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Polaris xp 2013 eps User Manual

Polaris xp 2013 eps
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10.3
ELECTRICAL
10
9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual
© Copyright 2012 Polaris Sales Inc.
GENERAL INFORMATION
Special Tools
SPX Corp: 1-800-328-6657 or http://polaris.spx.com/
Electrical Service Notes
Keep the following notes in mind when diagnosing an
electrical problem:
Refer to wiring diagram for stator and electrical
component resistance specifications.
When measuring resistance of a component that
has a resistance value under 10 Ohms, remember
to subtract meter lead resistance from the reading.
Connect the leads together and record the
resistance. The resistance of the component is
equal to tested value minus the lead resistance.
Become familiar with the operation of your meter.
Be sure leads are in the proper jack for the test
being performed (i.e. 10A jack for current
readings). Refer to the Owners Manual included
with your meter for more information.
Voltage, amperage, and resistance values
included in this manual are obtained with a
Fluke™ 77 Digital Multimeter (PV-43568). This
meter is used when diagnosing electrical
problems. Readings obtained with other meters
may differ.
Pay attention to the prefix on the multimeter
reading (K, M, etc.) and the position of the decimal
point.
For resistance readings, isolate the component to
be tested. Disconnect it from the wiring harness or
power supply.
Under-Dash Components
The following switches and components can be accessed
underneath the instrument / dash panel:
Speedometer
Digital Wrench® Diagnostic Connector
•AWD Switch
Headlamp Switch
12 Vdc Accessory Power Point
Ignition Switch
Fuse / Relay Box
Part Number Tool Description
PV-43568 Fluke™ 77 Digital Multimeter
PV-43526 Connector Test Kit
2870630 Timing Light
PU-50338 Battery Hydrometer
2460761 Hall Effect Sensor Probe Harness
2871745 Static Timing Light Harness
PU-50296
Battery Conductance Analyzer
(MDX-610P)
PU-49466 Relay Bypass
- Digital Wrench® (see Chapter 4)

Table of Contents

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Polaris xp 2013 eps Specifications

General IconGeneral
BrandPolaris
Modelxp 2013 eps
CategoryUtility Vehicle
LanguageEnglish

Summary

GENERAL INFORMATION

VEHICLE IDENTIFICATION

Details on model number designation, engine designation, and VIN.

VEHICLE AND ENGINE SERIAL NUMBER LOCATION

Information on where to find the VIN and engine serial numbers on the vehicle.

VEHICLE INFORMATION

Covers publication numbers and information on replacement keys.

SPECIAL TOOLS

Lists and describes specialized tools required for servicing the vehicle.

GENERAL SPECIFICATIONS

Provides detailed specifications for various models of the vehicle.

MISC. SPECIFICATIONS AND CHARTS

Includes conversion tables and torque specifications for bolts.

MAINTENANCE

PERIODIC MAINTENANCE CHART

Overview of inspection, adjustment, and lubrication intervals for vehicle maintenance.

GENERAL VEHICLE INSPECTION AND MAINTENANCE

Details daily inspections, frame checks, and component inspections.

FUEL SYSTEM AND AIR INTAKE

Procedures for servicing the fuel tank, lines, pump, and air intake system.

ENGINE

Covers engine oil level checks, oil and filter changes, and breather hose inspection.

COOLING SYSTEM

Information on coolant level, strength, pressure tests, hoses, radiator, and thermostat.

PVT / FINAL DRIVE / WHEEL AND TIRE

Service procedures for PVT system, drive shaft boots, wheels, and tires.

ELECTRICAL AND IGNITION SYSTEM

Covers battery maintenance, removal, installation, and testing.

STEERING

Inspection and adjustment of steering components and wheel alignment.

SUSPENSION (FOX™)

Details on spring preload and shock compression adjustments for FOX™ shocks.

SUSPENSION (WALKER EVANS™)

Procedures for adjusting spring preload and shock compression on Walker Evans™ shocks.

BRAKE SYSTEM

Inspection and service for brake fluid, pads, discs, hoses, and fittings.

PARKING BRAKE (INT’L MODEL)

Adjustment and inspection procedures for the parking brake system.

ENGINE / COOLING

GENERAL INFORMATION

Covers special tools and engine lubrication specifications.

ENGINE COOLING SYSTEM

Details cooling system specifications, pressure tests, and component procedures.

ENGINE SERVICE

Information on accessible components, top-end service, and engine removal/installation.

ENGINE DISASSEMBLY / INSPECTION - TOP END

Procedures for valve cover, camshaft, and cylinder head removal and inspection.

ENGINE DISASSEMBLY / INSPECTION - LOWER END

Covers stator cover, water pump, flywheel, and starter removal/inspection.

ELECTRONIC FUEL INJECTION

GENERAL INFORMATION

Includes special tools, EFI service notes, and system exploded views.

FUEL TANK

Details on fuel tank exploded view, fuel flow, and line removal/installation.

ELECTRONIC FUEL INJECTION

Covers principal components, EFI operation, and initial priming procedures.

ELECTRONIC CONTROL UNIT (ECU)

Information on ECU operation, service, and replacement procedures.

MANIFOLD AIR QUALITY SENSOR (MAQS)

Details MAQS operation, testing, and replacement.

CRANKSHAFT POSITION SENSOR (CPS)

Covers CPS operation, testing, and replacement procedures.

IDLE AIR CONTROL VALVE (IAC)

Explains IAC operation, testing, and replacement.

ENGINE COOLANT TEMPERATURE SENSOR (ECT)

Covers ECT operation, testing, and replacement.

DUAL THROTTLE BODY ASSEMBLY

Details throttle body operation, service, and removal.

FUEL INJECTORS

Covers injector operation, troubleshooting, testing, and replacement.

FUEL PUMP

Explains fuel pump operation, testing, and replacement.

IGNITION COIL

Covers ignition coil operation, HT lead replacement, and testing.

EFI DIAGNOSTICS

Information on instrument cluster trouble code display and diagnostic tables.

BODY / STEERING / SUSPENSION

TORQUE SPECIFICATIONS

Lists torque values for various chassis and suspension components.

SPECIAL TOOLS

Lists special tools required for body, steering, and suspension service.

CAB FRAME (RZR XP)

Details assembly and removal procedures for the RZR XP cab frame.

CAB FRAME (RZR XP 4)

Provides assembly and removal procedures for the RZR XP 4 cab frame.

BODY COMPONENT REMOVAL

Procedures for removing seats, engine service panel, bumpers, and hood.

STEERING ASSEMBLY

Exploded views and procedures for steering system components.

ELECTRONIC POWER STEERING (EPS)

Covers EPS system operation, troubleshooting, and component removal.

FRONT A-ARMS

Details removal and replacement procedures for front A-arms.

BALL JOINT SERVICE

Procedures for removing and installing ball joints.

FRONT STABILIZER BAR (INT’L)

Covers stabilizer bar linkage and stabilizer bar removal/installation.

REAR RADIUS RODS

Details removal and installation of rear radius rods.

REAR TRAILING ARM

Procedures for trailing arm removal, installation, and bearing replacement.

SHOCKS / SPRINGS / FASTENERS

Information on shock removal, installation, and replacement.

FOX™ SHOCK EXPLODED VIEWS (RZR XP)

Exploded views of FOX™ 2.0 ‘Piggyback’ shocks.

FOX™ SHOCK SERVICE (RZR XP)

Covers shock rebuild information and disassembly procedures.

WALKER EVANS™ SHOCK SERVICE (RZR XP 4)

Details shock service, rebuild, and disassembly for Walker Evans™ shocks.

CLUTCHING (PVT)

SPECIAL TOOLS AND SUPPLIES

Lists tools and supplies needed for PVT system service.

TORQUE SPECIFICATIONS

Provides torque values for PVT system fasteners.

PVT SYSTEM OVERVIEW

Explains general operation, drive clutch, driven clutch, and drive belt.

PVT SYSTEM SERVICE

Covers PVT covers, ducting, disassembly, and assembly procedures.

DRIVE BELT

Details belt removal, inspection, and installation procedures.

DRIVE CLUTCH SERVICE

Exploded view and disassembly/inspection of the drive clutch.

DRIVEN CLUTCH SERVICE

Covers driven clutch disassembly, bushing service, and assembly.

TROUBLESHOOTING

Troubleshooting guide for common PVT system issues.

FINAL DRIVE

SPECIAL TOOLS

Lists special tools required for final drive service.

TORQUE SPECIFICATIONS

Provides torque values for wheel hub and final drive components.

FRONT BEARING CARRIER

Details bearing carrier inspection, removal, replacement, and installation.

FRONT DRIVE SHAFT

Procedures for front drive shaft removal and installation.

PROPSHAFT SERVICE

Covers front and rear propshaft removal and installation.

FRONT GEARCASE / CENTRALIZED HILLIARD

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

REAR BEARING CARRIER

Details rear bearing carrier inspection, removal, replacement, and installation.

REAR DRIVE SHAFT

Procedures for rear drive shaft removal and installation.

DRIVE SHAFT CV JOINT / BOOT REPLACEMENT

Handling tips and procedures for outer CV joint and boot replacement.

WHEEL HUBS

Exploded views of front and rear wheel hubs.

TRANSMISSION

SPECIFICATIONS

Covers torque specifications, special tools, lubrication, and mounting values.

SHIFT LEVER

Details removal and installation procedures for the shift lever.

SHIFT CABLE

Covers inspection and adjustment procedures for the shift cable.

TRANSMISSION REMOVAL

Step-by-step instructions for removing the transmission assembly.

TRANSMISSION INSTALLATION

Procedures for installing the transmission assembly.

TRANSMISSION SERVICE

Covers transmission disassembly, inspection, and assembly.

TRANSMISSION SERVICE (INT’L)

Details differential operation and components for international models.

TROUBLESHOOTING

Checklist for diagnosing shifting difficulties and transmission problems.

TRANSMISSION EXPLODED VIEW

Exploded view of the transmission for reassembly reference.

BRAKES

GENERAL SPECIFICATIONS

Provides standard and service limit measurements for brake system components.

TORQUE SPECIFICATIONS

Lists torque values for brake system fasteners.

BRAKE SYSTEM SERVICE NOTES

Important notes for maintaining proper brake system function and pad life.

BRAKE NOISE TROUBLESHOOTING

Guide to diagnosing and resolving brake noise issues.

HYDRAULIC BRAKE SYSTEM OPERATION

Explains the function and components of the hydraulic brake system.

BRAKE SYSTEM EXPLODED VIEW

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

MASTER CYLINDER

Covers master cylinder removal, installation, and brake pedal lever service.

BRAKE BLEEDING / FLUID CHANGE

Procedure for bleeding brakes and changing brake fluid.

PARKING BRAKE (INT’L MODEL)

Details parking brake exploded view, inspection, and cable adjustment.

PARKING BRAKE CALIPER SERVICE (INT’L MODEL)

Procedures for parking brake caliper removal, disassembly, and new pad installation.

FRONT BRAKE PADS

Details front brake pad removal, inspection, and assembly.

REAR BRAKE PADS (RZR XP)

Procedure for rear brake pad removal, inspection, and assembly.

REAR BRAKE PADS (RZR XP 4)

Covers rear brake pad removal, inspection, and assembly for RZR XP 4.

FRONT BRAKE DISC

Details disc inspection, runout measurement, and disc replacement.

REAR BRAKE DISC

Covers rear brake disc inspection and replacement procedures.

TROUBLESHOOTING

Troubleshooting common brake issues like squeal, poor performance, and overheating.

ELECTRICAL

GENERAL INFORMATION

Includes special tools and important electrical service notes.

INSTRUMENT CLUSTER

Overview of the instrument cluster, display functions, and diagnostic mode.

SWITCHES / CONTROLS

Details testing and replacement for various switches and controls.

COOLING SYSTEM

Break-out diagram for the cooling system and fan control circuit testing.

EFI DIAGNOSTICS

Information on EFI component testing and fuel sender testing.

FUSE BOX: FUSES / RELAYS / CIRCUIT BREAKER

Overview of fuse box operation and detailed fuse/relay assignments.

CHARGING SYSTEM

Testing procedures for current draw and charging system performance.

BATTERY SERVICE

Covers battery specifications, general information, and testing procedures.

STARTING SYSTEM

Troubleshooting for starter motor issues and voltage drop tests.

ELECTRONIC POWER STEERING (EPS)

Details EPS operation, diagnosing, and troubleshooting procedures.

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