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2013 RANGER RZR S
Polaris 2013 RANGER RZR S User Manual
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10.22
ELECTRICAL
9924125 - 2013
RANGER
RZR
/ RZR S / RZR 4 Service Manual
© Copyright 2012 Polaris Sales Inc.
COOLING SYSTEM
Cooling System Br
eak-Out Diagram
393
395
Table of Contents
General Information Chapter
1
Table of Contents
1
Chapter 1
2
Engine Designation Number
2
Model Number Designation
2
Vehicle Identification
2
Vehicle Identification Number (Vin) Designation
2
Vehicle and Engine Serial Number Locations
3
Vehicle Information
4
Publication Numbers
4
Replacement Keys
4
Special Tools
5
General Specifications
6
Misc. Specifications and Charts
12
Conversion Table
12
Standard Bolt Torque Specification
13
Metric Bolt Torque Specification
13
Sae Tap / Drill Sizes
14
Metric Tap / Drill Sizes
14
Maintenance Chapter 2 Maintenance 2
15
Break-In Period / Maintenance Chart Key
17
Chapter 2
17
Periodic Maintenance Chart
17
Pre-Ride - 50 Hour Maintenance Interval
18
100 - 300 Hour Maintenance Interval
19
Maintenance Quick Reference
20
Maintenance Quick Reference, Continued
21
Grease Lubrication Points
22
Lubricants / Service Products
23
General Vehicle Inspection and Maintenance
24
Pre-Ride / Daily Inspection
24
Frame, Nuts, Bolts, and Fasteners
24
Shift Cable Inspection / Adjustment
24
Fuel System and Air Intake
25
Fuel Line / Fuel Pump / Fuel Filters
25
Vent Lines
25
Throttle Pedal Inspection
26
Throttle Freeplay Adjustment
26
Air Filter Service
27
Engine
29
Engine Oil Level
29
Engine Oil and Filter Service
30
Engine Breather Hose Inspection
31
Engine and Transmission Mounts
31
Compression and Leakdown Test
31
Exhaust - Spark Arrestor
32
Transmission and Gearcases
33
Transmission / Gearcase Specification Chart
33
Transmission Lubrication
33
Front Gearcase Lubrication
36
Rear Gearcase Lubrication
37
Cooling System
39
Cooling System Overview
39
Coolant Level Inspection
39
Coolant Strength / Type
40
Cooling System Pressure Test
40
Cooling System Hoses
40
Radiator
41
Coolant Drain
41
Final Drive / Wheel and Tire
42
Wheel and Hub Torque Table
42
Wheel Removal
42
Wheel Installation
42
Tire Inspection
43
Tire Pressure
43
Drive Shaft Boot Inspection
43
Electrical and Ignition System
44
Battery Maintenance
44
Battery Removal
44
Battery Installation
45
Battery off Season Storage
45
Battery Charging (Maintenance Free)
45
Spark Plug Service
45
Engine to Frame Ground
46
Steering
47
Steering Inspection
47
Steering Wheel Freeplay
47
Tie Rod End / Wheel Hub Inspection
47
Wheel Toe Alignment Inspection
48
Wheel Toe Adjustment
48
Suspension (Standard)
49
Spring Preload Adjustment
49
Suspension (Fox™)
50
Spring Preload Adjustment
50
Shock Compression Adjustment
51
Brake System
52
Brake Fluid Inspection
52
Brake Pad / Disc Inspection
52
Brake Hose and Fitting Inspection
52
Chapter 3 Engine / Cooling
53
Crankcase
54
Engine Specifications
54
Oil Pump / Gears / Engine Cover
55
Stator Cover / Starter / Water Pump / Lubrication System
56
Cylinder / Cylinder Head / Piston
57
Engine Efi Sensors / Valve Cover / General Components
58
Engine Torque Specifications
59
800 EFI Engine Service Specifications
60
Special Tools
62
Engine Cooling System
63
Cooling System Specifications / Pressure Test
63
Pressure Cap Test
63
Cooling System Exploded View
64
Radiator Removal
65
Cooling System Bleeding Procedure
66
General Engine Service
68
Engine Lubrication Specifications / Oil Pressure Test
68
Accessible Engine Components
68
Oil Flow Chart
69
Engine Removal
70
Engine / Transmission Separation
77
Engine Disassembly and Inspection
78
Cylinder Head Assembly Exploded View
78
Rocker Arms / Push Rods
78
Cylinder Head Removal
79
Cylinder Head Inspection / Warp
80
Valve Seal / Spring Service (on Engine)
80
Cylinder Head Disassembly
81
Valve Inspection
82
Combustion Chamber / Valve Seat Reconditioning
83
Cylinder Head Reassembly
85
Valve Sealing Test
86
Cylinder Removal
86
Valve Lifter Removal / Inspection
86
Piston Removal
87
Cylinder Inspection
88
Cylinder Hone Selection and Honing Procedure
89
Honing to Deglaze / Cleaning the Cylinder after Honing
89
Piston-To-Cylinder Clearance
90
Piston / Rod Inspection
90
Piston Ring Installed Gap
91
Starter Drive Bendix Removal / Inspection
91
Flywheel / Stator Removal / Inspection
92
Engine Crankcase Disassembly / Inspection
92
Camshaft Inspection
100
Engine Reassembly
101
Crankcase Reassembly
101
Flywheel / Stator Installation
110
Cylinder Head Reassembly
110
Oil Pump Priming
112
Engine Installation
113
Engine Assembly and Installation
113
Engine Break-In Period
114
Troubleshooting
115
Chapter 4 Electronic Fuel Injection
117
General Information
118
Special Tools
118
Service Notes
120
Efi System Exploded View
121
Efi System Component Locations
122
Fuel Tank
124
Exploded View
124
Fuel Line Removal / Installation
125
Electronic Fuel Injection
125
Electronic Control Unit (Ecu)
127
Crankshaft Position Sensor (Cps)
128
Temp / Manifold Absolute Pressure Sensor (T-Map)
128
Fuel Injectors
133
Fuel Injector Service
133
Fuel Pump
136
Fuel Sender Test
136
Fuel Pump Test
137
Fuel Pump Replacement
138
Fuel Tank Removal (Rzr / Rzr S)
141
Fuel Tank Removal (Rzr 4)
143
Fuel Tank Installation
145
Idle Air Control (Iac)
146
Throttle Position Sensor (Tps)
147
Tps Resistance Tests
147
Tps Tester / Regulator
147
Tps Replacement
148
Camshaft Phase Sensor
150
Engine Coolant Temperature Sensor (Ect)
151
Overview, Test and Replacement
151
Ignition Coil
152
Ignition Coil / Ht Lead Replacement
152
Ignition Coil Tests
152
Efi Diagnostics
153
Instrument Cluster Trouble Code Display
153
Efi Troubleshooting
156
Digital Wrench™ Operation
157
Digital Wrench™ Communication Errors
157
Digital Wrench™ - Diagnostic Connector
158
Digital Wrench™ Serial Number Location
158
Digital Wrench™ Version and Update ID
158
Digital Wrench™ Updates
159
Digital Wrench™ Feature Map
160
Engine Controller Reprogramming (Reflash)
161
Chapter 5 Body / Steering / Suspension
165
Special Tools
167
Torque Specifications
167
Cab Frame (Rzr / Rzr S)
168
Cab Frame (Rzr 4)
170
Body Exploded Views
172
Side Safety Nets
172
Dash Instruments / Controls / Glovebox
173
Hood / Front Body Work
174
Rear Bumper
175
Seat Assembly
176
Seat Belts / Mounting (Rzr / Rzr S)
176
Seat Belts / Mounting (Rzr 4)
177
Floor / Rocker Panels (Rzr / Rzr S)
178
Floor / Rocker Panels (Rzr 4)
179
Rear Cargo Box / Fenders (Rzr / Rzr S)
180
Rear Cargo Box / Fenders (Rzr 4)
181
Chassis / Main Frame (Rzr / Rzr S)
182
Chassis / Main Frame (Rzr 4)
183
Body Component Removal
184
Seats
184
Rear Service Panel (Rzr / Rzr S)
184
Rear Console Cover (Rzr 4)
184
Front Bumper
184
Rear Bumper
185
Hood and Front Body Work
185
Rear Fender, Flair and Tie down Removal
186
Cargo Box Assembly Removal
187
Rocker Panels, Console and Floor
187
Steering Assembly
189
Exploded View (Non-Eps Models)
189
Steering Wheel Removal (Non-Eps Models)
190
Steering Shaft Removal (Non-Eps Models)
190
Steering Shaft Bearing Replacement
191
Electronic Power Steering Assembly
192
Exploded View (Eps Models)
192
Upper Steering Shaft Removal (Eps Models)
193
Steering Wheel Removal (Eps Models)
194
Power Steering Unit Removal
194
Lower Steering Shaft Removal (Eps Models)
195
Lower Steering Shaft Installation (Eps Models)
196
Power Steering Unit Installation
196
Upper Steering Shaft Installation (Eps Models)
197
Front A-Arms
198
Removal / Replacement
198
Exploded View (Rzr)
199
Exploded View (Rzr S / Rzr 4)
199
Ball Joint Service
200
Service Preparation
200
Ball Joint Removal
200
Ball Joint Installation
201
Front Stabilizer Bar (Rzr / Rzr S Int'l)
202
Stabilizer Bar Linkage Removal
202
Stabilizer Bar Removal
202
Exploded View
202
Rear A-Arms
205
Installation
206
Exploded View (Rzr)
207
Exploded View (Rzr S / Rzr 4)
207
Rear Stabilizer Bar (Rzr)
208
Removal / Installation
208
Rear Stabilizer Bar (Rzr S / Rzr 4)
209
Removal / Installation
209
Shocks / Springs / Fasteners
210
Exploded View (Rzr / Rzr S)
210
Exploded View (Rzr S / Rzr S Int'l)
210
Exploded View (Rzr 4)
211
Shock Removal / Installation
211
Shock Replacement
211
Fox™ Podium Piggyback Shock Service
212
Fox™ 1.5 Podium 'Piggyback' Shock (Rzr S)
212
Fox™ 1.5 Podium 'Piggyback - General Service Information
213
Front Shock Service (Rzr S)
213
Rear Shock Service (Rzr S)
213
Fox™ 2.0 Podium 'Piggyback' Shock (Rzr 4 L.e. Models)
214
Fox™ 2.0 Podium 'Piggyback - General Service Information
215
Front Shock Service (Rzr 4 L.e Models)
215
Rear Shock Service (Rzr 4 L.e. Models)
215
Fox™ Podium 'Piggyback' Rebuild Information
216
Fox™ Podium 'Piggyback' Special Tools
216
Fox™ Podium 'Piggyback' Disassembly
216
Fox™ Podium 'Piggyback' Body and Reservoir Service
218
Fox™ Podium 'Piggyback' Component Rebuild
219
Fox™ Podium 'Piggyback' Assembly
220
Fox™ Podium Top Fill Shock Service
224
Fox™ 2.0 Podium Top Fill Shock (Rzr 4 Base Models)
224
Fox™ 2.0 Podium Top Fill - General Service Information
225
Front Shock Service (Rzr 4 Base Models)
225
Rear Shock Service (Rzr 4 Base Models)
225
Fox™ 2.0 Podium Top Fill Disassembly
226
Fox™ 2.0 Podium Top Fill Reassembly
229
Clutching Chapter 6 Clutching
235
Chapter 6
236
High Altitude Clutch Charts
236
Pvt System Overview
236
General Operation
236
Drive Clutch Operation
237
Driven Clutch Operation
237
Pvt Break-In (Drive Belt / Clutches)
237
Maintenance / Inspection
237
Overheating / Diagnosis
238
Ranger Rzr / Rzr S / Rzr 4
236
Ranger Rzr Eps (Ebs)
236
Special Tools and Supplies
236
Torque Specifications
236
Pvt System Service
239
Pvt Covers and Ducting Components
239
Pvt Disassembly
240
Pvt Assembly
241
Clutch Offset Procedure
242
Drive Belt (Non-Ebs)
244
Drive Belt (Ebs)
245
Drive Clutch Service
246
Exploded View
246
Shift Weights
246
Clutch Disassembly
247
Bearing Inspection
247
Drive Clutch Spring Inspection
248
Shift Weight Inspection
248
Button to Tower Clearance Inspection
249
Spider Removal
249
Roller, Pin, and Thrust Washer Inspection
250
Clutch Inspection
250
Moveable Sheave Bushing Inspection
251
Bushing Service
252
Clutch Assembly
254
Driven Clutch Service (Non-Ebs)
255
Exploded View
255
Clutch Disassembly / Inspection
255
Clutch Assembly
257
Driven Clutch Service (Ebs)
259
Clutch Disassembly
259
Bushing Service
261
Clutch Assembly
263
Exploded View
266
Troubleshooting
267
Chapter 7 Final Drive
269
Bearing Carrier Inspection / Removal
270
Final Drive
270
Front Bearing Carrier
270
Special Tools
270
Torque Specifications
270
Bearing Replacement
271
Bearing Carrier Installation
272
Front Drive Shaft
274
Drive Shaft Removal
274
Drive Shaft / CV Joint Handling Tips
275
Outer CV Joint / Boot Replacement
275
Inner Plunging Joint / Boot Replacement
276
Drive Shaft Installation
278
Propshaft Service
279
Removal / Installation (Rzr / Rzr S)
279
Removal / Installation (Rzr 4)
280
Support Bearing Replacement (Rzr 4)
281
Propshaft U-Joint Service
282
Disassembly
282
Assembly
283
Front Gearcase / Centralized Hilliard
284
Centralized Hilliard Exploded View
284
All Wheel Drive Operation
285
Awd Diagnosis
286
Gearcase Assembly
290
Gearcase Installation
292
Rear Bearing Carrier
294
Bearing Carrier Inspection / Removal
294
Bearing Replacement
295
Bearing Carrier Bushing Replacement
295
Bearing Carrier Installation
296
Rear Drive Shaft
297
Drive Shaft Removal
297
Outer CV Joint / Boot Replacement
298
Inner Plunging Joint / Boot Replacement
301
Drive Shaft Exploded View
303
Rear Gearcase
305
Gearcase Removal
305
Gearcase Disassembly
306
Gearcase Assembly
308
Gearcase Installation
309
Gearcase Exploded View
310
Rear Gearcase (Rzr S Int'l)
311
General Operation
311
Gearcase Removal
312
Gearcase Disassembly
313
Differential Disassembly
317
Differential Assembly
318
Gearcase Assembly
319
Gearcase Installation
321
Gearcase Exploded View
322
Wheel Hubs
323
Transmission Chapter 8 Transmission
325
Chapter 8
326
Installation
326
Removal
326
Shift Lever
326
Torque Values / Specifications
326
Shift Cable Inspection / Adjustment
327
Transmission Service
328
Transmission Removal / Service Notes
328
Transfer Case Disassembly
328
Transfer Case Reassembly
331
Transmission Shift Housing Disassembly
335
Transmission Shift Housing Reassembly
340
Troubleshooting
344
Transmission Exploded View
345
Brakes Chapter 9 Brakes
347
Brake Noise Troubleshooting
349
Brake System Service Notes
349
Hydraulic Brake System Operation
350
Brake System Exploded View
351
Chapter 9
351
Rzr / Rzr S / Rzr S Int'l
351
Rzr 4
351
Brake Pedal Lever
352
Master Cylinder
352
Brake Bleeding / Fluid Change
353
Front Brake Pads
354
Pad Removal
354
Pad Inspection
355
Pad Assembly / Installation
355
Brake Burnishing Procedure
356
Front Caliper Service
357
Caliper Exploded View (Rzr / Rzr S / Rzr S Int'l)
357
Caliper Exploded View (Rzr 4)
357
Caliper Removal
358
Caliper Disassembly
359
Caliper Inspection
360
Caliper Assembly
361
Caliper Installation
361
Front Brake Disc
362
Disc Runout
362
Disc Inspection
362
Disc Replacement
363
Rear Brake Pads
364
Pad Removal
364
Pad Inspection
365
Pad Assembly / Installation
365
Brake Burnishing Procedure
365
Rear Caliper Service
366
Caliper Exploded View
366
Caliper Removal
366
Caliper Disassembly
367
Caliper Inspection
367
Caliper Assembly
368
Caliper Installation
368
Rear Brake Disc
370
Disc Inspection
370
Disc Replacement
370
Troubleshooting
371
Brakes Squeal / Poor Brake Performance
371
Pedal Vibration
371
Caliper Overheats (Brakes Drag)
371
Brakes Lock
371
Electrical Chapter 10 Electrical
373
Chapter 10 Under-Dash Components
375
General Information
375
Switches / Controls
375
Brake Light Switch
375
Headlamp Switch
376
Ignition Key Switch
376
Ignition Key Switch (Int'l)
377
Awd / 2Wd Switch
377
Awd / 2Wd / Turf Switch (Int'l)
378
Turn Signal Switch (Int'l)
378
Transmission (Gear Position) Switch
379
Throttle Release Switch (Trs)
380
Rear Diff Solenoid (Int'l)
382
Differential Solenoid Overview
382
Differential Solenoid Circuit Operation
382
Vehicle Speed Sensor
382
Speed Sensor Location
382
Speed Sensor Testing
382
All Wheel Drive Coil
383
Operation Overview
383
Diagnosing System Failures
383
Instrument Cluster
384
Overview
384
Rider Information Display
385
Information Display Area
385
Diagnostic Mode
388
Instrument Cluster Pinouts
389
Instrument Cluster Removal
389
Instrument Cluster Installation
389
Head Lights (Incandescent)
390
Headlight Adjustment
390
Headlamp Bulb Replacement
390
Headlamp Housing Removal
391
Headlamp Housing Installation
391
Head Lights (Led)
391
Headlight Adjustment
391
Headlamp Replacement
392
Headlamp Installation
392
Tail / Brake Lights
393
Bulb Replacement
393
Cooling System
394
Cooling System Break-Out Diagram
394
Fan Control Circuit Operation / Testing
395
Fan Control Circuit Bypass Test
395
Coolant Temperature Sensor
395
Efi Diagnostics
395
Fuel Sender
395
Fuse Box: Fuses / Relays / Circuit Breaker
396
Overview / Operation
396
Fuse Box Detail
397
Relay Operation
398
Charging System
400
Current Draw - Key off
400
Charging System "Break Even" Test
400
Charging System Alternator Tests
401
Regulator / Rectifier
402
Charging System Testing Flow Chart
403
Battery Service
404
Battery Specifications
404
General Battery Information
404
Battery Removal / Installation
405
Battery off Season Storage
405
Battery Testing
405
Ocv - Open Circuit Voltage Test
405
Load Test
405
Battery Conductance Analyzer
406
Charging Procedure
406
Starting System
407
Troubleshooting
407
Voltage Drop Test
407
Starter Motor Removal
407
Starter Installation
408
Starter Drive Bendix
408
Starter Solenoid Bench Test
409
Starter Solenoid Operation
409
Starting System Testing Flow Chart
410
Electronic Power Steering (Eps)
411
Eps Operation
411
Proper Eps System Diagnosing
411
Eps System Breakout
412
Eps Troubleshooting (Using Digital Wrench™)
415
4
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Polaris 2013 RANGER RZR S Specifications
General
Brand
Polaris
Model
2013 RANGER RZR S
Category
Offroad Vehicle
Language
English
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