Polaris RANGER RZR S (2013) Service manual

GENERAL INFORMATION

PRELIMINARY VERSION

CHAPTER 1

GENERAL INFORMATION

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

1.1

9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual

GENERAL INFORMATION

PRELIMINARY VERSION

VEHICLE IDENTIFICATION

Model Number Designation

Example: R13VH76AD

GROUP

1st digit 2/3rd digit 4th digit* 5th digit* 6th digit* 7th digit* 8th digit 9th digit** 10th digit

A = ATV

R = RANGER

* = digits that would transfer to 17 digit VIN and ar ** = 9th digit will be used on color/featured versions o First 3 digits and 9th digit are used in model number only. They are not used with the 17 digit VIN.

MODEL

YEAR

11 12 13

CHASSIS DRIVELINE ENGINE CATEGORY OPTION REGION

C = Sportsman 6x6 D = Sportsman Tour E = Trail Boss F = Sportsman Youth G = Sport H = RANGER 6x6 J = RZR XP K = Sport Youth M = Sportsman N = Trail Blazer P = Phoenix R = RANGER Midsi S = RZR T = Sportsman X2 U = RANGER Ful V = RZR W = Multi-pass RGR X = Multi-pass RZR Z = Sportsman XP

lsize

A = 2x4 Chain B = 2x4 Shaft C = 4x4 AC Drive E = 4x4 Shaft / IRS G = 4x4 Chain rear /  shaft front H = 4x4 Shaft / IRS J = 2x4 Swing arm Manual

N = 4x4 Shaft ADC P = 2x4 / IRS Manual R = 6x6 Shaft / IRS T = 4x4 Shaft / Trailing Arm X = 4x4 Shaft EBS

e used in digits 4-8 respectively

f models (not including the base)

Displacement in cc divided

0 and rounded to two

by 1

digits

(i.e. 50 = 498cc)

- - - - - - - - - - - -

For electric vehicles

08 = 48 Volt 12 = 72 Volt

- - OR - -

5 = 550 6 = 570 7 = 760 8 = 850 9 = 875

E = EPS D = Diesel F = D + E

A = ORV D = Diesel E = EU On-road F = INT’L G = EV L = LSV M = Military S = Scandinavian V = EU On-road

C = Calif.

Engine Designation Number

1204620 RZR800-13...........................................................Twin Cylinder, Liquid Cooled, OHV 4 Stroke, Electric Start

Vehicle Identification Number (VIN) Designation

Example: 4XAVH76A4DB000000

Vehicle Descriptors Vehicle Identifiers

World Mfg. ID

Chassis

Driveline

Engine Size

Engine Modifier

Category

Check Digit

Model Year *

Mfg. Location

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17

4 X A V H 7 6 A 4 D B 0 0 0 0 0 0

* Model Year: A = 2010; B = 2011; C = 2012; D = 2013

Individual Serial No.

1.2

9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual

GENERAL INFORMATION

Figure 1-1

VIN

Engine Serial

Figure 1-2

Number

PRELIMINARY VERSION

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, behin

The engine model and serial number can be found on a decal a

pplied to the side of the engine’s cylinder (see Figure 1-2).

d the left rear fender, near the air box (see Figure 1-1).

9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual

1.3

GENERAL INFORMATION

Key Series Number

KEY COVER P/N 5533534

PRELIMINARY VERSION

VEHICLE INFORMATION

Publication Numbers

Model Model No. Owner’s Manual Parts Manual

2013 RAN

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.

GER RZR R13VH76AC, AD, AN, AS 9924099 9924104

GER RZR EPS R13VH7EAI 9924099 9924104

GER RZR S R13VE76AD, AI, AS, AW 9924099 9924100

GER RZR S INT’L R13VE76FI, FX 9924099 9924101

GER RZR 4 R13XE76AD 9924099 9924106

GER RZR 4 EPS R13XE7EAI 9924099 9924106

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.

Series# Part Number

20 4010278 21 4010278 22 4010321 23 4010321 27 4010321 28 4010321 31 4110141 32 4110148 67 4010278 68 4010278

1.4

9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual

GENERAL INFORMATION

Select “SPX Website - Tools, diagnostics” from

the “Service and Warranty” drop down menu

PRELIMINARY VERSION

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/

1.5

9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual

GENERAL INFORMATION

PRELIMINARY VERSION

GENERAL SPECIFICATIONS

MODEL: 2013 RANGER RZR

MODEL NUMBER: R13VH76AC, AD, AN, AS ENGINE NUMBER: 1204670

Category Dimension / Capacity

Length 103 in. / 261.6 cm

Width 50 in. / 127 cm

Height 69 in. / 175.3 cm

Wheel Base 77 in. / 196 cm

Ground Clearance 10 in. / 25.4 cm

Dry Weight 945 lbs. / 429 kg

Gross Vehicle Weight 1727 lbs. / 783 kg

Front Storage Ca

pacity

Cargo Box Dimension 42 in. x 22 in. / 107 cm x 56 cm

Cargo Box Capacity 300 lbs. / 136 kg

Maximum Weight

pacity (Payload)

Hitch Towing Capacity 1500 lbs. / 680 kg

Hitch Tongue Capacity 150 lbs. / 68 kg

ncludes rider(s), cargo, accessories

25 lbs. / 11.3 kg

740 lbs. / 335.6 kg

and trailer tongue weight)



MODEL: 2013 RANGER RZR EPS

MODEL NUMBER: R13VH7EAI ENGINE NUMBER: 1204670

Category Dimension / Capacity

Length 103 in. / 261.6 cm

Width 50 in. / 127 cm

Height 69 in. / 175.3 cm

Wheel Base 77 in. / 196 cm

Ground Clearance 10 in. / 25.4 cm

Dry Weight 961 lbs. / 436 kg

Gross Vehicle Weight 1727 lbs. / 783 kg

Front Storage Ca

pacity

Cargo Box Dimension 42 in. x 22 in. / 107 cm x 56 cm

Cargo Box Capacity 300 lbs. / 136 kg

Maximum Weight

pacity (Payload)

Hitch Towing Capacity 1500 lbs. / 680 kg

Hitch Tongue Capacity 150 lbs. / 68 kg



25 lbs. / 11.3 kg

740 lbs. / 335.6 kg

ncludes rider(s), cargo, accessories

and trailer tongue weight)

1.6

9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual

GENERAL INFORMATION

PRELIMINARY VERSION

MODEL: 2013 RANGER RZR / EPS

MODEL NUMBER: R13VH76AC, AD, AN, AS MODEL NUMBER: R13VH7EAI ENGINE NUMBER: 1204670

Engine

Platform

Engine Number 1204670 RZR800-13

Engine Displacement 760cc H.O.

Number of Cylinders 2

Bore & Stroke (mm) 80 x 76.5 mm

Compression Ratio 11:1

Compression Pressure 165 - 185 psi

Engine Idle Speed 1250 ± 100 RPM

Engine Max Operating RPM 6600 RPM

Lubrication Pressurized Wet Sump

Oil Requirements PS-4 Plus Synthetic

Oil Capacity 2 qts. / 1.9 liters

Coolant Capacity 4.8 qts. / 4.5 liters

Overheat Warning Instrument Cluster Indicator

Exhaust System

Fuel System Type Bosch M17 EFI

Fuel Delivery Electronic Fuel Pump (in tank)

Fuel Pressure 45 +/- 2 psi (310 +/- 14kPa)

Fuel Filters See Chapter 4

Fuel Capacity / Requirement

Alternator Max Output 500 Watts @ 3000 RPM

Headlights (Halogen) 2 - Halogen: Low 55 W / High 60 W

Headlights (LED)

Tail / Brake 2 - 6 Watts / 2 - 27 Watts

Starting System Electric Start

Ignition System Bosch M17 (ECU Controlled)

Ignition Timing (Variable) 3° - 10° BTDC @

Spark plug / Gap RC7YC3 / .035 in. (0.9 mm)

Battery (RZR)

Battery (RZR EPS)

Instrument Type Multifunction Instrument Cluster

DC Outlet Standard 12 Volt

Relays

Circuit Breaker Fan Motor: 20 Amp

Fuses (Fuse/Relay Box)

Fuses (Power Fuse Holder)

H.O. Domestic Twin

Liquid Cooled, 4-Stroke

Dual Headpipe / Single Silencer

Fuel System

7.25 gal. (27.4 liters)

87 Octane (minimum)

Electrical

2 - Dual Beam LED:

27 Watts; High 40 Watts

Low

Yuasa YTX20HL /

8 Amp Hr. / 310 CCA / 12 Volt

Deka ETX30L / 30 AH

365 CCA / 12 Volt

Chassis / EFI / Fan

Pump / EPS

Fuel

Drive / Fuel Pump: 10 Amp

ghts / EFI / Accessory: 20 Amp

EFI: 20 Amp

Chassis / EPS: 30 Amp

1200 RPM



Cylinder,

Drivetrain

Transmission Type Polaris Automatic PVT

Drive Ratio - Front 3.82:1

Drive Ratio - Final 3.70:1

Shift Type In Line Shift - H / L / N / R / P

Front Gearcase

Fluid Type / Capacity

Transmission: Main Gearcase

Fluid Type / Capacity

Transmission: Transfer Case

Fluid Type / Capacity

Rear Gearcase

Fluid Type / Capacity

Clutch Type (Standard Model) Standard PVT

Clutch Type (EPS Model) PVT with EBS

Drive Belt 3211113

Steering / Suspension

Front Suspension

Front Travel 9 in. / 23 cm

Rear Suspension Rolled IRS w/Anti-Sway Bar

Rear Travel 9.5 in. / 24 cm

Shock Preload Adjustment

Front / Rear

Toe Out 1/8 - 1/4 in. (3 - 6.4 mm)

Wheels / Brakes

Front Wheel Type / Size

Rear Wheel Type / Size

Front Tire Type / Size

Rear Tire Type / Size

Tire Air Pressure - Front / Rear 8 psi (55 kPa)

Brake - Front / Rear

Brake Fluid DOT 4

Polaris Demand Drive Plus

6.75 oz. (200 ml)

Polaris AGL Plus

24 oz. (710 ml)

Polaris AGL Plus

14 oz. (414 ml)

Polaris Premium ADF

26 oz. (769 ml)

Independent Dual A-arm

w/Anti-Sway Bar

Cam Adjustment

Steel / 12 x 6

Aluminum / 12 x 6

Steel / 12 x 8

Aluminum / 12 x 8

Ancla / 25 x 8 R12

Maxxis / 25 x 8 R12

Ancla / 25 x 10 R12

Maxxis / 25 x 10 R12

Foot Actuated - 4 Wheel

Hydraulic Disc

CLUTCH CHART (All Non-EPS Models)

Drive

Spring

Green

(7043789)

Green

(7043789)

Meters

(Feet)

Altitude

0-1500

(0-5

1500-3700

00 - 12000)

(50

000)

Shift

ight

23-62

(5632337)

23-58 (B)

(1322911)

CLUTCH CHART (EPS Model with EBS)

Meters

(Feet)

Altitude

0-1500

(0-5

1500-3700

00 - 12000)

(50

000)

Shift

Weight

23-66

(5632763)

23-62

(5632337)

Drive

Spring

Green

(7043789)

Green

(7043789)

Driven Spring

Blk / Almond

(7043167)

Blk / Almond

(7043167)

Driven Spring

Red

(3234452)

Red

(3234452)

1.7

9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual

GENERAL INFORMATION

PRELIMINARY VERSION

MODEL: 2013 RANGER RZR S

MODEL NUMBER: R13VE76AD, AI, AS, AW ENGINE NUMBER: 1204670

Category Dimension / Capacity

Length 104 in. / 264.2 cm

Width 60.5 in. / 154 cm

Height 70.5 in. / 179 cm

Wheel Base 77 in. / 196 cm

Ground Clearance 12.5 in. / 32 cm

Dry Weight 1000 lbs. / 454 kg

Gross Vehicle Weight 1782 lbs. / 808 kg

Front Storage Ca

pacity

Cargo Box Dimension 42 in. x 22 in. / 107 cm x 56 cm

Cargo Box Capacity 300 lbs. / 136 kg

Maximum Weight

pacity (Payload)

Hitch Towing Capacity 1500 lbs. / 680 kg

Hitch Tongue Capacity 150 lbs. / 68 kg

Includes rider(s), cargo, accessories

(

25 lbs. / 11.3 kg

740 lbs. / 335.6 kg

and trailer tongue weight)

MODEL: 2013 RANGER RZR S INT’L

MODEL NUMBER: R13VE76FI, FX ENGINE NUMBER: 1204670

Category Dimension / Capacity

Length 104 in. / 264.2 cm

Width 60.5 in. / 154 cm

Height 70.5 in. / 179 cm

Wheel Base 77 in. / 196 cm

Ground Clearance 12.5 in. / 32 cm

Dry Weight 1016 lbs. / 461 kg

Gross Vehicle Weight 1782 lbs. / 808 kg

Front Storage Ca

pacity

Cargo Box Dimension 42 in. x 22 in. / 107 cm x 56 cm

Cargo Box Capacity 300 lbs. / 136 kg

Maximum Weight

pacity (Payload)

Hitch Towing Capacity 1500 lbs. / 680 kg

Hitch Tongue Capacity 150 lbs. / 68 kg

Includes rider(s), cargo, accessories

(



25 lbs. / 11.3 kg

740 lbs. / 335.6 kg

and trailer tongue weight)

1.8

9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual

GENERAL INFORMATION

PRELIMINARY VERSION

MODEL: 2013 RANGER RZR S / INT’L

MODEL NUMBER: R13VE76AD, AI, AS, AW MODEL NUMBER: R13VE76FI, FX ENGINE NUMBER: 1204670

Engine

Platform

Engine Number 1204670 RZR800-13

Engine Displacement 760cc H.O.

Number of Cylinders 2

Bore & Stroke (mm) 80 x 76.5 mm

Compression Ratio 11:1

Compression Pressure 165 - 185 psi

Engine Idle Speed 1250 ± 100 RPM

Engine Max Operating RPM 6750 RPM

Lubrication Pressurized Wet Sump

Oil Requirements PS-4 Plus Synthetic

Oil Capacity 2 qts. / 1.9 liters

Coolant Capacity 4.8 qts. / 4.5 liters

Overheat Warning Instrument Cluster Indicator

Exhaust System

Fuel System Type Bosch M17 EFI

Fuel Delivery Electronic Fuel Pump (in tank)

Fuel Pressure 45 +/- 2 psi (310 +/- 14kPa)

Fuel Filters See Chapter 4

Fuel Capacity / Requirement

Alternator Max Output 500 Watts @ 3000 RPM

Headlights (Halogen) 2 - Halogen: Low 55 W / High 60 W

Headlights (LED)

Tail / Brake 2 - 6 Watts / 2 - 27 Watts

Starting System Electric Start

Ignition System Bosch M17 (ECU Controlled)

Ignition Timing (Variable) 3° - 10° BTDC @

Spark plug / Gap RC7YC3 / .035 in. (0.9 mm)

Battery

Instrument Type Multifunction Instrument Cluster

DC Outlet Standard 12 Volt

Relays

Circuit Breaker Fan Motor: 20 Amp

Fuses (Fuse/Relay Box)

Fuses (Power Fuse Holder)

H.O. Domestic Twin

Liquid Cooled, 4-Stroke

Dual Headpipe / Single Silencer

Fuel System

7.25 gal. (27.4 liters)

87 Octane (minimum)

Electrical

2 - Dual Beam LED:

27 Watts; High 40 Watts

Low

Yuasa YTX20HL /

8 Amp Hr. / 310 CCA / 12 Volt

Chassis / EFI / Fan

Fue

Drive / Fuel Pump: 10 Amp

ghts / EFI / Accessory: 20 Amp

EFI: 20 Amp

assis: 30 Amp



1200 RPM

l Pump

Cylinder,

Drivetrain

Transmission Type Polaris Automatic PVT

Drive Ratio - Front 3.82:1

Drive Ratio - Final 3.70:1

Shift Type In Line Shift - H / L / N / R / P

Front Gearcase

Fluid Type / Capacity

Transmission: Main Gearcase

Fluid Type / Capacity

Transmission: Transfer Case

Fluid Type / Capacity

Rear Gearcase

Fluid Type / Capacity

Rear Gearcase (INT’L)

Fluid Type / Capacity

Clutch Type Standard PVT

Drive Belt 3211133

Steering / Suspension

Front Suspension / Shock

Front Travel 12 in. / 30.5 cm

Rear Suspension / Shock

Rear Travel 12 in. / 30.5 cm

Shock Preload Adjustment

Front / Rear

Toe Out 1/8 - 1/4 in. (3 - 6.4 mm)

Wheels / Brakes

Front Wheel Type / Size Aluminum / 12 x 6

Rear Wheel Type / Size Aluminum / 12 x 8

Front Tire Type / Size

Rear Tire Type / Size

Tire Air Pressure - Front / Rear 8 psi (55 kPa)

Brake - Front / Rear

Brake Fluid DOT 4

Polaris Demand Drive Plus

6.75 oz. (200 ml)

Polaris AGL Plus

24 oz. (710 ml)

Polaris AGL Plus

14 oz. (414 ml)

Polaris Premium ADF

26 oz. (769 ml)

Polaris Premium ADF

22 oz. (650 ml)

Independent Dual A-arm

Standard: Monotube

FOX™: PODIUM

Rolled IRS w/Anti-Sway Bar

Standard: Monotube

FOX™: PODIUM

Standard: Cam Adjustment

FOX™: Threaded Spanner

Wrench Adjustment

ITP “900XCT” / 27 x 9 R12

Maxxis Bighorn / 26 x 9 R12

ITP “900XCT” / 27 x 11 R12

Maxxis Bighorn / 26 x 12 R12

Foot Actuated - 4 Wheel

Hydraulic Disc

CLUTCH CHART

Meters

(Feet)

Altitude

0-1500

(0-5

1500-3700

(50

00 - 12000)

000)

Shift

Weight

23-62

(5632337)

23-58 (B)

(1322911)

Drive

Spring

Green

(7043789)

Green

(7043789)

Driven Spring

Blk / Almond

(7043167)

Blk / Almond

(7043167)

1.9

9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual

GENERAL INFORMATION

PRELIMINARY VERSION

MODEL: 2013 RANGER RZR 4

MODEL NUMBER: R13XE76AD ENGINE NUMBER: 1204671

Category Dimension / Capacity

Length 130 in. / 330 cm

Width 60.5 in. / 154 cm

Height 75 in. / 190.5 cm

Wheel Base 103 in. / 262 cm

Ground Clearance 11.5 in. / 29 cm

Dry Weight 1255 lbs. / 569 kg

Gross Vehicle Weight 2206 lbs. / 1000 kg

Front Storage Ca

pacity

Cargo Box Dimension 42 in. x 22 in. / 107 cm x 56 cm

Cargo Box Capacity 300 lbs. / 136 kg

Maximum Weight

pacity (Payload)

Hitch Towing Capacity 1500 lbs. / 680 kg

Hitch Tongue Capacity 150 lbs. / 68 kg

Includes rider(s), cargo, accessories

(

25 lbs. / 11.3 kg

900 lbs. / 408 kg

and trailer tongue weight)

MODEL: 2013 RANGER RZR 4 EPS

MODEL NUMBER: R13XE7EAI ENGINE NUMBER: 1204671

Category Dimension / Capacity

Length 130 in. / 330 cm

Width 60.5 in. / 154 cm

Height 75 in. / 190.5 cm

Wheel Base 103 in. / 262 cm

Ground Clearance 11.5 in. / 29 cm

Dry Weight 1271 lbs. / 577 kg

Gross Vehicle Weight 2206 lbs. / 1000 kg

Front Storage Ca

pacity

Cargo Box Dimension 42 in. x 22 in. / 107 cm x 56 cm

Cargo Box Capacity 300 lbs. / 136 kg

Maximum Weight

pacity (Payload)

Hitch Towing Capacity 1500 lbs. / 680 kg

Hitch Tongue Capacity 150 lbs. / 68 kg

(



25 lbs. / 11.3 kg

900 lbs. / 408 kg

Includes rider(s), cargo, accessories

and trailer tongue weight)

1.10

9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual

GENERAL INFORMATION

PRELIMINARY VERSION

MODEL: 2013 RANGER RZR 4 / EPS

MODEL NUMBER: R13XE76AD MODEL NUMBER: R13XE7EAI ENGINE NUMBER: 1204671

Engine

Platform

Engine Number 1204671 RZR800-13

Engine Displacement 760cc H.O.

Number of Cylinders 2

Bore & Stroke (mm) 80 x 76.5 mm

Compression Ratio 11:1

Compression Pressure 165 - 185 psi

Engine Idle Speed 1250 ± 100 RPM

Engine Max Operating RPM 6750 RPM

Lubrication Pressurized Wet Sump

Oil Requirements PS-4 Plus Synthetic

Oil Capacity 2 qts. / 1.9 liters

Coolant Capacity 5.5 qts. / 5.2 liters

Overheat Warning Instrument Cluster Indicator

Exhaust System

Fuel System

Fuel System Type Bosch M17 EFI

Fuel Delivery Electronic Fuel Pump (in tank)

Fuel Pressure 45 +/- 2 psi (310 +/- 14kPa)

Fuel Filters See Chapter 4

Fuel Capacity / Requirement

Electrical

Alternator Max Output 500 Watts @ 3000 RPM

Headlights (Halogen) 2 - Halogen: Low 55 W / High 60 W

Headlights (LED)

Tail / Brake 2 - 6 Watts / 2 - 27 Watts

Starting System Electric Start

Ignition System Bosch M17 (ECU Controlled)

Ignition Timing (Variable) 3° - 10° BTDC @

Spark plug / Gap RC7YC3 / .035 in. (0.9 mm)

Battery

Instrument Type Multifunction Instrument Cluster

DC Outlets (2) Standard 12 Volt

Relays

Circuit Breaker Fan Motor: 20 Amp

Fuses (Fuse/Relay Box)

Fuses (Power Fuse Holder)



H.O. Domestic Twin

Liquid Cooled, 4-Stroke

Dual Headpipe / Single Silencer

7.25 gal. (27.4 liters)

87 Octane (minimum)

2 - Dual Beam LED:

27 Watts; High 40 Watts

Low

1200 RPM

Deka ETX30L / 30 AH

5 CCA / 12 Volt

Chassis / EFI / Fan

Pump / EPS

Fuel

Drive / Fuel Pump: 10 Amp

ghts / EFI / Accessory: 20 Amp

EFI: 20 Amp

hassis / EPS: 30 Amp

Cylinder,

Drivetrain

Transmission Type Polaris Automatic PVT

Drive Ratio - Front 3.82:1

Drive Ratio - Final 3.70:1

Shift Type In Line Shift - H / L / N / R / P

Front Gearcase

Fluid Type / Capacity

Transmission: Main Gearcase

Fluid Type / Capacity

Transmission: Transfer Case

Fluid Type / Capacity

Rear Gearcase

Fluid Type / Capacity

Clutch Type Standard PVT

Drive Belt 3211133

Steering / Suspension

Front Suspension / Shock

Front Travel 12 in. / 30.5 cm

Rear Suspension / Shock

Rear Travel 12 in. / 30.5 cm

Shock Preload Adjustment

Front / Rear

Toe Out 1/8 - 1/4 in. (3 - 6.4 mm)

Wheels / Brakes

Front Wheel Type / Size Aluminum / 12 x 6

Rear Wheel Type / Size Aluminum / 12 x 8

Front Tire Type / Size

Rear Tire Type / Size

Tire Air Pressure

Brake - Front / Rear

Brake Fluid DOT 4

Polaris Demand Drive Plus

6.75 oz. (200 ml)

Polaris AGL Plus

24 oz. (710 ml)

Polaris AGL Plus

14 oz. (414 ml)

Polaris Premium ADF

26 oz. (769 ml)

Independent Dual A-arm

FOX™ 2.0 PODIUM Top Fill

FOX™ 2.0 PODIUM Piggyback

Rolled IRS w/Anti-Sway Bar

FOX™ 2.0 PODIUM Top Fill

FOX™ 2.0 PODIUM Piggyback

Threaded Spanner Wrench

Adjustment

ITP “900XCT” / 27 x 9 R12

Maxxis Bighorn / 26 x 9 R12

ITP “900XCT” / 27 x 11 R12

Maxxis Bighorn / 26 x 12 R12

Front: 10 psi (69 kPa) Rear: 12 psi (83 kPa)

Foot Actuated - 4 Wheel

Hydraulic Disc

CLUTCH CHART

Meters

(Feet)

Altitude

0-1500

(0-5

1500-3700

(50

00 - 12000)

000)

Shift

Weight

23-62

(5632337)

23-58 (B)

(1322911)

Drive

Spring

Green

(7043789)

Green

(7043789)

Driven Spring

Blk / Almond

(7043167)

Blk / Almond

(7043167)

1.11

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GENERAL INFORMATION

PRELIMINARY VERSION

MISC. SPECIFICATIONS AND CHARTS

Conversion Table

°C to °F: °C x 9/5 + 32 = °F °F to °C: °F - 32 x 5/9 = °C

1.12

9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual

Standard Bolt Torque Specification

Grade 2

Grade 5

Grade 8

PRELIMINARY VERSION

GENERAL INFORMATION

Bolt Size

1/4-20 5 (7) 8 (11) 12 (16)

1/4-28 6 (8) 10 (14) 14 (19)

5/16-18 11 (1 5) 17 (23) 25 (35)

5/16-24 12 (16) 19 (26) 29 (40)

3/8-16 20 (27) 30 (40) 45 (62)

3/8-24 23 (32) 35 (48) 50 (69)

7/16-14 30 (40) 50 (69) 70 (97)

7/16-20 35 (48) 55 (76) 80 (110)

1/2-13 50 (69) 75 (104) 110 (152)

1/2-20 55 (76) 90 (124) 120 (166)

Grade 2

-lbs (Nm)

Grade 5

ft-lbs (Nm)

Grade 8

ft-lbs (Nm)

Metric Bolt Torque Specification

Grade

Bolt Size

M3 .3 (.5) .5 (.7) 1 (1.3) 1.5 (2) 1.5 (2)

M4 .8 (1.1) 1 (1.5) 2 (3) 3 (4.5) 4 (5)

M5 1.5 (2.5) 2 (3) 4.5 (6) 6.5 (9) 7.5 (10)

M6 3 (4) 4 (5.5) 7.5 (10) 11 (15 ) 13 (18)

M8 7 (9.5) 10 (13) 18 (25) 26 (35) 33 (45)

M10 14 (19) 18 (25) 37 (50) 55 (75) 63 (85)

M12 26 (35) 33 (45) 63 (85) 97 (130) 11 (150)

M14 37 (50) 55 (75) 103 (140) 151 (205) 177 (240)

M16 59 (80) 85 (115) 159 (215) 232 (315) 273 (370)

M18 81 (110) 118 (160) 225 (305) 321 (435) 376 (510)

4.6 4.8 8.8 / 8.9 10.9 12.9

ft-lbs (Nm) Dry Threads

1.13

9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual

GENERAL INFORMATION

PRELIMINARY VERSION

SAE Tap / Drill Sizes

Decimal Equivalents

Metric Tap / Drill Sizes

1.14

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MAINTENANCE

PRELIMINARY VERSION

CHAPTER 2

MAINTENANCE

PERIODIC MAINTENANCE CHART. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3

BREAK-IN PERIOD / MAINTENANCE CHART KEY . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3

PRE-RIDE - 50 HOUR MAINTENANCE INTERVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4

100 - 300 HOUR MAINTENANCE INTERVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5

MAINTENANCE QUICK REFERENCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6

MAINTENANCE QUICK REFERENCE, CONTINUED..... . . . . . . . . . . . . . . . . . . . . . . . . 2.7

GREASE LUBRICATION POINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.8

LUBRICANTS / SERVICE PRODUCTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.9

GENERAL VEHICLE INSPECTION AND MAINTENANCE. . . . . . . . . . . . . . . . . . . . . . . 2.10

PRE-RIDE / DAILY INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.10

FRAME, NUTS, BOLTS, AND FASTENERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.10

SHIFT CABLE INSPECTION / ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.10

FUEL SYSTEM AND AIR INTAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.11

FUEL LINE / FUEL PUMP / FUEL FILTERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.11

VENT LINES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.11

THROTTLE PEDAL INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.12

THROTTLE FREEPLAY ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.12

AIR FILTER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.13

ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.15

ENGINE OIL LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.15

ENGINE OIL AND FILTER SERVICE. . . . . . . . . . . . . . .

ENGINE BREATHER HOSE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.17

ENGINE AND TRANSMISSION MOUNTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.17

COMPRESSION AND LEAKDOWN TEST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.17

EXHAUST - SPARK ARRESTOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.18

TRANSMISSION AND GEARCASES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.19

TRANSMISSION / GEARCASE SPECIFICATION CHART . . . . . . . . . . . . . . . . . . . . . . 2.19

TRANSMISSION LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.19

FRONT GEARCASE LUBRICATION . . . . . . . . . . . . . . .

REAR GEARCASE LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.23

COOLING SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.25

COOLING SYSTEM OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.25

COOLANT LEVEL INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.25

COOLANT STRENGTH / TYPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.26

COOLING SYSTEM PRESSURE TEST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.26

COOLING SYSTEM HOSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.26

RADIATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.27

COOLANT DRAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.27

FINAL DRIVE / WHEEL AND TIRE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.28

WHEEL AND HUB TORQUE TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.28

WHEEL REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.28

WHEEL INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.28

TIRE INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.29

TIRE PRESSURE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.29

DRIVE SHAFT BOOT INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.29

ELECTRICAL AND IGNITION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.30

BATTERY MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.30

BATTERY REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.30

BATTERY INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.31

BATTERY OFF SEASON STORAGE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.31

BATTERY CHARGING (MAINTENANCE FREE). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.31

SPARK PLUG SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.31

ENGINE TO FRAME GROUND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.32

. . . . . . . . . . . . . . . . . . . . . . . . 2.16

. . . . . . . . . . . . . . . . . . . . . . . . 2.22

2.1

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MAINTENANCE

PRELIMINARY VERSION

STEERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.33

STEERING INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.33

STEERING WHEEL FREEPLAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.33

TIE ROD END / WHEEL HUB INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.33

WHEEL TOE ALIGNMENT INSPECTION

WHEEL TOE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.34

SUSPENSION (STANDARD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.35

SPRING PRELOAD ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.35

SUSPENSION (FOX™). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.36

SPRING PRELOAD ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.36

SHOCK COMPRESSION ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.37

BRAKE SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.38

BRAKE FLUID INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.38

BRAKE PAD / DISC INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.38

BRAKE HOSE AND FITTING INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.38

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.34

2.2

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MAINTENANCE

WARNING

PRELIMINARY VERSION

PERIODIC MAINTENANCE CHART

Periodic Maintenance Overview

Inspection, adjustment and lubrication of important components are explained in the periodic maintenance chart.

Inspect, clean, lubricate, adjust and replace p use genuine Pure Polaris parts available from your Polaris dealer.

NOTE: Service and adjustments are critical. If you’re no procedures, have a qualified dealer perform these operations.

Maintenance intervals in the following chart are based upon aver approximately 10 miles per hour. Vehicles subjected to severe use must be inspected and serviced more frequently.

Severe Use Definition

• Frequent immersion in mud, water or sand

• Racing or race-style high RPM use

• Prolonged low speed, heavy load operation

• Extended idle

• Short trip cold we

Pay special attention to the oil level. A rise in oil level during cold weather can indicate contaminants collecting in the oil sump or crankcase. Change oil immediately if the oil level begins to rise. Monitor the oil level, and if it continues to rise, discontinue use and determine the cause or see your dealer.

ather operation

arts as necessary. When inspection reveals the need for replacement parts,

t familiar with safe service and adjustment

age riding conditions and an average vehicle speed of

Break-In Period

The break-in period consists of the first 25 hours of operation, or the time it takes to use 14 gallons (53 liters) of fuel. Careful treatment of a new engine and drive components will result in more efficient performance and longer life for these components.

• Drive vehicle slowly at first while varying the throttle position. Do not operate at sustained idle.

• Pull only light loads.

• Perform regular checks on fluid levels and other areas outlined on the daily pre-ride inspection checklist.

• Change both the engine oil and filter after 25 hours or one month.

• See “Owner’s Manual” for additional break-in information.

Maintenance Chart Key

The following symbols denote potential items to be aware of during maintenance:

 = CAUTION: Due to the nature of these adjustments, it is recommended this service be performed by an authorized Polaris dealer.



= 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.

Improperly performing the procedures marked could result in component failure and lead to serious injury or death.



Have an authorized Polaris dealer perform these services.

2.3

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MAINTENANCE

PRELIMINARY VERSION

Pre-Ride - 50 Hour Maintenance Interval

Maintenance Interval

Item

Hours Calendar

 Steering - Pre-Ride -

 Front / Rear Suspension - Pre-Ride -

Tires - Pre-Ride -

 Brake Fluid Level - Pre-Ride -

 Brake Pedal Travel - Pre-Ride -

Brake Systems - Pre-Ride -

Wheels / Fasteners - Pre-Ride -

Frame Fasteners - Pre-Ride -



Engine Oil Level - Pre-Ride -



Air Filter - Pre-Ride - Inspect; replace as needed

Coolant Level - Daily - Check level daily, change coolant every 2 years

Head Lamp / Tail Lamp - Daily -



Air Filter - Weekly - Inspect; replace as needed



Brake Pad Wear 10 H Monthly 100 (160) Inspect periodically



Battery 25 H Monthly 250 (400) Check terminals; clean;

EEngine Breather Filter

(if equipped)

EEngine Oil Change 

(Break-In Period)

Front Gearcase Oil 



(Demand Drive Plus)

Rear Gearcase Oil 



(ATV Angle Drive Fluid)

Transmission - Main



(AGL Gearcase Lubricant)

Transmission - Transfer



(AGL Gearcase Lubricant)

 General Lubrication 50 H 3 M 500 (800) Lubricate all fittings, pivots, cables, etc.

Shift Linkage 50 H 6 M 500 (800) Inspect, lubricate, adjust

 Steering 50 H 6 M 500 (800) Lubricate

 Front / Rear Suspension 50 H 6 M 500 (800) Lubricate



Throttle Cable / Throttle Pedal 50 H 6 M 500 (800) Inspect; adjust; lubricate; replace if necessary

Throttle Body Air Intake Ducts

nge

/ Fla

Cooling System 50 H 6 M 500 (800)

25 H Monthly 250 (400) Inspect; replace if necessary

25 H 1 M 250 (400)

50 H 6 M 500 (800) Inspect ducts for proper sealing / air leaks

(whichever comes first)

Miles

(KM)

Remarks

Make adjustments as needed.  See Pre-Ride Checklist on Page 2.10.

Check operation; apply dielectric grease if

placing

test

Perform a break-in oil change after the first 25 hours or one month of operation

Initial fluid level inspection; add lubricant if needed

Initial fluid level inspection; add lubricant if

eeded

Inspect coolant strength se test system yearly

asonally; pressure

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.

2.4

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MAINTENANCE

PRELIMINARY VERSION

100 - 300 Hour Maintenance Interval

Maintenance Interval

(whichever comes first)

Item

Hours Calendar

EEngine Oil and

Oil Filter Change

Front Gearcase Oil 



(Demand Drive Plus)

Rear Gearcase Oil 



(ATV Angle Drive Fluid)

Transmission - Main



(AGL Gearcase Lubricant)

Transmission - Transfer



(AGL Gearcase Lubricant)



Fuel System 100 H 12 M 1000 (1600)



Spark Plug 100 H 12 M 1000 (1600) Inspect; replace as needed

Drive Belt 100 H 12 M 1000 (1600) Inspect; replace as needed

 Radiator 100 H 12 M 1000 (1600) Inspect; clean external surfaces

 Cooling Hoses 100 H 12 M 1000 (1600) Inspect for leaks

 Engine Assembly Mounts 100 H 12 M 1000 (1600) Inspect, torque to specification

Exhaust Muffler / Pipe 100 H 12 M 1000 (1600) Inspect

 Wiring 100 H 12 M 1000 (1600)

 Clutches (Drive and Driven) 100 H 12 M 1000 (1600) Inspect; clean; replace worn parts

 Front Wheel Bearings 100 H 12 M 1000 (1600) Inspect; replace as needed

 Shocks 100 H - - Visually inspect shock seals



Shocks - 12 M 1500 (2400) Change shock oil and inspect seals



 Brake Fluid 200 H 24 M 2000 (3200) Change every two years (DOT 4)

Spark Arrestor 300 H 36 M 3000 (4800) Clean out

Toe Adjustment -



Headlight Aim - Adjust as needed

 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.

100 H 6 M 1000 (1600)

100 H 12 M 1000 (1600) Change lubricant

Miles

(KM)

Perform a break-in oil change at 25 hours or one month / always replace oil filter when changing engine oil

Check for leaks at fill cap, fuel line / rail, and fuel pump. Replace lines every two years.

Inspect for wear, routing, security; apply diel

ectric grease to connectors subjected to

water, mud, etc.

Inspect periodically; adjust when parts are r

eplaced

Remarks

2.5

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MAINTENANCE

PRELIMINARY VERSION

Maintenance Quick Reference

III. # Item Lube Rec. Method Frequency*

Change after 1st month or first

5 hours of operation, 100 hours

thereafter; Change more often

(25 hours) in severe duty

conditions or short trip cold

weather operation

1 Engine Oil

Polaris PS-4 Plus

Per

formance Synthetic

4-Cycle Engine Oil

Add oil to proper level on

stick

dip

2 Engine Coolant Polaris 60/40 Coolant

3 Brake Fluid Polaris DOT 4 Brake Fluid

* More often under severe use, such as operated in water or under severe loads.

Maintain coolant level in

olant reservoir bottle.

Maintain fluid level between

“MAX and “MIN” lines on the

master cylinder reservoir

Check level daily, change

coolant every 2 years

Check level during pre-ride

inspection; change fluid every

two years

2.6

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MAINTENANCE

PRELIMINARY VERSION

Maintenance Quick Reference, Continued.....

III. # Item Lube Rec. Method Frequency*

4 Front Gearcase Polaris Demand Drive Plus

5 Rear Gearcase

6 Transmission

* More often under severe use, such as operated in water or under severe loads.

Polaris ATV Angle Drive

uid (ADF)

Polaris AGL Plus

Gearcase Lubric

ant

Add lubricant until it is visible

at the fill hole threads

Add lubricant until it is visible

at the fill hole threads

Add lubricant until it is visible

at the fill hole threads

Initial level check at 25 hours;

nge according to intervals

cha

Initial level check at 25 hours; change according to intervals

2.7

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PRELIMINARY VERSION

Grease Lubrication Points

There are grease fittings at each A-arms pivot point, each front or rear stabilizer bushing, and on the front propshaft yoke. Apply grease until all traces of water have been purged out at each of these areas.

Item Recommended Lube Method Frequency

Front Propshaft Yoke(s)

A-arm Pivot Bushings

Stabilizer Bar Bushings

Polaris Premium U-Joint Grease

Grease fittings every 500

miles (800 km).

Grease before long periods

of stor

age, and after

thoroughly washing or

submerging the vehicle.

2.8

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MAINTENANCE

PRELIMINARY VERSION

LUBRICANTS / SERVICE PRODUCTS

Polaris Lubricants, Maintenance and Service Products

Part No. Description

Engine Lubricant

2870791 Fogging Oil (12 oz. Aerosol)

2876244

2876245

2540086 Engine Oil Filter

2202166 Engine Oil Change Kit (Twin Cylinder)

2878068

2878069

2878070

PS-4 Plus Performance Synthetic 4-Cycle Engine Oil (Quart)

PS-4 Plus Performance Synthetic 4-Cycle Engine Oil (Gallon)

Gearcase / Transmission Lubricants

AGL Plus Gearcase Lubricant (1 Qt.) (12 Count)

AGL Plus Gearcase Lubricant (1 Gal.) (4 Count)

AGL Plus Gearcase Lubricant (2.5 Gal.) (2 Count)

NOTE: Each item can be purchased separately at your local Polaris dealer.

Part No. Description

Additives / Sealants / Thread Locking Agents / Misc.

2871950

2871326

2870652 Fuel Stabilizer (16 oz.) (12 count)

2872189 DOT 4 Brake Fluid (12 count)

2871557 Crankcase Sealant, 3-Bond 1215 (5 oz.)

NOTE: The number count indicated by each part number units that are shipped with each order.

Loctite™ Threadlock 242  (6 ml.) (12 count)

Premium Carbon Clean  (12 oz.) (12 count)

in the table above indicates the number of

2876160

2872276

2877922 Demand Drive Plus (Quart)

2877923 Demand Drive Plus (2.5 Gallon)

2870465 Oil Pump for 1 Gallon Jug

2871312 Grease Gun Kit

2871322

2871423

2871460 Starter Drive Grease (12 Count)

2871515 Premium U-Joint Lube (3 oz.) (24 Count)

2871551 Premium U-Joint Lube (14 oz.) (10 Count)

2871329 Dielectric Grease (Nyogel™)

ATV Angle Drive Fluid (8 oz.) (12 Count)

ATV Angle Drive Fluid  (2.5 Gal) (2 Count)

Grease / Specialized Lubricants

Premium All Season Grease  (3 oz. cartridge) (24 Count)

Premium All Season Grease  (14 oz. cartridge) (10 Count)

Coolant

2871323 60/40 Coolant (Gallon) (6 Count)

2871534 60/40 Coolant (Quart) (12 Count)

2.9

9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual

MAINTENANCE

Shift Cable

Mount

Dust Boot

Clevis Pin

Shift Cable

Lower

Jam Nut

Upper

Jam Nut

PRELIMINARY VERSION

GENERAL VEHICLE INSPECTION AND MAINTENANCE

Pre-Ride / Daily Inspection

Perform the following pre-ride inspection daily, and when servicing the vehicle at each scheduled maintenance.

• Tires - check condition and pressures

• Fuel tank - fill to proper level

• All brakes - check operation and adjustment

• Throttle - check for free operation and closing

• Headlights/Taillights/Brakelights - also check ope

ration of all indicator lights and switches

• Ignition switch - check for proper function

• Wheels - check for tightness of wheel nuts and axle nuts; check to be sure axle nuts are secured by cotter pins

• Air cleaner element - check for dirt; clean or replace

• Steering - check for free operation noting any unusual looseness in any area

1. Locate the shift cable in the rear LH wheel well area.

2. Inspect shift cable, clevis pin, pivot bushings, and dust boo

t. Replace if worn or damaged.

3. If adjustment is required, loosen the lower jam nut and pull the cable out of the mount to move the upper jam nut.

• Loose parts - visually inspect vehicle for any damaged or loose nuts, bolts or fasteners

• Engine coolant - check for proper level at the recovery bottle

• Check all front and rear suspension components for wear or damage.

Frame, Nuts, Bolts, and Fasteners

Periodically inspect the torque of all fasteners in accordance with the maintenance schedule. Check that all cotter pins are in place. Refer to specific fastener torques listed in each chapter.

Shift Cable Inspection / Adjustment

Shift cable adjustment may be necessary if symptoms include:

• No AWD or gear position display on instrument

• Ratcheting noise on deceleration

• Inability to engage into a gear

• Excessive gear lash (noise)

• Gear selector moving out of desired range

uster

4. Adjust the shift cable so there is the same amount of ble travel when shifting slightly past the detents of

ca HIGH (H) gear and PARK (P).

5. Thread the upper or lower jam nut as required to

btain proper cable adjustment.

NOTE: This procedure may require a few attempts to

ain the proper adjustment.

obt

6. Once the proper adjustment is obtained, place the

shift cable and upper jam nut into the mount. Tighten the lower jam nut against the mount.

7. Start engine and shift through all gears to ensure the

hift cable is properly adjusted. If transmission still

s ratchets after cable adjustment, the transmission will require service.

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MAINTENANCE

WARNING

Injector Rail

Connector

Fuel Pump

Connector

Fuel Line

Fuel Pump Asm

PRELIMINARY VERSION

FUEL SYSTEM AND AIR INTAKE

Fuel System

Gasoline is extremely flammable and explosive

under certain conditions.

Always stop the engine and refuel outdoors or in

a well ventilated area.

Do not smoke or allow open flames or sparks in

r near the area where refueling is performed or

where gasoline is stored. Do not overfill the tank. Do not fill the tank If you get gasoline in your eyes or if you swallow

gasoline, seek medical attention immediately.

If you spill gasoline on y immediately wash it off with soap and water

and change clothing.

Never start the engine or let it run in an enclosed

ea. Engine exhaust fumes are poisonous and

can result in loss of consciousness or

death in a short time.

Never drain the fuel when the engine is hot.

Severe burns

our skin or clothing,

may result.

neck.

Fuel Pump / Fuel Filters

The RZR 800 EFI engine uses a serviceable, highvolume, high-pressure, fuel pump that includes a preliminary filter and an internal fine filter located before the pump regulator.

NOTE: Neither filter is servica replace the fuel pump as an assembly.

ble individually. Must

Fuel Line

1. Check the quick-connect fuel line for signs of wear, deterioration, damage or leakage. Replace if necessary.

2. Be sure fuel line is routed and retained properly.

IMPORTANT: Make sure line is not kinked or pinched.

3. Replace fuel line every two years.

NOTE: Refer to Chapter 4 for fuel and all other information related to the EFI System.

pump replacement

Vent Lines

1. Check fuel tank, front gearcase, rear gearcase and transmission vent lines for signs of wear, deterioration, damage or leakage. Replace every two years.

2. Be sure vent lines are routed properly and secured with cable

IMPORTANT: Ensure lines are not kinked or pinched.

ties.

2.11

9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual

MAINTENANCE

Throttle Cable

TRS

Throttle Pedal

PRELIMINARY VERSION

Throttle Pedal Inspection

This vehicle is equipped with a Throttle Release Switch (TRS) used to detect when the throttle pedal has returned to the rest position.

NOTE: The throttle pedal lever is designed to have a

ew degrees of freeplay prior to engaging the throttle

f arm that pulls the throttle cable.

Always check that the throttle pedal moves independently

f the cable pull lever at the start of throttle pedal travel and

o that the throttle pedal returns normally before starting the engine.

There should be minimal freeplay between the throttle

le and the cable pull lever. If there is excessive play

cab due to cable stretch or misadjustment, it will cause a delay in throttle response, especially at low engine speed. The throttle may also not open fully. If the throttle cable has no freeplay, the throttle may be hard to control, and the idle speed may be erratic.

Throttle Freeplay Adjustment

Inspection

1. Place the transmission in PARK.

2. Start the engine, and warm it up thoroughly.

3. Measure the distance the throttle arm (A) moves e the engine begins to pick up speed. Throttle

befor cable freeplay should be 1/16” - 1/8” (1.5 - 3 mm).

Check throttle pedal freeplay periodically in accordance

the Periodic Maintenance Chart. Adjust the freeplay

with if necessary (see “Throttle Freeplay Adjustment”).

NOTE: The throttle pedal lever (B) is designed to

e a few degrees of freeplay prior to engaging the

hav throttle arm (A) that pulls the throttle cable.

Adjustment

1. Remove both seats and rear service panel.

2. Remove cargo box as an assembly (see Chapter 5).

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MAINTENANCE

Intake Duct

Boot

Jam Nut

Adjuster

Air Box Cap

PRELIMINARY VERSION

3. Remove the (2) push rivets retaining the air intake box and remove the box from the frame.

4. Loosen the hose clamp retaining the PVT intake duct and remove the duct from the vehicle to access the throttle cable freeplay adjustment.

NOTE: While adjusting, lightly move the throttle

l in and out.

peda

7. Re-tighten the jam nut after final adjustment is made.

8. Apply a small amount of grease to the inside of the bo

ot and slide it over the cable adjuster to its original

position.

9. Reinstall the PVT intake duct and tighten the hose clamp.

10. Reinstall the air intake box and (2) push rivets.

11. Reinstall the cargo box, all fasteners and reconnect the taillight harness

12. Reinstall the rear service panel and seats.

Air Filter Service

It is recommended that the air filter be inspected as part of pre-ride inspection. Always apply grease to the seal under the air box cap and on the sealing edges of the air filter when servicing. In extremely dusty conditions, air filter replacement will be required more often.

5. Slide back the cable adjuster boot.

The filter should be inspec procedure:

Removal

1. The air box is located just above the left rear wheel in

e wheel well area.

2. Unlatch the (3) clips and remove the air box cap. Ins

pect the seal. It should adhere tightly to the cover

and seal all the way around.

ted using the following

6. Using a 14 mm open-end wrench, loosen the a

djustment jam nut. Using a 12 mm open-end wrench, move the cable adjuster until 1/16” to 1/8” (1.5 - 3 mm) of freeplay is achieved at the throttle pedal.

9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual

3. Remove the air filter assembly.

4. Inspect the air filter element and replace if necessary. Do

not attempt to clean the air filter, the filter should

be replaced.

2.13

MAINTENANCE

Cap

Seal

Air Filter

Apply Grease

Cap

Seal

Clip (3)

Boot

Air Box Can

Air Intake Duct

Breather

Seal

Fitting

Breather

Intake Box

Air Filter

Clamps

Front

Foam Seal

Filter

Hose

Foil

Filter Ring

Primary

Foam Seal

Intake Seal

PRELIMINARY VERSION

NOTE: If the filter has been soaked with fuel or oil it must be replaced.

NOTE: Service more frequently if vehicle is operated

t conditions or at high throttle operation for

in we extended periods.

Installation

1. Clean the air box thoroughly.

Air Box / Air Filter Exploded View

2. Place the filter ring over the end of the filter.

NOTE: Apply a small amount of general purpose

se to the sealing edges of the filter and the air

grea box cap seal before installing.

3. Install the filter into the air box and be sure it fits tightly.

4. Install air box cap and secure with clips.

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MAINTENANCE

Dipstick

Lever Lock

Dipstick

Lever Lock

Maintain Oil Level In SAFE Range

DO NOT Overfill the Engine

Dipstick

Always read top side of dipstick to

properly check oil level in crankcase

PRELIMINARY VERSION

ENGINE

Engine Oil Level

The twin cylinder engine is a wet-sump engine, meaning the oil is contained in the bottom of the crankcase. To check the oil level follow the procedure listed below:

1. Position vehicle on a level surface.

2. Place the transmission in Park (P).

3. Stop the engine and allow it to cool down before emoving the dipstick.

IMPORTANT: Do not run the machine and then check

he dipstick.

4. Locate the engine oil dipstick:

• RZR / RZR S: Re

service panel to access the dipstick.

move both seats and the rear

6. Reinstall the dipstick completely, but do

NOTE: Make certain the dipstick is inserted all the way into the filler tube to keep the angle and depth of dipstick consistent.

7. Remove dipstick and check to see that the oil level is n the SAFE range. Add oil as indicated by the level

i on the dipstick. Do not overfill (see NOTE below!).

NOTE: Due to the dipstick entry angle into the

kcase, the oil level will read higher on the

cran bottom side of the dipstick. Proper level indication is determined on the upper surface of the dipstick as it is being removed, regardless of the level marks being on top or on bottom (see the next illustration).

not lock it.

• RZR 4: Remove the right rear passenger seat to

access the dipstick.

NOTE: A rising oil level between checks in cool

ther driving can indicate contaminants such as

wea gas or moisture collecting in the crankcase. If the oil level is over the full mark, change the oil immediately.

5. Lift the lever lock, remove dipstick and wipe dry with clean cloth.

9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual

8. Reinstall the dipstick and lock the lever.

2.15

MAINTENANCE

WARNING

CAUTI ON

Drain Plug

NOTE: Drain plug is accessed through the skid plate.

= T

Oil Filter

PRELIMINARY VERSION

Engine Oil and Filter Service

Always change engine oil and filter at the intervals outlined in the Periodic Maintenance Chart. Always change the oil filter whenever changing the engine oil.

Personal injury can occur when handling used

oil. Hot oil can cause burns or skin damage.

Recommended Engine Oil / Filter:

PS-4 Plus Synthetic 4-Cycle Engine Oil

(PN 2876244) (Quart)

Engine Oil Filter (PN 2540086)

Capacity: 2 Quarts (1.9 L)

1. Position vehicle on a level surface.

6. Allow oil to drain completely.

7. Replace the sealing washer on drain plug.

NOTE: The sealing surface on the drain plug should be clea

8. Reinstall drain plug and torque to specification.

9. Place shop towels beneath oil

n and free of burrs, nicks or scratches.

Crankcase Drain Plug:

16 ft-lbs (22 Nm)

filter. Using Oil Filter Wrench (PU-50105) and a 3/8” extension, turn the oil filter counter-clockwise to remove it.

2. Place the transmission in PARK (P).

3. Start the engine. Allow it to idle for tw minutes until warm. Stop the engine.

4. Clean area around oil drain plug at bottom of engine.

Oil may be hot. Do not allow hot oil to come into

contact with skin, as serious burns may result.

o to three

Oil Filter Wrench:

PU-50105: 2.5” (64 mm)

10. Using a clean dry cloth, clean filter sealing surface on e crankcase.

11. Lubricate O-ring on new filter with a film of fresh

ine oil. Check to make sure the O-ring is in good

eng condition.

12. Install new filter to specification.

Oil Filter:

Turn by hand until filter O-ring contacts

sealing surface, then turn an additional 1/2

turn

5. Place a drain pan beneath engine crankcase and emove the drain plug.

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MAINTENANCE

Breather

Hose

PRELIMINARY VERSION

13. Remove the engine oil dipstick (see “Engine Oil Level”).

14. Fill the sump with 2 qts. (1.9 L) of PS-4 Plus Sy Engine Oil (2876244).

15. Verify the transmission is still pos

16. Start the engine and let it idle for one to two minutes.

17. Stop the engine and inspect for leaks.

18. Re-check the oil level on the dipstick and add oil as

ecessary to bring the level to the upper mark on the

n dipstick.

19. Dispose of used oil and oil filter properly.

itioned in PARK (P).

nthetic

Engine Breather Hose Inspection

The engine is equipped with a breather hose. Inspect the breather hose for possible kinks or wear. The hose is formed for a proper fit. Follow the breather hose from the side of the airbox to the engine valve cover.

Compression and Leakdown Test

NOTE: This engine does NOT have decompression components. Compression readings will vary in proportion to cranking speed during the test.

A smooth idle generally indicates good compression. Low

ine compression is rarely a factor in running condition

eng problems above idle speed.

A cylinder leakdown test is the be condition. Follow manufacturer's instructions to perform a cylinder leakage test (never use high pressure leakage testers, as crankshaft seals may dislodge and leak).

Cylinder Compression:

165-185 PSI

Cylinder Leakdown

Service Limit: 15%

(Inspect for cause if test exceeds 15%)

st indication of engine

NOTE: Make sure line is not kinked or pinched.

Engine and Transmission Mounts

Periodically inspect engine and transmission mounts for cracks or damage.

Refer to Chapter 3 “Engine Assembly and Installation” for

ounting fastener torque values.

9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual

2.17

MAINTENANCE

WARNING

= T

Silencer

Retaining

Arrestor

Screen

Nut

Screw

PRELIMINARY VERSION

Exhaust - Spark Arrestor

Do not clean spark arrestor immediately after the

engine has been run, as the exhaust system

becomes very hot. Serious burns could result from

contact with the exhaust components. Allow

components to cool sufficiently before proceeding.

Wear eye protection and gloves.

Never run the engine in an enclosed area. Exhaust

ntains poisonous carbon monoxide gas that can

cause loss of consciousness or death in a very

short time.

Periodically clean spark arrestor to remove accumulated carbon (see “Periodic Maintenance Chart”).

1. Remove the retaining screw, nut and spark arrestor m the end of the silencer.

fro

2. Use a non-synthetic brush to clean the arrestor

een. A synthetic brush may melt if components are

scr warm.

3. Inspect the screen for wear and damage. Replace if

eeded.

4. Reinstall the arrestor and torque the screw to

ification.

spec

Spark Arrestor Screw:

40 in-lbs (4.5 Nm)

2.18

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TRANSMISSION AND GEARCASES

= T

PRELIMINARY VERSION

Transmission / Gearcase Specification Chart

MAINTENANCE

Gearcase Lubricant Capacity Fill Plug Torque

Transmission

ain Gearcase)

Transmission

ransfer Case)

Front Gearcase Demand Drive Plus 6.75 oz. (200 ml) 8-10 ft-lbs (11-14 Nm) 8-10 ft-lbs (11-14 Nm)

Rear Gearcase ATV Angle Drive Fluid 26 oz. (769 ml) 40-50 ft-lbs (54-68 Nm) 30-45 in-lbs (3-5 Nm)

Rear Gearcase

ferential (INT’L)

Dif

AGL Plus

Gearcase Lubricant

AGL Plus

Gearcase Lubricant

ATV Angle Drive Fluid 22 oz. (650 ml) 40-50 ft-lbs (54-68 Nm) 30-45 in-lbs (3-5 Nm)

24 oz. (710 ml) 40-50 ft-lbs (54-68 Nm) 30-45 in-lbs (3-5 Nm)

14 oz. (414 ml) 40-50 ft-lbs (54-68 Nm) 30-45 in-lbs (3-5 Nm)

Drain / Level Check

Plug Torque

Transmission Lubrication

Transmission Specifications

Specified Lubricant:

AGL Plus Gearcase Lubricant (PN 2878068)

Approximate Capacity at Change:

Main Gearcase - 24 oz. (710 ml)

Transfer Case - 14 oz. (414 ml)

Drain / Level Plug Torque:

30-45 in-lbs (3-5 Nm)

Fill Plug Torque:

40-50 ft-lbs (54-68 Nm)

The transmission lubricant levels should be checked and changed in accordance with the maintenance schedule.

• Be sure vehicle is positioned on a level surface when checking or changing fluid.

• Check vent hose to be sure it is routed properly and unobstructed.

Transfer Case - Lubricant Level Check:

1. Position vehicle on a level surface.

2. Remove the fill plug.

3. Remove the level check plug.

4. Add the recommended fluid through the fill plug until it begins to flow out the level check plug hole.

hole

5. Reinstall level check plug and

Level Check Plug:

30-45 in-lbs (3-5 Nm)

torque to specification.

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MAINTENANCE

= T

PRELIMINARY VERSION

6. Reinstall the fill plug and torque to specification.

Fill Plug:

40-50 ft-lbs (54-68 Nm)

Main Gearcase - Lubricant Level Check:

The fill plug is located on the side of the gearc below the shift lever bell crank. Maintain the fluid level even with the bottom of the fill plug hole.

1. Position vehicle on a level surface.

2. Remove the fill / level plug and c

heck the fluid level.

ase just

Transmission Lubricant Change:

The lubricant change procedure is relatively the same for

e main gearcase and the transfer case. To minimize

th confusion, perform the lubricant change on only one gearcase at a time. Access the drain plugs through the drain holes in the skid plate.

Transfer Case Lubricant Change:

1. Remove the fill plug and the lev “Transfer Case - Lubricant Level Check”).

2. Place a drain pan under the transfer case drain plug.

3. Remove the drain plug and allow to drain completely.

4. Clean and reinstall the drain plug with a new O-ring.

que drain plug to specification.

Tor

Drain Plug:

30-45 in-lbs (3-5 Nm)

el check plug (refer to

3. If fluid level is not at fill plug hole, add the recommended fluid as needed.

4. Reinstall the fill / level plug and torque to specification.

Fill / Level Plug:

40-50 ft-lbs (54-68 Nm)

5. Add the recommended fluid through the until it begins to flow out the level plug hole. Do not overfill.

6. Reinstall level check plug and torque to specification.

Level Check Plug:

30-45 in-lbs (3-5 Nm)

7. Reinstall the fill plug and torque to specification.

Fill Plug:

40-50 ft-lbs (54-68 Nm)

Main Gearcase Lubricant Change:

1. Remove the fill / level plug (refer to “Main Gearcase Lubricant Level Check”).

2. Place a drain pan under the main gearcase drain plug.

fill plug hole

3. Remove the drain plug and allow to drain completely.

2.20

9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual

4. Clean and reinstall the drain plug with a new O-ring.

= T

PRELIMINARY VERSION

Torque drain plug to specification.

MAINTENANCE

Drain Plug:

30-45 in-lbs (3-5 Nm)

5. Add the recommended fluid through Maintain the fluid level at the bottom of the fill plug hole when filling the Main Gearcase. Do not overfill.

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.

the fill plug hole.

2.21

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MAINTENANCE

= T

PRELIMINARY VERSION

Front Gearcase Lubrication

The front gearcase lubricant level should be checked and changed in accordance with the maintenance schedule.

• Be sure vehicle is positioned on a level surface when checking or changing fluid.

• Check vent hose to be sure it is routed properly and unobstructed.

Front Gearcase Specifications

Specified Lubricant:

Polaris Demand Drive Plus (PN 2877922)

Capacity: 6.75 oz. (200 ml)

Fill Plug: 8-10 ft-lbs (11-14 Nm)

Drain Plug: 8-10 ft-lbs (11-14 Nm)

Lubricant Level Check:

The fill plug is located on the bottom right side of the front gearcase. Maintain the lubricant level even with the bottom threads of the fill plug hole.

2. Remove the fill plug and check the fluid level.

3. Add the recommended fluid as needed. Maintain the lubricant level even w plug hole.

4. Reinstall the fill plug and torque to

8-10 ft-lbs (11-14 Nm)

Lubricant Change:

The drain plug is located on the bottom of the gearcase.

ith the bottom threads of the fill

specification.

Fill Plug:

1. Remove the fill plug.

2. Place a drain pan under the drain plug.

3. Remove the drain plug and allow fluid to drain

ompletely.

4. Clean the drain plug.

5. Reinstall the drain plug with a new O-ring and torque to specification.

6. Add the recommended fluid. Maintain the lubricant level even with the bottom threads of the fill plug hole.

1. Position vehicle on a level surface.

2.22

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MAINTENANCE

= T

PRELIMINARY VERSION

7. Reinstall the fill plug and torque to specification.

Fill / Drain Plug:

8-10 ft-lbs (11-14 Nm)

8. Check for leaks. Dispose of used lubricant properly.

Rear Gearcase Lubrication

The rear gearcase lubricant level should be checked and changed in accordance with the maintenance schedule.

• Be sure vehicle is positioned on a level surface when checking or changing fluid.

• Check vent hose to be sure it is routed properly and unobstructed.

Rear Gearcase Specifications

Specified Lubricant:

ATV Angle Drive Fluid (PN 2876160)

Capacity: 26 oz. (769 ml)

RZR S INT’L Capacity: 22 oz. (650 ml)

Fill Plug Torque: 40-50 ft-lbs (54-68 Nm)

Drain Plug Torque: 30-45 in-lbs (3-5 Nm)

Lubricant Level Check:

The fill plug is located on the right side of the rear gearcase. Maintain the fluid level even with the bottom of the threads of the fill plug hole.

1. Position the vehicle on a level surface.

2. Remove the fill plug and check lubricant level should be even with the bottom of the threads of the fill plug hole.

3. Add the recommended lubricant as needed.

the fluid level. The

2.23

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MAINTENANCE

= T

PRELIMINARY VERSION

4. Reinstall the fill plug and torque to specification.

Fill Plug:

40-50 ft-lbs (54-68 Nm)

Lubricant Change:

The drain plug is located on the bottom right side of the r

ear gearcase.

1. Remove the fill plug.

2. Place a drain pan under the drain plug.

3. Remove the drain plug and allow the lubricant to drain completely.

4. Clean the drain plug.

5. Reinstall the drain plug with new O-ring and torque to

ification.

spec

7. Reinstall the fill plug and torque to

Fill Plug:

40-50 ft-lbs (54-68 Nm)

8. Check for leaks. Dispose of used lubricant properly.

specification.

Drain Plug:

30-45 in-lbs (3-5 Nm)

6. Add the recommended lubricant. Maintain the fluid

vel even with the bottom threads of the fill plug hole.

2.24

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MAINTENANCE

Recovery Bottle

Pressure Cap

WARNING

PRELIMINARY VERSION

COOLING SYSTEM

Cooling System Overview

The engine coolant level is controlled, or maintained, by the recovery system. The recovery system components are the recovery bottle, radiator filler neck, radiator pressure cap and connecting hose.

As coolant operating temper expanding (heated) excess coolant is forced out of the radiator past the pressure cap and into the recovery bottle. As engine coolant temperature decreases the contracting (cooled) coolant is drawn back up from the tank past the pressure cap and into the radiator.

NOTE: Some coolant level drop on new machines is

rmal as the system is purging itself of trapped air.

no Observe coolant levels often during the break-in period.

NOTE: Overheating of engine could occur if air is

t fully purged from system.

Polaris Premium 60/40 coolant is already premixed and

eady to use. Do not dilute with water.

ature increases, the

2. Remove the hood from the front cab.

3. View the coolant level in the recovery bottle.

4. If the coolant level is below the MIN coolant level in the radiator.

NOTE: If overheating is evident, allow system to cool completely and check coolant level in the radiator and inspect for signs of trapped air in system.

Never remove the pressure cap when the

engine is warm or hot. Escaping steam can

cause severe burns. The engine must be cool

before removing the pressure cap.

5. Remove the pressure cap. Using a funnel, add coolant to the top of the filler

6. Reinstall the pressure cap.

NOTE: Use of a non-standard pressure cap will not allow the

recovery system to function properly.

neck.

line, inspect the

Coolant Level Inspection

The pressure cap and recovery bottle are located under the front hood of the vehicle. The coolant level must be maintained between the minimum and maximum levels indicated on the recovery bottle.

With the engine at operating level should be between the upper and lower marks on the coolant recovery bottle. If not, perform the following procedure:

temperature, the coolant

7. Remove recovery bottle cap and add coolant using a

nnel.

8. Fill recovery bottle to MAX lev premix Anti Freeze/Coolant or 50/50 or 60/40 mixture of antifreeze and distilled water as required for freeze protection in your area.

9. Reinstall the recovery bottle cap.

10. If coolant was required, start engine and check for

eaks. Make sure radiator fins are clean to prevent

l overheating.

el with Polaris 60/40

1. Position the vehicle on a level surface.

2.25

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MAINTENANCE

Antifreeze Hydrometer

CAUTI ON

PRELIMINARY VERSION

Coolant Strength / Type

Test the strength of the coolant using an antifreeze hydrometer.

• A 50/50 or 60/40 mixture of antifreeze and distilled ater will provide the optimum cooling, corrosion

w protection, and antifreeze protection.

• Do not use tap water, straight antifreeze, or

straight water in the system. Tap water contains minerals and impurities which build up in the system.

• Straight water or antifreeze may cause the system

to freeze, corrode, or overheat.

Polaris 60/40 Anti-Freeze / Coolant

(PN 2871323)

Cooling System Hoses

1. Inspect all hoses for cracks, deterioration, abrasion or leaks. Replace if necessary.

2. Check tightness of all hose clamps.

Cooling System Pressure Test

Refer to Chapter 3 for cooling system pressure test procedure.

Do not over-tighten hose clamps at radiator,

or radiator fitting may distort, causing a

restriction to coolant flow.

Radiator hose clamp torque is 36 in-lbs (4 Nm).

2.26

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MAINTENANCE

CAUTI ON

Flush radiator fins

in this direction

WARNING

Drain Here

PRELIMINARY VERSION

Radiator

1. Check radiator (A) air passages for restrictions or damage.

2. Carefully straighten any bent radiator fins.

3. Remove any obstructions with compressed air or low

essure water.

Coolant Drain

1. Remove the hood from the front cab.

Never drain the coolant when the engine and radiator are warm or hot. Hot coolant can cause severe burns. Allow engine and radiator to cool.

2. Slowly remove the pressure cap to relieve any cooling em pressure.

syst

3. Place a suitable drain pan underneath the radiator

fitting on

4. Drain the coolant from the radiator by removing the

ower coolant hose from the radiator as shown.

l Properly dispose of the coolant.

the front RH side of the vehicle.

Washing the vehicle with a high-pressure

washer could damage the radiator fins and

impair the radiators effectiveness. Use of a high-

pressure washer is not recommended.

5. Allow coolant to completely drain.

2.27

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MAINTENANCE

Aluminum Wheel

30 ft-lbs + 90° (1/4 turn)

Steel Wheel

27 ft-lbs (37 Nm)

CAUTI ON

Wheel Nuts (4)

Hub Nut

Use a new

cotter pin

Note

Tire Rotation

Val ve stem

facing outward

(RZR Only)

PRELIMINARY VERSION

FINAL DRIVE / WHEEL AND TIRE

Wheel and Hub Torque Tabl e

Item Nut Type Specification

Aluminum Wheels

ast)

Steel Wheels

/ Camo)

(Black

Hub Retaining

Lug Nut

Flange Nut

- 80 ft-lbs (108 Nm)

30 ft-lbs + 90° (1/4 turn)

27 ft-lbs (37 Nm)

Wheel Installation

1. Verify the transmission is still in PARK (P).

2. Install the wheel hub, washers, and hub nut, if viously removed.

pre

3. Place the wheel in the correct position on the wheel

. Be sure the valve stem is toward the outside and

hub rotation arrows on the tire point toward forward rotation.

4. Attach the wheel nuts and finger tighten them.

5. Carefully lower the vehicle to the ground.

6. Torque the wheel nuts and/or hub nut to the proper

rque specification listed in the torque table at the

to beginning of this section.

7. If hub nut was removed, install a new cotter pin after

e hub nut has been tightened.

NOTE: Do not lubricate the stud or the lug nut.

Wheel Removal

1. Position the vehicle on a level surface.

2. Place the transmission in PARK (P) and stop the engine.

3. Loosen the wheel nuts slightly. If wheel hub removal

quired, remove the cotter pin and loosen the hub

is re nut slightly.

4. Elevate the appropriate side o a suitable stand under the frame.

5. Remove the wheel nuts and remove the wheel.

6. If hub removal is required, remove the hub nut and washers.

f the vehicle by placing

If wheels are improperly installed it could affect vehicle handling and tire wear. On vehicles with tapered rear wheel nuts, make sure tapered end

of nut goes into taper on wheel.

2.28

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MAINTENANCE

WARNING

Tread Depth 1/8" (3 mm)

CAUTI ON

Front Boots

Rear Boots

PRELIMINARY VERSION

Tire Inspection

• Improper tire inflation may affect vehicle maneuverability.

• When replacing a tire always use original equipment size and type.

• The use of non-standard size or type tires may affect vehicle handling.

Operating with worn tires will increase the

possibility of the vehicle skidding easily with

possible loss of control.

Worn tires can cause an accident.

Always replace tires when the tread depth

sures 1/8", (.3 cm) or less.

mea

Tire Tread Depth

Replace tires when tread depth is worn to 1/8" (3 mm) or

les

Tire Pressure

Remove the valve stem cap and check tire pressure using the tire pressure gauge included in the vehicle’s tool kit.

Maintain proper tire pressure.

Refer to the warning tire pressure decal

applied to the vehicle.

RZR / RZR S

Tire Pressure Inspection (Cold)

Front Rear

8 psi (55 kPa) 8 psi (55 kPa)

RZR 4

Tire Pressure Inspection (Cold)

Front Rear

10 psi (69 kPa) 12 psi (83 kPa)

Drive Shaft Boot Inspection

Inspect the drive shaft boots for damage, tears, wear or leaking grease. If the boots exhibit any of these symptoms, they should be replaced. Refer to Chapter 7 for drive shaft boot replacement.

2.29

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MAINTENANCE

WARNING

CAUTI ON

Battery

RZR / RZR S

RZR 4

Battery

PRELIMINARY VERSION

ELECTRICAL AND IGNITION SYSTEM

Battery Maintenance

Keep battery terminals and connections free of corrosion. If cleaning is necessary, remove the corrosion with a stiff wire brush. Wash with a solution of one tablespoon baking soda and one cup water. Rinse well with tap water and dry off with clean shop towels. Coat the terminals with dielectric grease or petroleum jelly.

CALIFORNIA PROPOSITION 65 WARNING:

Batteries, battery posts, terminals and related

accessories contain lead and lead compounds,

and other chemicals known to the State of

California to cause cancer and birth defects or

other reproductive harm.

WASH HANDS AFTER HANDLING.

Battery Removal

1. Remove the driver’s seat to access the battery.

Battery electrolyte is poisonous. It contains sulfuric acid. Serious burns can result from

contact with skin, eyes or clothing. Antidote:

External: Flush with water.

Internal: Drink

Follow with milk of magnesia, beaten egg, or

vegetable oil. Call physician immediately.

Eyes: Flush with

Batteries produce explosive gases.

Keep s

Ventilate when charging or using in an enclosed

space. Always shield eyes when

KEEP OUT OF REACH OF CHILDREN.

NOTE: Batteries must be fully charged before use or

ttery life will be reduced by 10-30% of full

ba potential. Charge battery according to “Charging Procedure” provided in Chapter 10. Do not use the vehicle’s stator/alternator to charge a new battery.

large quantities of water or milk.

water for 15 minutes and get

prompt medical attention.

parks, flame, cigarettes, etc. away.

working near batteries.

2. Disconnect the black (negative) battery cable.

3. Disconnect the red (positive) battery cable.

4. Remove the hold-down strap and lift the battery out vehicle.

of the

To reduce the chance of sparks: Whenever

removing the battery, disconnect the black (negative) cable first. When reinstalling the

battery, install the black (negative) cable last.

2.30

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MAINTENANCE

RZR 4 Shown

WARNING

Note for

reassembly

Inspect electrode for wear and buildup

PRELIMINARY VERSION

Battery Installation

IMPORTANT: Using a new battery that has not been fully charged can damage the battery and result in a shorter life. It can also hinder vehicle performance. Follow the battery charging procedure in Chapter 10 “Electrical” before installing the battery.

1. Ensure the battery is

2. Place the battery in the battery holder and secure with hold-down strap.

3. Coat the terminals with dielectric grease or petroleum

jelly

4. Connect and tighten the red (positive) cable first.

5. Connect and tighten the black (negative) cable last.

fully charged.

Spark Plug Service

1. Remove the rear service panel:

• RZR / R

seats.

• RZR 4: Remove both rear passenger seats.

A hot exhaust system and engine can cause

serious burns. Allow engine to cool or wear

protective gloves when removing the spark plugs.

2. Remove the cargo box assem plugs (see Chapter 5).

3. Remove both spark plug caps and clean plug area so

o dirt or debris can fall into engine when plugs are

n removed.

ZR S: Remove the driver and passenger

bly to access the spark

6. Verify that cables are properly routed and reinstall the driver’s

Battery Off Season Storage

Refer to Chapter 10 “Electrical” for off season storage procedures.

Battery Charging (Maintenance Free)

Refer to Chapter 10 “Electrical” for charging procedure.

seat.

4. Clean plug area so no dirt and debris can fall into gine when plugs are removed.

5. Remove spark plugs.

6. Inspect electrodes for wear and carbon buildup. Look

r a sharp outer edge with no rounding or erosion of

fo the electrodes.

9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual

2.31

MAINTENANCE

= T

Gap - .035" (0.90 mm)

Spark Plug Gap

Engine

Ground Strap

RZR / RZR S

Ground Terminal

RZR 4

Ground Terminal

PRELIMINARY VERSION

7. Clean with electrical contact cleaner or a glass bead

spark plug cleaner only. CAUTION: A wire brush or coated abrasive should not be used.

8. Measure gap with a wire gauge. Adjust gap if ecessary by carefully bending the side electrode.

9. If necessary, replace spark plug with proper type.

TION: Severe engine damage may occur if the

CAU

incorrect spark plug is used.

10. Apply anti-seize compound to the spark plug threads.

11. Install spark plugs and torque to specification.

Engine To Frame Ground

Inspect ground cable connections. Be sure they are clean and tight. The engine ground cable runs from the starter motor to the chassis ground terminal.

Spark Plug:

18 ft-lbs (24 Nm)

Recommended Spark Plug:

Champion RC7YC3

12. Install the plug caps to the appropriate cylinder by

eferencing the MAG and PTO spark plug cap decals.

2.32

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MAINTENANCE

WARNING

Tie Rod

U-Joints

Gearbox

Tie Rod

Check for Loose Wheel or Hub

PRELIMINARY VERSION

STEERING

Steering Inspection

The steering components should be checked periodically for loose fasteners, worn tie rod ends, ball joints, and damage. Also check to make sure all cotter pins are in place. If cotter pins are removed, they must not be reused. Always use new cotter pins.

Replace any worn or damaged steering components.

teering should move freely through the entire range of

S travel without binding. Check routing of all cables, hoses, and wiring to be sure the steering mechanism is not restricted or limited.

NOTE: Whenever steering components are

placed, check front end alignment.

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.

Use only genuine Polaris replacement parts.

Steering Wheel Freeplay

Check steering wheel for specified freeplay and operation.

1. Position the vehicle on level ground.

2. Lightly turn the steering wheel left and right.

3. There should be 0.8”-1.0” (20-25 mm) of freeplay.

4. If there is excessive freeplay rough, inspect the following components.

• Tie Rod Ends

• Steering Shaft U-Joints

• Steering Gearbox

or the steering feels

Tie Rod End / Wheel Hub Inspection

• To check for play in the tie rod end, grasp the steering tie rod, pull in all directions feeling for movement.

• Replace any worn steering components. Steering

ld move freely through entire range of travel

shou without binding.

• Elevate front end of machine so front wheels are

f the ground. Check for any looseness in front

of hub/wheel assembly by grasping the tire firmly at top and bottom first, and then at front and rear. Try to move the wheel and hub by pushing inward and pulling outward.

9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual

• If abnormal movement is detected, inspect the hub

nd wheel assembly to determine the cause

a (loose wheel nuts or loose front hub nut).

• Refer to Chapter 7 “Final Drive” for front hub

vice procedures.

ser

2.33

MAINTENANCE

= In. / mm.

CAUTI ON

PRELIMINARY VERSION

Wheel Toe Alignment Inspection

1. Place machine on a smooth level surface and set steering wheel in a straight ahead position. Secure the steering wheel in this position.

2. Place a chalk mark on the center line of the front tires

proximately 10” (25.4 cm) from the floor or as close

ap to the hub/axle center line as possible.

Wheel Toe Adjustment

If toe alignment is incorrect, measure the distance between vehicle center and each wheel. This will tell you which tie rod needs adjusting.

NOTE: It is important the height of both marks be equally positioned to get an accurate measurement.

3. Measure the distance between the marks and record

measurement. Call this measurement “A”.

the

4. Rotate the tire Position chalk marks facing rearward, even with the hub/axle center line.

5. Again measure the distance between the marks and

cord. Call this measurement “B”. Subtract

re measurement “B” from measurement “A”. The difference between measurements “A” and “B” is the vehicle toe alignment. The recommended vehicle toe tolerance is 1/8” to 1/4” (.3 to .6 cm) toe out. This means the measurement at the front of the tire (A) is 1/8” to 1/4” (.3 to .6 cm) wider than the measurement at the rear (B).

(A) - (B) = 1/8 to 1/4" (.3 to .6 cm)

s 180 by moving the vehicle forward.

Wheel Toe-Out:

NOTE: Be sure steering wheel is straight ahead

ore determining which tie rod needs adjustment.

bef

During tie rod adjustment, it is very important that

the following precautions be taken when

tightening tie rod end jam nuts.

If the rod end is positioned incorrectly it will not

pivot, and may break.

To adjust toe alignment:

• Hold tie rod end to keep it from rotating.

• Loosen jam nuts at both end of the tie rod.

• Shorten or lengthen the tie rod until alignment is as re

quired to achieve the proper toe setting as

specified in “Wheel Toe Alignment”.

2.34

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MAINTENANCE

= T

WARNING

Increase

Preload

Decrease

Preload

Cam

PRELIMINARY VERSION

• IMPORTANT: When tightening the tie rod end jam

nuts, the rod ends must be held parallel to prevent rod end damage and premature wear. Damage may not be immediately apparent if done incorrectly.

• After alignment is complete, t specification.

Tie Rod End Jam Nut:

12-14 ft-lbs (16-19 Nm)

orque jam nuts to

SUSPENSION (STANDARD)

Spring Preload Adjustment

The front and rear shock absorber springs are adjustable by rotating the adjustment cam to change spring tension preload.

Uneven adjustment may cause poor handling of the

vehicle, which could result in an accident and

serious injury or death. Always adjust both the left

and right spring preloads equally.

Suspension Spring Adjustment

1. Position the vehicle on a level surface and stop the gine.

2. Raise and safely support front or rear of vehicle off the

ground to allow the suspension to fully extend.

NOTE: The tires should not be touching the ground.

3. To adjust the suspension, rotate the adjustment cam

clockwise to increase spring tension or counterclockwise to decrease spring tension.

4. Each notch of the adjustment will add 6% - 8%

preload to the spring over the primary position.

9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual

Shock Spanner Wrench:

PN 2871095

2.35

MAINTENANCE

WARNING

Increase

Preload

Decrease

Preload

Preload Measurement

Shock shown is

for reference only

PRELIMINARY VERSION

SUSPENSION (FOX™)

Spring Preload Adjustment

The front and rear shocks have a spring preload adjustment. Suspension spring preload may be adjusted to suit different riding conditions or vehicle payloads.

Uneven adjustment may cause poor handling of

the vehicle, which could result in an accident

and serious injury or death. Always adjust both

the left and right spring preloads equally.

RZR S - Factory Spring Preload Setting

Front Rear

4.34 in. (11 cm) 5.15 in. (13 cm)

RZR 4 (Base) - Factory Spring Preload Setting

Front Rear

IMPORTANT: Always return the spring preload to the factory setting after the load is removed from the vehicle. The increased suspension height will negatively impact vehicle stability when operating without a load.

4.5 in. (11.4 cm) 5.29 in. (13.4 cm)

RZR 4 (L.E.) - Factory Spring Preload Setting

Front Rear

4.31 in. (10.9 cm) 4.99 in. (12.7 cm)

NOTE: Refer to the shock illustration within this procedure for spring preload measurement location.

1. Raise and safely support front or rear of vehicle off e ground to allow the suspension to fully extend.

2. Loosen the upper jam nut adjustment ring (1). Turn

the lower preload or counter-clockwise to decrease preload.

IMPORTANT: DO NOT increase the spring preload by

e than one inch (25.4 mm) over the factory setting.

mor

3. Once you have obtained the correct preload, hold the wer adjustment ring while tightening the upper

lo adjustment ring to lock them in place.

adjustment ring (2) clockwise to increase

Shock Spanner Wrench

(PN 2870803)

2.36

9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual

Shock Compression Adjustment

Clicker

Adjuster

RZR 4 L.E.

Increase

Damping

Decrease

Damping

Shown

PRELIMINARY VERSION

The compression damping adjustment is located on top of the shock ‘Piggyback’ reservoir of each shock.

Turn the clicker adjuster knob to make damping adjustments.

NOTE: When the clicker adjuster is turned

lockwise until it stops, the damping is in the fully

c closed position.

MAINTENANCE

Turn the clicker clockwise to increase c damping. Turn the clicker counter-clockwise to decrease compression damping.

NOTE: The factory setting is 10 clicks from closed.

er to the “Compression Adjustment Table”

Ref below.

Compression Adjustment Table

Setting Compression Damping

Softest Full counter-clockwise position

Factory 10 clicks from closed

Firmest 2 clicks from closed

ompression

2.37

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MAINTENANCE

Master Cylinder

Maximum

Minimum

Measure Pad Material

Service Limit: .040" (1 mm)

Thickness

Measure Brake Disc Thickness

Service Limit:

.170" (4.32 mm)

Front

Disc

Rear

Disc

PRELIMINARY VERSION

BRAKE SYSTEM

Brake Fluid Inspection

Always check the brake pedal travel and inspect the brake fluid reservoir level before each operation. If the fluid level is low, add DOT 4 brake fluid only.

Brake fluid should be changed every two years. The fluid

uld also be changed anytime the fluid becomes

sho contaminated, the fluid level is below the minimum level, or if the type and brand of the fluid in the reservoir is unknown.

The brake fluid master cylinder reservoir can be accessed through the lef

1. Position the vehicle on a level surface.

2. Place the transmission in PARK (P).

3. View the brake fluid level in the reservoir. The level

ould be between the MAX and MIN level lines.

4. If the fluid level is lower than the MIN lev

brake fluid until it reaches the MAX level line.

t front wheel well.

el line, add

Brake Pad / Disc Inspection

1. Check the brake pads for wear, damage, or looseness.

2. Inspect the brake pad wear surface for excessive

ar.

3. Pads should be changed when the worn to .040” (1 mm).

4. Check surface condition of the brake discs.

friction material is

5. Install the reservoir cap and apply the brake pedal cefully for a few seconds and check for fluid

for leakage around the master cylinder fittings and the brake caliper fittings.

5. Measure the thickness of the front and rear brake s.

disc

6. The disc(s) should be replaced if thickness is less than

70” (4.32 mm).

Brake Hose and Fitting Inspection

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

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ENGINE / COOLING

PRELIMINARY VERSION

CHAPTER 3

ENGINE / COOLING

ENGINE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.2

CRANKCASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.2

OIL PUMP / GEARS / ENGINE COVER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.3

STATOR COVER / STARTER / WATER PUMP / LUBRICATION SYSTEM

CYLINDER / CYLINDER HEAD / PISTON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.5

ENGINE EFI SENSORS / VALVE COVER / GENERAL COMPONENTS . . . . . . . . . . . . 3.6

ENGINE TORQUE SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.7

800 EFI ENGINE SERVICE SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.8

SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.10

ENGINE COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.11

COOLING SYSTEM SPECIFICATIONS / PRESSURE TEST . . . . . . . . . . . . . . . . . . . . 3.11

PRESSURE CAP TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.11

COOLING SYSTEM EXPLODED VIEW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.12

RADIATOR REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.13

COOLING SYSTEM BLEEDING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.14

GENERAL ENGINE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.16

ENGINE LUBRICATION SPECIFICATIONS / OIL PRESSURE TEST . . . . . . . . . . . . . 3.16

ACCESSIBLE ENGINE COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.16

OIL FLOW CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.17

ENGINE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.18

ENGINE / TRANSMISSION SEPARATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.25

ENGINE DISASSEMBLY AND INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.26

CYLINDER HEAD ASSEMBLY EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.26

ROCKER ARMS / PUSH RODS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.27

CYLINDER HEAD REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.27

CYLINDER HEAD INSPECTION / WARP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.28

VALVE SEAL / SPRING SERVICE (ON ENGINE). . . . . . . . . .

CYLINDER HEAD DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.29

VALVE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.30

COMBUSTION CHAMBER / VALVE SEAT RECONDITIONING

CYLINDER HEAD REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.33

VALVE SEALING TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.34

CYLINDER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.34

VALVE LIFTER REMOVAL / INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.34

PISTON REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.35

CYLINDER INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.36

CYLINDER HONE SELECTION AND HONING PROCEDURE. . . . . . . . . . . . . . . . . . . 3.37

HONING TO DEGLAZE / CLEANING THE CYLINDER AFTER HONING. . . . . . . . . . . 3.37

PISTON-TO-CYLINDER CLEARANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.38

PISTON / ROD INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.38

PISTON RING INSTALLED GAP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.39

STARTER DRIVE BENDIX REMOVAL / INSPECTION . . . . . .

FLYWHEEL / STATOR REMOVAL / INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.40

ENGINE CRANKCASE DISASSEMBLY / INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . 3.40

CAMSHAFT INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.48

ENGINE REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.49

CRANKCASE REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.49

FLYWHEEL / STATOR INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.58

CYLINDER HEAD REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.58

OIL PUMP PRIMING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.60

ENGINE INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.61

ENGINE ASSEMBLY AND INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.61

ENGINE BREAK-IN PERIOD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.62

TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.63

. . . . . . . . . . . . . . . . . . . 3.28

. . . . . . . . . . . . . . . . . . 3.31

. . . . . . . . . . . . . . . . . . . 3.39

. . . . . . . . . . 3.4

3.1

9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual

ENGINE / COOLING

PRELIMINARY VERSION

ENGINE SPECIFICATIONS

Crankcase Exploded Views

3.2

9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual

Oil Pump / Gears / Engine Cover Exploded View

PRELIMINARY VERSION

ENGINE / COOLING

3.3

9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual

ENGINE / COOLING

PRELIMINARY VERSION

Stator Cover / Starter / Water Pump / Lubrication System Exploded View

3.4

9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual

Cylinder / Cylinder Head / Piston Exploded View

PRELIMINARY VERSION

ENGINE / COOLING

3.5

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ENGINE / COOLING

NOTE: See chapter 4 for more information on the EFI System

PRELIMINARY VERSION

Engine EFI Sensors / Valve Cover / General Components Exploded View

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ENGINE / COOLING

PRELIMINARY VERSION

Engine Torque Specifications

Fastener Size in-lbs (Nm) ft-lbs (Nm)

Camshaft Gear 8 mm - 22 ± 2 (30 ± 3)

Camshaft Phase Sensor Bolt 6 mm 50 ± 5 (5.65 ± 0.55) -

Camshaft Thrust Plate 6 mm 115 ± 12 (13 ± 1.35) 9.5 ± 1 (13 ± 1.35)

Coolant Bleed Screw 6 mm 70 ± 10 (7.9 ± 1.15) -

Coolant Bypass Hose Fitting 3/8 NPT 120 (13.5) -

Counterbalance Gear 8 mm - 22 ± 2 (30 ± 3)

Crankcase Bolts 8 mm - * 22 ± 2 (30 ± 3)

Crankcase Breather 5 mm 84 ± 8 (9.5 ± 0.9) -

Cylinder Head Bolts 11 mm - * 35 ± 4 (47.5 ± 5.5)

Exhaust Manifold 8 mm 216 ± 24 (24.5 ± 2.70) 18 ± 2 (24.5 ± 2.7)

Flywheel 14 mm - 65 ± 7 (88 ± 9.50)

Injector Rail 8 mm 216 ± 24 (24.5 ± 2.70) 18 ± 2 (24.5 ± 2.7)

Magneto Cover 6 mm * 96 ± 12 (10.85 ± 1.35) -

Oil Baffle Weldment 5 mm 60 ± 6 (6.8 ± 0.68) -

Oil Drain Bolt (Crankcase) 12 mm 192 ± 24 (21.7 ± 2.7) 16 ± (21.7)

Oil Fill Tube Bolt 5 mm 50 ± 5 (5.64 ± 0.56) -

Oil Filter Pipe Fitting 20 mm - 35 ± 4 (47.5 ± 5.4)

Oil Pick Up 5 mm 60 ± 6 (6.8 ± 0.68) -

Oil Pressure Relief Plug 10 mm - 17 ± 2 (23 ± 2.7)

Oil Pump Housing Screw 6 mm * 84 ± 8 (9.5 ± 0.9) -

Rocker Arm 8 mm - * 22 ± 2 (30 ± 3)

Rocker Cover 6 mm * 84 ± 8 (9.5 ± 0.9) -

Spark Plug 14 mm 216 ± 24 (24.5 ± 2.7) 18 ± 2 (24.5 ± 2.7)

Starter Motor 6 mm * 84 ± 8 (9.5 ± 0.9) -

Stator Assembly 6 mm 84 ± 8 (9.5 ± 0.9) -

Stator Housing 6 mm * 96 ± 12 (10.85 ± 1.35) -

Stator Wire Retainer Plate 5 mm * 96 ± 12 (10.85 ± 1.35) -

Thermistor Sensor 3/8 NPT - 17 ± 2 (23 ± 3)

Thermostat Housing 6 mm 84 ± 8 (9.5 ± 0.9) -

Throttle Body Adaptor Bolts 8 mm 216 ± 24 (24.5-± 2.7) 18 ± 2 (24.5 ± 2.7)

T-MAP Sensor Bolt 5 mm 25 ± 3 (2.8 ± 0.3)

Water Pump Housing Cover 6 mm * 96 ± 12 (10.85 ± 1.35) -

Water Pump Impeller Nut

NOTE: * See exploded views for notes or torque sequences.

8 mm 108 ± 3 (12 ± 0.35) -

3.7

9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual

ENGINE / COOLING

PRELIMINARY VERSION

800 EFI Engine Service Specifications

Cylinder Head - Engine Specifications

Main Component: Cylinder Head RZR800-13 (1204620)

Cam Lobe Height - Intake 1.357” (34.477 mm)

Cam Lobe Height - Exhaust 1.342” (34.096 mm)

Camshaft Journal Outer Diameter - Mag 1.654"  0.00039" (42  0.010 mm)

Camshaft Journal Outer Diameter - Center 1.634" 0.00039" (41.50  0.010 mm)

Camshaft

Counter Balance Counter Balance End Play 0.005" (0.127 mm)

Cylinder Head

Camshaft Journal Outer Diameter - PTO 1.614"  0.00039" (41  0.010 mm)

Camshaft Journal Bore Inner Diameter - Mag 1.656"  0

Camshaft Journal Bore Inner Diameter - Center 1.637"  0.00039" (41.58  0.010 mm)

Camshaft Journal Bore Inner Diameter - PTO 1.617"  0.00039" (41.07  0.010 mm)

Camshaft Oil Clearance 0.00276"  0.00079" (0.07  0.02 mm)

Camshaft End Play 0.0167"  0.0098"

Cylinder Head - Surface warp limit 0.00394" (0.1 mm)

Cylinder Head - Standard height 3.478" (88.35 mm)

.00039" (42.07  0.010 mm)

(0.425  0.25 mm)

Valve Seat

Valve Gui de

Valve

Valve Sp ring

Valve Seat - Contacting Width - Intake 0.0472" 

Valve Seat - Contacting Width - Exhaust 0.0591" 

Valve Seat Angle 45.5  0.2

Valve Guide Inner diameter 0.2367"  0.00029"

Valve Guide Protrusion Above Head 0.807"  0.0039" (20.50  0.01 mm)

Valve Stem Diameter - Intake 0.2356"  0.00039" (5.985  0.01 mm)

Valve Stem Diameter - Exhaust 0.2351"  0.00039"

Valve Stem Oil Clearance - Intake 0.00228"  0.00098" (0.058  0.025 mm)

Valve Stem Oil Clearance - Exhaust 0.00275"  0.00098" (0.0870  0.025 mm)

Valve Stem Overall Length - Intake 4.51"  0.0

Valve Stem Overall Length - Exhaust 4.5453"  .01496" (115.45  0.38 mm)

Valve Spring Overall Length - Free Length 1.735" (46.069 mm)

Valve Spring Overall Length - Installed Height

Intake - 1.4638" (37.18 mm)  Exhaust - 1.4736" (37.43 mm)

0.00787" - 0.0039" (1.20  0.20 - 0.10 mm)

0.00787" - 0.0039" (1.50  0.20 - 0.10 mm)

55

(6.012  0.007 mm)

(5.972  0.01 mm)

1476" (114.5550  0.375 mm)

3.8

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ENGINE / COOLING

PRELIMINARY VERSION

Cylinder / Piston - Engine Specifications

Main Components: Cylinder / Piston / Connecting Rod RZR800-13 (1204620)

Cylinder

Lifter

Piston

Piston Pin

Cylinder - Surface warp limit (mating with cylinder head)

Cylinder Bore - Standard 3.1495" (80 mm)

Cylinder Taper Limit 0.00031" (0.008 mm)

Cylinder Out of Round Limit 0.00030" (0.0075 mm)

Cylinder to Piston Clearance .0015" .000

Lifter Outer Diameter Standard 0.84245"  0.00025" (21.39 8  0.00635 mm)

Lifter Block Bore 0.8438"  0.00062" (21.4322  0.0157 mm)

Piston - Standard 3.14803"  .00028" (79.960

Piston Standard Inner Diameter of  Piston Pin Bore

Piston Pin Outer Diameter 0.70866" - 0.70846" (18 - 17.995 mm)

Piston Pin - Standard Clearance - Piston Pin to Pin

Bore

Piston Pin - Degree of Fit Piston pin must be push fit (by hand) at 68° F (20° C)

0.004" (0.10 mm)

59" (.040  .015 mm)

0.70902"  .00012" (18.009

0.00047"  0.00024"

(0.012  0.006 mm)

 .007 mm)

 0.003 mm)

Piston / Connecting Rod / Crankshaft - Engine Specifications

Main Components: Piston / Connecting Rod RZR800-13 (1204620)

Top Ring - Standard 0.0059 - 0.0138" (0.15 - 0.35 mm)

Top Ring - Limit > 15% Leakdown

Installed Gap

Piston Ring

Ring to Groove Clearance

Connecting Rod Small End I.D. 0.7096" 0.70846"

Connecting Rod Small End  Radial Clearance

Connecting Rod

Crankshaft Crankshaft Runout Limit 0.00236" (0.060 mm)

Connecting Rod Big End  Side Clearance

Connecting Rod Big End  Radial Clearance

Second Ring - Standard 0.0098 - 0.0197" (0.25 - 0.50 mm)

Second Ring - Limit > 15% Leakdown

Oil Ring - Standard 0.0197 0.0

Oil Ring - Limit > 15% Leakdown

Top Ring - Standard 0.0024"  0.0008" (0.060  0.020

Top Ring - Limit > 15% Leakdown

Second Ring - Standard 0.0028"  0.0008" (0.070  0.020

Second Ring - Limit > 15% Leakdown

0.00098" 0.00039" (0.025  0.010 mm)

0.01181" 0.00591" (0.30  0.15 mm)

0.0015" 0.0006" (0.038  0.015 mm)

098" (0.50 0.25 mm)

(18  17.995 mm)

mm)

3.9

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ENGINE / COOLING

PRELIMINARY VERSION

Special Tools

Part Number Tool Description

PU-50105 OIL FILTER WRENCH

PU-45257 VALVE SPRING COMPRESSOR

PU-45652 VALVE PRESSURE HOSE

2871043 FLYWHEEL PULLER

2870390 PISTON SUPPORT BLOCK

PU-45497-1 CAM GEAR SPRING INSTALLATION KIT

PU-45497-2 CAM GEAR TOOTH ALIGNMENT TOOL

PU-45498 CAM SPANNER WRENCH

PU-45838 GEAR HOLDER

PA-44995 WATER PUMP MECHANICAL SEAL INSTALLER

PU-45543 UNIVERSAL DRIVER HANDLE

PA-45483 MAIN SEAL INSTALLER

PU-45658 CRANKSHAFT MAIN SEAL SAVER

PA-45401 WATER PUMP SEAL SAVER

2870975 MITY VAC™PRESSURE

PU-45778 OIL SYSTEM PRIMING TOOL

SPX Corporation: 1-800-328-6657 or http://polaris.spx.com/

TEST TOOL

3.10

9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual

ENGINE COOLING SYSTEM

WARNING

Remove

Cap

Te st H ere

Pressure Cap

PRELIMINARY VERSION

Cooling System Specifications

ENGINE / COOLING

Condition Coolant Temperature F (C)

Room Temperature 68F (

Thermostat Closed 175° F (79° C)

Thermostat Open 180° F (82° C)

Fan Off 194F (

Thermostat Full Open Lift 202° F (94° C)

Fan On 205F (

Engine Temperature Overheat Ind

Engine Protection Ignition Misfire

Engine Protection Shutdown

Cooling System Capacity

Pressure Cap Relief 13 PSI

Recommended Coolant

Use only high quality antifre distilled water in a 50/50 or 60/40 ratio, depending on freeze protection required in your area.

icator

Item Specification

Polaris Premium Antifreeze

Moving Vehicle: 235

Idle Vehicle: 241F (

Moving Vehicle: 239

Idle Vehicle: 244F (118C)

Moving Vehicle: 257

Idle Vehicle: 262F (128C)

RZR / RZR S 4.8 qts. (4.5 l)

RZR 4 5.5 qts. (5.2 l)

2871534 - Quart

2871323 - Gallon

eze/coolant mixed with

20C)

90C)

96C)



F (113 C)

116C)



F (115C)



F (125C)

Never remove pressure cap when engine is

warm or hot. The cooling system is under

pressure and serious burns may result.

Allow the engine to cool before servicing.

2. Remove pressure cap and pr system using a commercially available tester.

3. The system must maintain 10 psi for five minutes. If pressure loss is evident within five minutes, check radiator, hoses, clamps and water pump seals.

essure test the cooling

Pressure Cap Test

1. Remove the front hood (see Warning under “Cooling System Pressure Test”).

2. Remove pressure cap and test using a pressure cap tester (commercially available).

3. The pressure cap relief pressure is 13 psi. Replace cap if it does not meet this specification.

CAUTION: Using

to a buildup of deposits which may restrict coolant flow and reduce heat dissipation, resulting in possible engine damage. Polaris Premium 60/40 Antifreeze/Coolant is recommended for use in all cooling systems and comes pre-mixed, ready to use.

tap water in the cooling system will lead

Cooling System Pressure Test

1. Remove the hood from the front cab.

3.11

9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual

ENGINE / COOLING

Recovery Bottle

Engine Inlet Hose

Engine Outlet Hose

Radiator

Shroud

Radiator

Pressure Cap

Fan Motor

(Water Pump Cover)

(Thermostat Housing)

Outlet Hose

Inlet Hose

Filler Neck

To Top Fitting on Filler Neck

To Lower Fitting on Filler Neck

Bypass Hose (To Cylinder Head)

Coolant Flow Diagram

Radiator

Recovery Bottle

Engine

Water Pump

Engine

Thermostat Housing

Filler Neck

Engine

Cylinder Head Bypass

PRELIMINARY VERSION

Cooling System Exploded View

3.12

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ENGINE / COOLING

WARNING

Drain Here

Recovery

Engine

T-Fitting

Radiator

Fan Motor Asm.

Screws

Grommets

Inserts

Hose

Outlet Hose

Engine

Inlet Hose

PRELIMINARY VERSION

Radiator Removal

1. Remove the hood from the front cab.

Never drain the coolant when the engine and radiator are warm or hot. Hot coolant can cause severe burns. Allow engine and radiator to cool.

2. Slowly remove the pressure cap to relieve any cooling tem pressure.

sys

3. Place a suitable drain pan underneath the radiator

g on the front RH side of the vehicle.

fittin

4. Drain the coolant from the radiator by removing the

wer coolant hose from the radiator as shown.

lo Properly dispose of the coolant.

8. Remove the (2) upper radiator retaining bolts and the

4) bolts retaining the lower radiator mount bracket.

( Remove the bracket from the frame.

9. Disconnect the fan motor and remove the radiator m the vehicle. Take care not to damage the cooling

fro fins.

10. Reverse procedure for installation.

5. Allow coolant to completely drain.

6. Remove the front bumper (see Chapter 5).

7. Remove the upper engine outlet hose and recovery se from the top of the radiator.

3.13

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ENGINE / COOLING

WARNING

CAUTI ON

Pressure Cap

Recovery Bottle

Pressure Cap

Top LH Side

of Cylinder Head

Spark Plug

PRELIMINARY VERSION

Cooling System Bleeding Procedure

Always wear safety glasses and proper shop

clothing when performing the procedures in this

manual. Failing to do so may lead to possible

injury or death.

Use caution when performing these procedures.

Coolant may be hot and may cause

severe injury or burns.

NOTE: If the coolant level is LOW in the radiator, or if there are leaks in the system, the coolant system will not draw coolant from the reservoir tank.

NOTE: Use this procedure when a unit overheats

nd no apparent leaks in the cooling system are

a found.

1. Drive the vehicle onto a slight incline or use properly ht rated ramps. If an incline is not available,

weig slightly elevate the front of the vehicle.

2. Place the vehicle in Park and block the rear wheels.

3. Remove pressure cap and top off coolant.

4. Remove recovery bottle cap and fill bottle to the full line.

5. Leave the cap off of the radiator to allow any possible air to escape.

6. Start the engine and let it idle for 5-10 minutes or until

he thermostat opens and allows coolant to flow

t through the system.

7. Squeeze the coolant lines by hand to help purge the

ystem of air.

8. Slightly loosen the bleed screw (C) on the cylinder

d to let air escape. If no air is present, a steady

hea stream of coolant will stream out. If air is present, the screw will bubble and sputter as the air escapes.

Be sure the engine has cooled and no pressure is built up in the cooling system before removing

the pressure cap. The coolant may be hot and

could cause severe injury or burns.

3.14

9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual

9. Tighten the bleed screw to specification and properly

= T

WARNING

PRELIMINARY VERSION

install the pressure cap.

Coolant Bleed Screw:

70 ± 10 in-lbs (8 ± 1.13 Nm)

NOTE: If there is air in the system you will see air

bbles forming through the radiator filler neck.

10. Add Polaris Premium Antifreez neck if the level goes down. If no bubbles are seen at the filler neck, the system should be purged of air.

Be sure to install the pressure cap before

shutting off the engine.

Coolant may spit out of the radiator.

e to the radiator filler

ENGINE / COOLING

11. Stop the engine and let cool, neck with coolant. If you hear or see a “glug” at the filler neck, or there is a dropping of the coolant level, indicating that coolant has been pulled into the system; completely filled the cooling system at the radiator filler neck.

12. Repeat this procedure, if overheating still occurs.

Fill the recovery bottle only after you have

top off the radiator filler

3.15

9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual

ENGINE / COOLING

PRELIMINARY VERSION

GENERAL ENGINE SERVICE

Engine Lubrication Specifications

Oil Capacity: Approximately 2 U.S. Quarts (1.9 l)

Oil Type: Polaris PS-4 PLUS (PN 2876244)

or PS-4 Extreme Duty (PN 2878920)

Oil Filter: PN 2540086

Filter Wrench: PU-50105 - 2.5” (64 mm)

- Oil Pressure Specification -

27-55 PSI @ 6000 RPM, PS-4 PLUS Synthetic

Engine at operating temperature

Oil Pressure Test

1. Remove blind plug/sender from left side of crankcase.

2. Insert a 1/8 NPT oil pressure gauge adaptor into the

nkcase and attach the gauge.

cra

3. Start engine and allow it to reach operating temperature, while monitoring the gauge.

Accessible Engine Components

The following components can be serviced or removed with the engine installed:

• Starter Motor / Drive

• Cylinder Head

• Cylinder

• Piston / Rings

• Rocker Arms

•Water Pump

The following components require engine removal for se

rvice:

• Flywheel

• Alternator (Stator)

• Counterbalance Shaft or Bearings

• Gear Train Components

• Camshaft

• Oil Pump / Oil Pump Drive Gear

• Connecting Rod

• Crankshaft

• Crankshaft Main Bearings

• Crankcase

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 Standard: 31 PSI

Maximum: 55 PSI

3.16

9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual

ENGINE / COOLING

PRELIMINARY VERSION

Oil Flow Chart

This chart describes the flow of oil through the 800 EFI engine. Beginning in the crankcase sump, the oil is drawn through an oil galley to the feed side of the oil pump. The oil is then pumped through the oil filter. If the oil filter is obstructed, a bypass valve contained in the filter allows oil to bypass the filter element. At this point, the oil is supplied to the main oil galley through a crankcase passage. Oil is then diverted three ways from the main oil galley, with the first path entering the camshaft bores, onto the rear balance shaft journal and then draining back into the crankcase sump. The second oil path from the main oil galley feeds the lifter bores and then drains back to the crankcase sump. The third oil path flows through a crankcase galley to the MAG side crankshaft journal and also to the front balance shaft journal and onto the crankcase sump.

3.17

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ENGINE / COOLING

WARNING

PRELIMINARY VERSION

Engine Removal

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.

IMPORTANT: Some engine repair procedures can be

rformed without removing the engine assembly

pe from the vehicle. Refer to “Accessible Engine Components” on Page 3.14 for further information.

NOTE: The use of an overhead or portable engine

ist is the only recommended method for removing

ho and installing the engine / transmission / rear gearcase assembly.

NOTE: Have an assistant help guide the engine in

nd out of the vehicle while using an engine hoist to

a prevent personal injury or damage to vehicle components.

Always wear safety glasses and proper shop

clothing when performing the procedures in this

manual. Failing to do so may lead to possible

injury or death.

8. Remove the (2) screws (A) from the rear of the center console (RZR / RZR S only).

9. Remove the rear seat base assembly from the

hicle:

• RZR / RZR S: Remove the (2) fasteners (B) from

the rear seat base (as shown above).

• RZR 4: Remove the (2) fasteners and seat latch

plunger (C). Slide the rear seat base to the left and remove it.

1. If vehicle was recently operated, allow it to cool down fore attempting to perform any work.

2. Clean work area.

3. Thoroughly clean the engine and chassis.

4. Drain appropriate lubricant(s):

• If servicing the engine, drain engine oil.

• If servicing the transmission, drain the lubricant om the main gearcase and transfer case.

• If servicing the rear gearcase, drain the gearcase

lubricant.

5. Remove the driver’s seat (see Chapter 5).

6. Disconnect (-) negative battery cable.

7. Remove the passenger seat(s) and remove the rear rvice panel (see Chapter 5).

10. Remove the rear bumper, rear cargo box and box pports from the vehicle (see Chapter 5).

3.18

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ENGINE / COOLING

Remove

Push Rivets

Outlet Duct

PVT Cover

Harness

Connection

Ignition

Coil

Frame Support

PVT Duct

PRELIMINARY VERSION

11. Remove the (2) push rivets and remove the intake box from the vehicle.

12. Elevate the rear of the vehicle off the ground using a suitable ATV lift and remove both rear wheels.

13. Remove all exhaust components from vehicle and

ngine.

14. Loosen the hose clamp attaching PVT cover. Leave the duct attached to the upper frame support.

the outlet duct to the

16. Remove the high tension leads from the spark plugs d disconnect the ignition coil harness.

IMPORTANT: Mark or note which ignition coil wire

oes to which cylinder and ignition coil post. The

g engine will misfire if the spark plug wires are installed incorrectly. The spark plug wires are marked with PTO and MAG from the factory and should be installed to the corresponding cylinder and ignition coil post.

17. Remove the vent lines from the upper bolt-in frame

race and plug vent lines to prevent fluid leakage

b during removal.

15. Remove the (8) screws that retain the PVT cover and emove cover.

18. Remove the (6) fasteners retaining the upper bolt-in me brace and remove it from the vehicle with the

fra ignition coil and PVT duct attached.

3.19

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ENGINE / COOLING

Standard RZR

Shown

Standard RZR

Shown

Loosen

Clamp

PRELIMINARY VERSION

19. Remove the rear stabilizer bar from the linkage on both sides of the vehicle.

20. Remove the (4) fasteners retaining the stabilizer bar

nd bracket and remove the assembly from the

a vehicle.

23. Disconnect the T-MAP, IAC and TPS sensor onnectors from throttle body.

24. Remove the remaining bolt attaching the airbox to the

ame (see photo).

25. Remove the airbox and throttle body from the vehicle

21. Remove the engine breather hose from the valve cover.

22. Loosen the hose clamp between the throttle body and

ake adaptor.

int

as an a cable to bend excessively or kink. Carefully place the assembly on the floor next to the vehicle. Insert a shop towel into the engine intake adaptor to prevent dirt from entering the engine.

NOTE: Ensure throttle cable is not being

essively bent or kinked while removed from the

exc vehicle.

26. Mark the fuel injector harnesses to identify MAG and PT Disconnect the fuel injector harnesses.

ssembly. Take care in not allowing the throttle

O harness connections to aid during reassembly.

3.20

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ENGINE / COOLING

Disconnect Here

DO NOT

Disconnect Here

Fuel

Injector

Harness

Squeeze locking tabs together

Push lock outward

Remove

Clip

Lower

Jam Nut

Mark Upper

Jam Nut

Gear Switch

Connector

PRELIMINARY VERSION

NOTE: The fuel injector harness connector and locking spring is bonded to the fuel injectors with an epoxy mix. DO NOT attempt to disconnect the connector from the fuel injectors. Damage will occur to the injector and/or harness if attempting to separate at that location. Separate the fuel injector from the vehicle by disconnecting at the end of the harness as shown.

IMPORTANT: Take note of PTO and MAG fuel injector

rness connectors before disconnecting them. The

ha harnesses are different and incorrectly (PTO - Gray; MAG - Black).

can not

be connected

28. Disconnect the shift cable from the transmission bell ank.

29. Mark the upper jam nut and loosen the lower jam nut.

Pull the shift cable out of the mount.

27. Disconnect the fuel line from the fuel injector rail by slightly squeezing the lock tabs and gently pushing the connector lock out. To separate the lines, pull the fuel line from the tank strait down.

NOTE: If the upper jam nut is moved, shift cable adjustment will be required during engine installation (see Chapter 2 “Shift Cable Inspection / Adjustment”).

30. Disconnect the transmission gear indicator switch harness.

9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual

3.21

ENGINE / COOLING

CPS

Connector

Stator

Connector

Speed Sensor

Connector

Cam Phase

Connector

Castle Nut

PRELIMINARY VERSION

31. Disconnect the CPS harness.

32. Disconnect the stator / alternator harness.

34. Disconnect the cam phase sensor connector.

35. Remove the castle nuts from both rear wheel hubs.

33. Disconnect the transmissio

3.22

n speed sensor harness.

9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual

36. Remove the through-bolt that attaches the upper A to the rear hub on both sides of the vehicle.

arm

ENGINE / COOLING

Hub Carrier

ECT

Connector

Coolant

Bypass

PRELIMINARY VERSION

37. Pivot the A-arms upward and rear hub carriers downward and remove the drive shafts from the hub carriers.

38. Grasp the rear drive shafts and pull sharply outward

n the shafts to disengage them from the rear

o gearcase.

39. Disconnect the engine coolant temperature (ECT) sor harness and the bypass coolant hose.

sen

40. Loosen the hose clamp and remove the lower coolant

ose from the water pump cover inlet and drain

h coolant into a suitable container.

41. Remove the filler neck pressure cap to relieve the

NOTE: Clean area around drive shaft orifices on

th sides of rear gearcase and cover orifices using

bo duct tape. This will prevent the lubricant from leaking out during removal.

9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual

cooling syst

NOTE: Use a portable wet-vac or syphon to prevent

ny coolant from spilling.

42. Remove the upper coolant hose from the thermostat

ousing outlet to relieve any coolant vacuum created

h in the engine. Allow engine coolant to completely drain. Properly dispose of the engine coolant / antifreeze.

43. Remove the (+) positive battery cable from the starter

otor terminal and (-) negative battery cable from the

m starter motor engine mount.

em vacuum.

3.23

ENGINE / COOLING

Remove

(2) Lower Bolts

Standard RZR

Shown

Transmission/Gearcase

Mount Plate

Engine/Transmission

Mount Plate

PRELIMINARY VERSION

44. Remove RH engine mount fastener.

45. Remove the (2) lower bolts that retain the LH nsmission mount to the frame.

tra

NOTE: The use of an overhead or portable engine

is the only recommended method for removing

hoist and installing the engine / transmission / rear gearcase assembly.

47. Using an engine hoist, hook a chain between the ine / transmission mounting plate and the

eng transmission / rear gearcase mounting plate.

46. Remove the (2) rear gearcase mount bracket fastene vehicle.

3.24

rs and mount bolt and remove bracket from

NOTE: Have an assistant help guide the engine in and out prevent personal injury or damage to vehicle components.

9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual

of the vehicle while using an engine hoist to

ENGINE / COOLING

Allow valve cover

to clear frame

Standard RZR

Shown

PRELIMINARY VERSION

48. Lift the front portion of the assembly out first to allow the engine valve cover to clear the vehicle frame.

49. Remove propshaft from the transmission output shaft.

50. Then move assembly towards the front of the vehicle while lifting the rear portion of the frame.

51. Then lift assembly high enough to clear vehicle frame

nd completely remove it from the vehicle to a work

a bench.

it out to allow the rear gearcase to clear

2. Remove the (6) fasteners retaining the inner clutch ver to the engine and transmission.

3. Remove only the (4) outer fasteners retaining the

ngine to the transmission bracket.

4. Tilt the assembly up and remove the remaining (2)

nuts that

retain the transmission to the engine.

Engine / Transmission Separation

Once the engine / transmission / rear gearcase assembly has been removed from the vehicle, the engine and transmission will need to be separated to allow engine servicing. Use the following procedure to separate the engine from the assembly.

1. Remove the drive belt, drive clutch and driven clutch see Chapter 6).

(

5. Carefully separate the engine and perform the equired service (see “Engine Disassembly and

r Inspection”).

3.25

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ENGINE / COOLING

Push Rods

Hydraulic Lifters

Valves

Cylinder Head

Coolant Bleeder

Springs

Spring Retainers

Rocker Arms

Retainer Locks (keepers)

Valve Spring Seats (2)

Valve Seals (2 )

Head Bolts

PRELIMINARY VERSION

ENGINE DISASSEMBLY AND INSPECTION

Cylinder Head Assembly Exploded View

3.26

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ENGINE / COOLING

WARNING

PRELIMINARY VERSION

Rocker Arms

1. Remove the valve cover.

2. Mark or tag rocker arms in order of disassembly to ep them in order for reassembly.

3. Inspect the wear pad at the valve end of the rocker

rm for indications of scuffing or abnormal wear. If the

a pad is grooved, replace the rocker arm.

NOTE: Do not attempt to true this surface by

rinding.

4. Check the rocker arm pad and fulcrum seat for

excessive wear, cracks, nicks or burrs.

5. If the push rod (A) is visibly be

nt, it should be replaced.

Cylinder Head Removal

NOTE: The cargo box assembly and the upper frame bolt-in brace must be removed to allow enough clearance to remove all the cylinder head bolts. Refer to Chapter 5 for removal procedures.

1. Loosen the six cylinder head bolts (A) evenly 1/8 turn ach in a criss-cross pattern until loose.

2. Remove bolts (A) and tap cylinder head (B) lightly with soft face hammer until loose. CAUTION: Tap only

a in reinforced areas or on thick parts of cylinder head casting to avoid damaging the head or cylinder.

Push Rods

1. Clean push rods (A) in a suitable solvent. Blow dry push rods with compressed air.

2. Use compressed air to confirm the oil passage is clear

the center of the push rod.

Always wear safety glasses when working with

compressed air to prevent personal injury.

3. Check the ends of the push rods (A) for nicks, grooves, roughness or excessive wear.

4. The push rods (A) can be visually checked for

htness while they are installed in the engine by

straig rotating them with the valve closed. Push rods can also be checked with a dial indicator or rolled across a flat surface to check for straightness.

3. Remove cylinder head (B) and head gasket (C) from cylinder (D).

the

3.27

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ENGINE / COOLING

CAUTION

= In. / mm.

Measure at different points on the surface.

WARNING

PU-45257

PRELIMINARY VERSION

Cylinder Head Inspection

Thoroughly clean cylinder head surface to remove all traces of gasket material and carbon.

Use care not to damage sealing surface.

Cylinder Head Warp

Lay a straight edge (A) across the surface of the cylinder head (B) at several different points and measure warp by inserting a feeler gauge between the straight edge and the cylinder head surface. If warp exceeds the service limit, replace the cylinder head.

Valve Seal / Spring Service (On Engine)

NOTE: The following procedure is only for servicing the top end of the valve train when replacing valve springs or replacing valve seals.

In some cases the valve train can be serviced while the

ylinder head is still on the engine. Keep all parts in order

c with respect to their location in the cylinder head.

Wear eye protection or a face shield during

cylinder head disassembly and reassembly.

1. Having already removed the valve cover, rocker arms pushrods, align the cylinder to be worked on at

and top dead center (TDC). Install the Valve Pressure Hose (PU-45652) into the spark plug hole. Hook the hose to an air compressor and supply 50 to 100 psi to the hose. This will seat the valves during valve spring removal. Do not remove air supply until reassembly is completed.

2. Using the Valve Spring Compressor (

compress the valve spring and remove the valve keepers.

PU-45257),

Cylinder Head Warp Limit:

.004" (.1016 mm) max

NOTE: A small parts magnet (A) can aid in the removal

NOTE: To prevent damage to the valve seals, do not compr remove the valve keepers.

3. Remove spring retainer and spring.

4. The valve seals are now serviceable.

of the retainers (B).

ess the valve spring more than is needed to

3.28

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ENGINE / COOLING

= In. / mm.

Valve Spring Free Length

Mark the Valves

PRELIMINARY VERSION

Cylinder Head Disassembly

1. Carefully remove the cylinder components.

2. Place the hydraulic lifters (C), pushrods (D), and rocker arms (E) in a safe, clean area.

4. Remove valve guide seals.

IMPORTANT: It is recommended to replace seals

ever the cylinder head is disassembled.

when Hardened, cracked or worn valve seals will cause excessive oil consumption and carbon buildup.

5. Mark the valves with a white pen. Remove the valves from the cylinder head. This will ensure that the valves

e properly placed during engine reassembly.

3. Measure free length of spring with a Vernier caliper. are to specifications. Replace spring if

Comp measurement is out of specification.

Valve Spring Free Length:

Std: 1.735" (44.069 mm)

3.29

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ENGINE / COOLING

Measure valve stem in several places. Rotate the valve 90 degrees and measure for wear.

= In. / mm.

PRELIMINARY VERSION

Valve Inspection

1. Remove all carbon from valves with a soft wire wheel or brush.

2. Check valve face for runout, pitting, and burnt spots. To check for or use “V” blocks and a dial indicator.

3. Check end of valve stem (A) for flaring, pitting, wear

r damage. Inspect split keeper groove (B) for wear

o or flaring of the keeper seat area.

bent valve stems, mount valve in a drill

Valve Stem Diameter:

Intake: 0.2356"  0.00039"

(5.985  0.01 mm)

Exhaust: 0.2351"  0.00039"

(5.972  0.01 mm)

5. Measure valve guide (C) inside diameter at the top le and end of the guide using a small hole gauge

midd and a micrometer. Measure in two directions.

Valve Guide I.D.:

0.23672"  0.000295"

NOTE: The valves can be re-faced or end ground, if

cessary. They must be replaced if extensively

ne worn, burnt, bent, or damaged.

4. Measure diameter of valve stem three places, then rotate 90 degrees and measure again (six measurements total). Compare to specifications.

3.30

with a micrometer in

9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual

6. Subtract valve stem measurement from the valve guide measurement to obtain stem to guide clearance.

NOTE: The valve guides canno sure to measure each guide and valve combination individually.

(6.0617

Valve Stem Oil Clearance:

Intake: 0.00228"  0.00098"

(0.058

Exhaust: 0.00275"  0.00098"

(0.087

 0.0075 mm)

 0.025 mm)

t be replaced. Be

ENGINE / COOLING

WARNING

Combustion Area

PRELIMINARY VERSION

Combustion Chamber

1. Clean all accumulated carbon deposits from combustion chamber and valve seat area with carbon cleaner and a soft plastic scraper.

IMPORTANT: Do not use a wire brush, metal scraper,

abrasive cleaners to clean the bottom of the

or cylinder head. Extensive damage to the cylinder head may result. Wear safety glasses during cleaning.

NOTE: Valve seat width and point of contact on the

alve face is very important for proper sealing. The

v valve must contact the valve seat over the entire circumference of the seat, and the seat must be the proper width all the way around. If the seat is uneven, compression leakage will result. If the seat is too wide, seat pressure is reduced, causing carbon accumulation and possible compression loss. If the seat is too narrow, heat transfer from valve to seat is reduced. The valve may overheat and warp, resulting in burnt valves.

Valve Seat Reconditioning

NOTE: Polaris recommends that the work be done by a local machine shop that specializes in this area.

NOTE: The cylinder head valve guides cannot be

placed.

Wear eye protection or a face shield during

cylinder head disassembly and reassembly.

Valve Seat Inspection

Inspect valve seat in cylinder head for pitting, burnt spots,

oughness, and uneven surface. If any of the above

r conditions exist, the valve seat must be reconditioned. If

the valve seat is cracked the cylinder head must be replaced.

Follow the manufacture valve seat cutters in the commercially available cylinder head reconditioning kit. Abrasive stone seat reconditioning equipment can also be used. Keep all valves in order with their respective seat.

rs instructions provided with the

1. Install pilot into valve guide.

2. Apply cutting oil to valve seat and cutter.

3. Place 46

 cutter on the pilot and make a light cut.

3.31

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ENGINE / COOLING

= In. / mm.

Proper Seat Contact

on Valve Face

Bottom 60°

Seat 45°

Top 30°

Seat

Width

PRELIMINARY VERSION

4. Inspect the cut area of the seat:

* If the contact area is less th of the seat, rotate the pilot 180 cut.

* If the cutter now contacts the uncut portion of the seat, check the pilot. Look for burrs, nicks, or runout. If the pilot is bent it must be replaced.

* If the contact area of the cutter is in the same place, the valve guide is distorted from improper installation.

* If the contact area of the initial cut is greater than 75%, continue to cut the seat until all pits are removed and a new seat surface is evident. NOTE: Remove only the amount of material necessary to repair the seat surface.

5. To check the contact area of the seat on the valve face, ap the valve seat. If using an interference angle (46 apply black permanent marker to the entire valve face (A).

ply a thin coating of Prussian Blue paste to

an 75% of the circumference

 and make another light

)

NOTE: When using an interference angle, the seat

act point on the valve will be very narrow, and is

cont a normal condition. Look for an even and continuous contact point all the way around the valve face (A).

6. Insert valve into guide and tap valve lightly into place

w times.

a fe

7. Remove valve and check where the Prussian Blue indicates seat contact on the valve face. The valve seat should contact the middle of the valve face or slightly above, and must be the proper width.

* If the indicated seat contact is at the top edge of the valve

and contacts the margin area (B) it is too high on the

face valve face. Use the 30 cutter to lower the valve seat.

* If too low, use the 60 cutter to raise the seat. When contact area is centered on the valve face, measure seat width.

* If the seat is too wide or uneven, use both top and bottom cutters to narrow the seat.

* If the seat is too narrow, widen using the 45 re-check contact point on the valve face and seat width after each cut.

3.32

 cutter and

8. Clean all filings from the area w Rinse and dry with compressed air.

9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual

Valve Seat Width:

Intake Std: .028" (.7 mm)

Limit: .055" (1.4 mm)

Exhaust Std: .039” (1.0 mm)

Limit: .071" (1.8 mm)

ith hot soapy water.

ENGINE / COOLING

PU-45257

PRELIMINARY VERSION

9. Lubricate the valve guides with clean engine oil, and apply oil or water based lapping compound to the face of the valve.

NOTE: Lapping is not required with an interference

ngle valve job.

10. Insert the valve into its respective guide and lap using

lapping tool or a section of fuel line connected to the

a valve stem.

11. Rotate the valve rapidly back and forth until the cut

nds smooth. Lift the valve slightly off of the seat,

sou rotate 1/4 turn, and repeat the lapping process. Do this four to five times until the valve is fully seated, and repeat process for the other valve(s).

Cylinder Head Reassembly

NOTE: Assemble the valves one at a time to maintain proper order.

1. Apply engine oil to valve guides and seats.

2. Coat valve stem with molybdenum disulfide grease or tic engine oil.

synthe

3. Install valve carefully with a rotating motion to avoid

damaging valve seal.

4. Valve seals should be installed after the valves are in

e head to avoid valve seal damage. Install new valve

th seals on valve guides.

5. Dip valve spring and retainer in clean engine oil and

nstall.

6. Place retainer on spring and install Valve Spring

Compressor ( gap even on both sides.

NOTE: A small magnet can be used to aid in the

tallation of the keepers.

ins

PU-45257). Install split keepers with the

12. Thoroughly clean cylinder head and valves.

7. Repeat procedure for remaining valves. When all

es are installed, tap lightly with soft faced hammer

valv on the end of the valves to seat the split keepers.

NOTE: To prevent damage to the valve seals, do not

ompress the valve spring more than necessary to

c install the keepers.

3.33

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ENGINE / COOLING

Mark Hydraulic Lifter

Inspect Hydraulic Lifter

PRELIMINARY VERSION

Valve Sealing Test

1. Clean and dry the combustion chamber area (A).

2. Pour a small amount of clean solvent onto the intake port and check for leakage around each intake valve. The valve seats should hold fluid with no seepage.

3. Repeat for exhaust valves by pouring fluid into

ust port.

exha

Cylinder Removal

1. Follow engine disassembly procedures to remove rocker cover and cylinder head.

2. Tap cylinder (A) lightly with a rubber mallet in the

inforced areas only until loose.

3. Rock cylinder forward and backward while lifting it

rom the crankcase, supporting pistons and

f connecting rods. Support pistons with Piston Support Block (PN 2870390).

Valve Lifter Removal / Inspection

1. Remove the valve lifters by reaching into the crankcase and pushing the lifter up through the lifter bore by hand.

2. Thoroughly clean the lifters in cleaning solvent and

e them with a clean, lint-free cloth.

wip

3. Mark the lifters with a white pen if using the lifters for

sembly. This will ensure that the lifters are

reas properly placed during engine reassembly.

4. Check the lifters for wear or scores.

5. Check the bottom end of lifter to a slight convex.

6. If the bottom surface has worn flat, it may be used with

original camshaft only.

the

make sure that it has

NOTE: Lifters that are scored, worn, or if the bottom

not smooth should be replaced with new lifters

is and cam as an assembly. If replacing the lifters, the camshaft should also be replaced.

3.34

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ENGINE / COOLING

Compression

Rings

Oil Ring

PRELIMINARY VERSION

Piston Removal

1. Remove the circlip. Mark the piston with a white pen to ensure proper orientation (if reused) during assembly.

NOTE: If the pistons are to be reused, reassemble

he pistons in the same cylinder and direction from

t which they were removed.

NOTE: New pistons are non-directional and can be

ed in either cylinder.

plac

4. Repeat procedure for second ring.

5. Remove the oil control ring.

The oil control ring is a three piece design consisting of a

p and bottom steel rail and a center expander section.

to The top rail has a locating tab on the end which fits into a notch (B) in the upper oil ring land of the piston.

To Remo ve :

A) Remove the top rail first follo

B) Remove the expander.

wed by the bottom rail.

2. Remove piston circlip and push piston pin out of piston. If necessary, heat the crown of the piston slightly with a propane torch. CAUTION: Do not apply heat to the piston rings. The ring may lose radial tension.

3. Remove top compression ring:

*Using it off the piston. CAUTION: Do not expand the ring more than the amount necessary to remove it from the piston, or the ring may break.

*By hand: open and push up on the opposite side. Do not scratch the ring lands.

a piston ring pliers: Carefully expand ring and lift

Placing both thumbs as shown, spread the ring

3.35

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ENGINE / COOLING

= In. / mm.

Measure at different

points on surface.

= In. / mm.

1/2” Down From Top of Cylinder

1/2” Up From Bottom

PRELIMINARY VERSION

Cylinder Inspection

1. Remove gasket material from cylinder sealing surfaces.

2. Inspect top of the cylinder (B) for warp using a straight edge (A) and feeler gauge (C). Refer to Ill. 1 and Ill. 2.

4. Inspect cylinder for taper and out of round with a lescoping gauge or a dial bore gauge. Measure in

te two different directions, front to back and side to side, on three different levels (1/2" down from top, in the middle and 1/2" up from bottom). Record measurements. If cylinder is tapered or out of round beyond .002", the cylinder must be replaced.

Cylinder Taper Limit: .002" (.050 mm) Max.

Cylinder Out of Round:

Limit: .002" (.050 mm) Max.

Cylinder Warp: .004" (0.1 mm) Max.

3. Inspect cylinder for wear, scratches, or damage.

(Both Cylinders): 3.1496" (80 mm)

Standard Bore Size

3.36

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ENGINE / COOLING

CAUTION

Example of Cross Hatch Pattern

PRELIMINARY VERSION

Cylinder Hone Selection and Honing Procedure

Cylinders may be wet or dry honed depending upon the hone manufacturer’s recommendations. Wet honing removes more material faster and leaves a more distinct pattern in the bore.

A hone which will straighten as well as remove

material from the cylinder is very important.

Using a common spring loaded glaze breaker

for honing is not advised for nicasil cylinders.

Polaris recommends using a rigid hone or

arbor honing machine.

Honing To Deglaze

A finished cylinder should have a cross-hatch pattern to ensure piston ring seating and to aid in the retention of the fuel/oil mixture during initial break in. Hone cylinder according to hone manufacturer's instructions, or these guidelines:

• Honing should be done with a diamond hone. ylinder could be damaged if the hone is not hard

C enough to scratch the nicasil lining.

• Use a motor speed of approximately 300-500

RPM, run the hone in and out of the cylinder rapidly until cutting tension decreases. Remember to keep the hone drive shaft centered (or cylinder centered on arbor) and to bring the stones approximately 1/2” (1.3 cm) above and below the bore at the end of each stroke.

If cylinder wear or damage is necessary to replace the cylinder. The cylinders are lined with a nicasil coating and are not repairable. Hone only enough to de-glaze the outer layer of the cylinder bore.

IMPORTANT: Clean the cylinder after honing

excessive, it will be

Cleaning the Cylinder After Honing

It is very important that the cylinder be thoroughly cleaned after honing to remove all grit material. Wash the cylinder in a solvent, then in hot, soapy water. Pay close attention to areas where the cylinder sleeve meets the aluminum casting (transfer port area). Use electrical contact cleaner if necessary to clean these areas. Rinse thoroughly, dry with compressed air, and oil the bore immediately with Polaris Lubricant.

• Release the hone at regular intervals and inspect

the bore glazed, and to check for correct cross-hatch.  NOTE: Do not allow cylinder honing.

• After honing has been completed, inspect cylinder

for thinning or peeling.

to determine if it has been sufficiently de-

to heat up during

9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual

3.37

ENGINE / COOLING

5 mm

Piston

Piston Pin

Piston Pin Measurement Locations

PRELIMINARY VERSION

Piston-to-Cylinder Clearance

Measure piston outside diameter at a point 5 mm up from the bottom of the piston at a right angle to the direction of the piston pin.

Subtract this measurement from the maximum cylinder

re measurement obtained during the “Cylinder

bo Inspection” procedure.

Piston to Cylinder Clearance:

See “800 EFI Engine Service Specifications”

on page 3.8

2. Measure piston pin O.D. Rep pin if out of specification.

Piston Pin O.D.:

See “800 EFI Engine Service Specifications”

on page 3.8

3. Measure connecting rod small end ID.

lace piston and/or piston

Piston O.D.:

See “800 EFI Engine Service Specifications”

on page 3.8

Piston / Rod Inspection

1. Measure piston pin bore.

Piston Pin Bore:

See “800 EFI Engine Service Specifications”

on page 3.8

Connecting Rod Small End I.D.:

See “800 EFI Engine Service Specifications”

on page 3.8

3.38

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ENGINE / COOLING

Piston

Ring

Feeler Gauge

25-50 mm

PRELIMINARY VERSION

4. Measure piston ring to groove clearance by placing the ring in the ring land and measuring with a thickness gauge. Replace piston and rings if ring-togroove clearance exceeds service limits.

See “800 EFI Engine Service Specifications”

on page 3.8

Piston Ring Installed Gap

1. Place each piston ring (A) inside cylinder (B) using a piston to push ring squarely into place as shown.

3. If the bottom installed gap measurement exceeds the rvice limit, replace the rings. If ring gap is smaller

se than the specified limit, file ring ends until gap is within specified range.

NOTE: Always check piston ring installed gap after

e-boring a cylinder or when installing new rings. A

r re-bored cylinder should always be scrubbed thoroughly with hot soapy water, rinsed, and dried completely. Wipe cylinder bore with oil immediately to remove residue and prevent rust.

Starter Drive Bendix Removal / Inspection

1. Remove stator housing bolts and remove housing.

2. Remove the flywheel nut and washer. Install Flywheel

ller (PN 2871043) and remove flywheel.

NOTE: Do not thread the puller bolts into the f

lywheel more than 1/4" or stator coils may be

damaged.

3. Remove starter bendix assembly (A). Note the thrust

washers located on both sides of the bendix.

4. Inspect the thrust washer for wear or damage and

replace if

Piston Ring Installed Gap:

See “800 EFI Engine Service Specifications”

on page 3.8

NOTE: Ring should be installed with the mark facing upward.

2. Measure installed gap with a feeler gauge (C) at both th

e top and bottom of the cylinder.

IMPORTANT: A difference in end gap indicates cylinder taper. The cylinder should be measured for excessive taper and out of round.

9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual

5. After the bendix is removed, remove the two bolts retaining the starter. Tap on the starter assembly (B) with a soft faced mallet to loosen the starter from the crankcase.

necessary.

3.39

ENGINE / COOLING

CAUTI ON

Remove Stator

Cover

2871043

PRELIMINARY VERSION

6. Inspect gear teeth on starter drive. Replace starter drive if gear teeth are cracked, worn, or broken.

7. Inspect the bendix bushing (C) in the mag cover for

r. Replace as needed.

wea

Flywheel / Stator Removal / Inspection

1. Remove stator cover bolts and remove stator cover.

4. Use caution when removing the wire holddown (B)

and the stator assembly (D). Do not tap or bump the gear /stator housing cover or the stator. This could cause the seal around the gear/stator housing cover and the crankcase to break, causing a leak.

5. Remove the bendix (E) if necessary.

Engine Crankcase Disassembly / Inspection

2. Remove flywheel nut and washer.

3. Install Flywheel Puller ( flywheel (A).

Do not thread the puller bolts into the flywheel

more than 1/4" or stator coils may be damaged.

3.40

PN 2871043) and remove

9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual

1. Remove stator cover (A) and water pump cover (B).

ENGINE / COOLING

CAUTI ON

2871043

Counterbalance Gear

Camshaft Gear

Crank Gear

PRELIMINARY VERSION

2. Remove the nut (C), washer (D) and water pump impeller (E). Remove part of the water pump seal behind the impeller.

3. Remove flywheel nut and washer.

4. Install Flywheel Puller ( flywheel (F).

PN 2871043) and remove

5. Remove the starter bendix (G), wire holddown plate (H), and the woodruff key (I) from the crankshaft. The stator does not have to be removed at this point.

6. Remove the gear/stator housing bolts and remove the gear/stator housing cover (J) and gasket from the crankcase. Be sure to catch the excess oil from the crankcase.

Do not thread the puller bolts into the flywheel

more than 1/4" or stator coils may be damaged.

7. Note the position of the gears in the photo.

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3.41

ENGINE / COOLING

Timing Marks

Water Pump Gear

3 Loaded Springs

CAUTI ON

PU-45497-1

Accent Timing Marks

PRELIMINARY VERSION

8. Use a white pen to accent the timing marks on the following gears: camshaft gear (K), crankshaft gear (M), or counterbalance gear (N) This will ensure proper gear alignment and timing during reassembly of the gears.

NOTE: If replacing one of the gears, it is

commended that all of the gears be replaced. A

re gear kit is available.

9. Use the Cam Gear Tooth Alignment Tool (PU-45497-

) to align and hold the cam split gear assembly. With

2 the split gear aligned, remove the bolt and cam gear assembly.

11. The cam gear assembly contains three loaded rings. To open the cam gear assembly:

• Place the cam gear on a flat surface with the mark side facing up.

timing

• While holding both gears together, lightly work a

small flathead screwdriver between the two gears.

• Remove the top gear. The springs should stay in

place.

Wear safety glasses at all times. Use caution

when working with the top gear.

The springs could cause injury or become lost

should they pop out.

12. Remove all three springs using one of the tapered

pins from (PU-45497-1).

NOTE: Install the Cam Gear Tooth Alignment Tool

PU-45497-2) into the assembly hole counter

( clockwise from the timing mark (see page 3.42).

10. Inspect the cam gear teeth and check to make sure re is spring tension offsetting the teeth between the

the two gears. If there is no tension, check the springs inside of the cam gear assembly.

13. With a white marking pen, accent the timing mark on e gear that contains the springs.

3.42

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ENGINE / COOLING

Inspect Teeth & Tabs

Replace 3 Springs

Install Springs

PU-45497-1

Align Timing Marks

PRELIMINARY VERSION

14. Inspect the gear teeth and the three tabs on the gears for wear.

15. Install the new springs into the grooves of the cam

ear.

To Assemble:

• Hold the spring with one finger.

• Start the pointed end of the tapered pin into the cam ge hole until the end of the dowel is almost flush with the spring.

• Perform this procedure with all three tapered pins.

• Do not push the pins too far through or the springs will pop

NOTE: Do not remove the tapered pins at this time.

17. Note in photograph that the Tapered Pins (PU-45497-

1) are below flush with end of the springs. This helps

to align the three gear tabs during the next step.

ar hole. Slowly push the dowel through the

out.

Cam Gear Spring Installation Tool Kit:

(PU-45497)

Tapered Pins:

PU-45497-1)

(

Cam Gear Tooth Align Tool:

PU-45497-2)

16. Insert the pointed dowels from the Tapered Pins (PU5497-1) into the cam gear.

18. Line up the two gears using the timing marks and the ree gear tabs referenced earlier. Push the gears

th back together, using both hands and hold securely.

(

3.43

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ENGINE / COOLING

PU-45497-2

PU-45498

2871043

PRELIMINARY VERSION

19. Once the gears are pressed together, firmly hold the gears together with one hand. Carefully remove the Tapered Pins (PU-45497-1) by pulling them out one at a time with the other hand.

20. After the tapered pins are removed, be sure the cam gear assembly is held together tightly. Place the cam gear assembly on a flat surface. Use the Cam Gear Tooth Alignment Tool (PU-45497-2) to align the teeth of the cam gears, as shown in the picture.

NOTE: Install the Cam Gear Alignment Tool (PU-

5497-2) into one assembly hole counter clockwise

4 from the timing mark.

21. To remove the balance shaft gear, the flat side of the mshaft (P) must face the balance shaft gear. To

ca rotate the camshaft, use the Cam Spanner Wrench (PU-45498) to rotate the camshaft so the flat side of the camshaft faces the balance shaft gear.

NOTE: This Cam Spanner Wrench (PU-45498) is only nee valve train is assembled. If the rocker arms are removed, the cam-shaft can be turned by hand.

22. Remove the bolt and nut from the balance shaft gear.

ded to rotate the camshaft when the entire

ry to remove the balance shaft gear. If the gear does

T not come off manually, use the Flywheel Puller (PN

2871043) to remove the balance shaft gear.

NOTE: For ease of installing the Cam Gear

nment Tool (PU-45497-2), use a twisting motion

Alig when pushing down on the tool.

3.44

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ENGINE / COOLING

2871043

Mark Rotors

Max Tip Clearance

0.006” (0.15 mm)

PRELIMINARY VERSION

23. Inspect the crankshaft gear (Q) for broken or worn teeth. If the crankshaft gear does not need to be replaced, it does not need to be removed. If the crankshaft gear is damaged, remove the crankshaft gear with the Flywheel Puller (PN 2871043).

24. Install the two puller bolts (R). Tig up so that the bolts are at equal length.

hten the puller bolts

26. Rotate the water/oil pump gear bolts are visible though the gear. Remove the four bolts with a hex wrench. Pull out the pump.

27. Inspect the oil pump rotors for wear. Mark the rotors with a white pen to ensure upon reassembly that the correct sides of the rotors are installed and mesh with the same edges as previously installed.

(S), so that all four

NOTE: If replacing the old rotors, new replacement

otors will fit into the original oil/water pump

25. Install the Flywheel Puller (PN 2

the crankshaft gear, if needed.

871043) and remove

r housing.

28. Use a feeler gauge to mea the two rotors. Measure the gap between the two rotor tips as shown below. The clearance should not exceed 0.006" (0.15 mm).

sure the clearance between

9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual

3.45

ENGINE / COOLING

= T

22 ± 2 ft-lbs

(30 ± 3 Nm).

Chamfer

End First

CAUTI ON

Press Off Gear

Press out shaft

and bearing

assembly.

Bearing

Retaining Ring

Press Off Bearing

PRELIMINARY VERSION

29. Remove the oil pressure relief. The oil pressure relief consists of a bolt, washer, spring, and valve (dowel). Inspect the valve (dowel) for signs of possible obstructions. Use compressed air to blow out any debris.

30. Reinstall the valve (dowel chamfered end first). Install

spring, washer, and bolt. Torque to specification.

the

31. Carefully press the gear off the assembly while pporting the housing assembly.

Wear appropriate safety gear during this

procedure. Protective gloves, clothing and eye

wear are required.

32. Remove snap ring from the assembly. Place housing

in a support and press out the bearing/shaft assembly.

Oil Pressure Relief Bolt:

22 ± 2 ft-lbs (30 ± 3 Nm)

NOTE: Be sure to place the tapered end of the valve

dowel) in first. If the valve is installed incorrectly, oil

( pressure and oil priming problems will occur.

3.46

9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual

33. Place the shaft in a press to remove the bearing.

ENGINE / COOLING

Press On Bearing

Press Bearing / Shaft

Assembly using

outer race only

Separate

Crankcase Halves

PRELIMINARY VERSION

34. Press shaft into the new bearing.

35. Press the bearing/shaft assembly using the bearing's o

uter race. Do not use the shaft to press the assembly into the housing, as bearing damage may result. Install retaining ring.

37. Remove thrust plate (U).

38. Remove PTO end engine mount. Remove crankcase olts. Tap on the reinforced areas on the cases using

b soft hammer. Carefully separate the two crankcase halves.

36. Press gear onto shaft while supporting the housing.

NOTE: Only remove the oil baffle if the baffl damaged. When removing the oil baffle bolts, use a heat gun to heat the bolts and loosen the Loctite This will prevent any possible damage to the bolts or to the crankcase casting.

e is

.

3.47

9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual

ENGINE / COOLING

= In. / mm.

Cam Lobe Height

PRELIMINARY VERSION

39. Remove and clean oil pick up (V) and oil baffle weldment (W).

40. Remove balance shaft and crankshaft.

Camshaft Inspection

1. Thoroughly clean the cam shaft.

2. Visually inspect each cam lobe for wear, chafing or age.

dam

3. Measure height of each cam lobe using a micrometer.

ompare to specification.

41. Remove and inspect crankshaft mai

for abnormal wear. It is recommended to replace the bearings anytime the engine is disassembled.

n journal bearings

Cam Lobe Height

Intake (Std):

1.357” (34.477 mm)

Exhaust (Std.):

1.342” (34.096 mm)

3.48

9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual

Polaris RANGER RZR S (2013) Service manual

Specifications and Main Features

Frequently Asked Questions

User Manual