGINE DISASSEMBLY AND INSPECTION

Detailed instructions for disassembling and inspecting engine components.

ENGINE REASSEMBLY

Procedures for reassembling engine components and the overall engine.

ENGINE INSTALLATION

Procedure for installing the engine assembly back into the vehicle.

TROUBLESHOOTING

Common engine and cooling system problems and their potential causes and remedies.

ELECTRONIC FUEL INJECTION

GENERAL INFORMATION

Overview of EFI system, special tools, and service notes.

FUEL TANK

Exploded view and fuel flow diagram for the fuel tank system.

ELECTRONIC FUEL INJECTION

Details on principal EFI components and system operation.

ELECTRONIC CONTROL UNIT (ECU)

Overview of ECU operation, service, and replacement procedures.

TEMP / MANIFOLD ABSOLUTE PRESSURE SENSOR (T-MAP)

Operation, testing, and replacement of the T-MAP sensor.

CRANKSHAFT POSITION SENSOR (CPS)

Operation, testing, and replacement of the CPS sensor.

FUEL INJECTORS

Overview of fuel injectors, service, testing, and replacement.

FUEL PUMP

Overview of fuel pump operation, fuel sender testing, and fuel pump replacement.

IDLE AIR CONTROL (IAC)

Operation, testing, and replacement of the IAC motor.

THROTTLE POSITION SENSOR (TPS)

Operation, resistance tests, and adjustment of the TPS.

CAMSHAFT PHASE SENSOR

Operation, testing, and replacement of the camshaft phase sensor.

ENGINE COOLANT TEMPERATURE SENSOR (ECT)

Operation, testing, and replacement of the ECT sensor.

IGNITION COIL

Operation, replacement, and testing of the ignition coil.

EFI DIAGNOSTICS

Information on diagnostic trouble codes and EFI system troubleshooting.

DIGITAL WRENCH™ OPERATION

Guide to using the Digital Wrench™ diagnostic software and its features.

BODY / STEERING / SUSPENSION

TORQUE SPECIFICATIONS

List of torque values for various body, steering, and suspension components.

SPECIAL TOOLS

List of special tools required for body, steering, and suspension service.

CAB FRAME (RZR / RZR S)

Procedures for assembly and removal of the cab frame for RZR and RZR S models.

CAB FRAME (RZR 4)

Procedures for assembly and removal of the cab frame for RZR 4 models.

BODY EXPLODED VIEWS

Exploded views of various body components like safety nets and dash assemblies.

BODY COMPONENT REMOVAL

Step-by-step removal procedures for body components like seats and bumpers.

STEERING ASSEMBLY

Details on steering assembly, including exploded views and component removal.

ELECTRONIC POWER STEERING ASSEMBLY

Exploded view and procedures for EPS system removal and installation.

FRONT A-ARMS

Procedures for removal, replacement, and service of front A-arms.

BALL JOINT SERVICE

Procedures for servicing ball joints, including removal and installation.

CLUTCHING

SPECIAL TOOLS AND SUPPLIES

List of specialized tools and supplies required for clutch service.

TORQUE SPECIFICATIONS

Torque values for PVT system fasteners.

HIGH ALTITUDE CLUTCH CHARTS

Clutch settings for RZR models at different altitudes.

PVT SYSTEM OVERVIEW

General operation and description of the Polaris Variable Transmission system.

PVT SYSTEM SERVICE

Procedures for servicing PVT covers, ducting, and disassembly.

DRIVE BELT (NON-EBS)

Procedures for removing, inspecting, and installing the drive belt on non-EBS models.

DRIVE BELT (EBS)

Procedures for removing, inspecting, and installing the drive belt on EBS models.

DRIVE CLUTCH SERVICE

Detailed service procedures for the drive clutch, including disassembly and inspection.

DRIVEN CLUTCH SERVICE (NON-EBS)

Service procedures for the driven clutch on non-EBS models.

DRIVEN CLUTCH SERVICE (EBS)

Service procedures for the driven clutch on EBS models.

TROUBLESHOOTING

Diagnosing and resolving common clutch and PVT system issues.

FINAL DRIVE

SPECIAL TOOLS

List of special tools required for final drive service.

TORQUE SPECIFICATIONS

Torque values for final drive components.

FRONT BEARING CARRIER

Procedures for inspection, removal, replacement, and installation of front bearing carriers.

FRONT DRIVE SHAFT

Procedures for removal, installation, and handling of drive shafts and CV joints.

PROPSHAFT SERVICE

Procedures for removal, installation, and U-joint service of the propshaft.

FRONT GEARCASE / CENTRALIZED HILLIARD

Exploded view and operation of the front gearcase and AWD system.

REAR BEARING CARRIER

Procedures for inspection, removal, replacement, and installation of rear bearing carriers.

REAR DRIVE SHAFT

Procedures for removal, installation, and CV joint/boot replacement of rear drive shafts.

WHEEL HUBS

Exploded views of front and rear wheel hubs.

TRANSMISSION

TORQUE VALUES / SPECIFICATIONS

List of torque values for transmission and transfer case components.

SHIFT LEVER

Procedures for removal and installation of the shift lever.

TRANSMISSION SERVICE

Notes on transmission removal, transfer case disassembly, and reassembly.

TROUBLESHOOTING

Checklist for diagnosing shifting difficulties.

TRANSMISSION EXPLODED VIEW

Exploded view of the shift housing and transfer case components.

BRAKES

GENERAL SPECIFICATIONS

General specifications for front and rear brake systems.

TORQUE SPECIFICATIONS

Torque values for brake system components.

SPECIAL TOOLS

List of special tools for brake system service.

BRAKE SYSTEM SERVICE NOTES

Important notes and tips for servicing the brake system.

HYDRAULIC BRAKE SYSTEM OPERATION

Explanation of how the hydraulic brake system components function.

BRAKE SYSTEM EXPLODED VIEW

Exploded views of the brake system for RZR and RZR 4 models.

MASTER CYLINDER

Procedures for master cylinder removal, installation, and brake fluid service.

BRAKE PEDAL LEVER

Procedures for brake pedal lever removal and installation.

BRAKE BLEEDING / FLUID CHANGE

Procedure for bleeding brake lines and changing brake fluid.

FRONT BRAKE PADS

Procedures for front brake pad removal, inspection, and installation.

FRONT CALIPER SERVICE

Exploded views, removal, disassembly, inspection, assembly, and installation of front calipers.

FRONT BRAKE DISC

Procedures for inspecting and replacing front brake discs.

REAR BRAKE PADS

Procedures for rear brake pad removal, inspection, and installation.

REAR CALIPER SERVICE

Exploded views, removal, disassembly, inspection, assembly, and installation of rear calipers.

REAR BRAKE DISC

Procedures for inspecting and replacing rear brake discs.

TROUBLESHOOTING

Troubleshooting common brake system issues like noise and performance problems.

ELECTRICAL

GENERAL INFORMATION

Includes special tools, service notes, under-dash components, and switches.

SWITCHES / CONTROLS

Details on brake light, headlamp, ignition, AWD, turn signal, and transmission switches.

VEHICLE SPEED SENSOR

Location, testing, and troubleshooting of the vehicle speed sensor.

REAR DIFF SOLENOID (INT’L)

Overview and circuit operation of the rear differential solenoid.

ALL WHEEL DRIVE COIL

Operation overview and diagnosing system failures for the AWD coil.

INSTRUMENT CLUSTER

Overview, rider information display, diagnostic mode, and cluster pinouts.

HEAD LIGHTS (INCANDESCENT)

Procedures for headlight adjustment and bulb replacement.

HEAD LIGHTS (LED)

Procedures for headlight adjustment and replacement of LED headlamps.

TAIL / BRAKE LIGHTS

Procedure for tail and brake light bulb replacement.

COOLING SYSTEM

Break-out diagram, fan control circuit, and coolant temperature sensor information.

EFI DIAGNOSTICS

Information on EFI component testing and diagnostic procedures.

FUEL SENDER

Procedure for testing the fuel sender resistance.

FUSE BOX: FUSES / RELAYS / CIRCUIT BREAKER

Overview and detailed description of the fuse box components.

Relay Operation

Explanation of the function of various relays in the system.

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