Polaris 2013 RANGER RZR S Service Manual

Table of Contents

• 1. Table of Contents
• 2. VEHICLE IDENTIFICATION
• 3. VEHICLE AND ENGINE SERIAL NUMBER LOCATIO...
• 4. VEHICLE INFORMATION
• 5. SPECIAL TOOLS
• 6. GENERAL SPECIFICATIONS
• 12. MISC. SPECIFICATIONS AND CHARTS
• 13. STANDARD BOLT TORQUE SPECIFICATION
• 14. SAE TAP / DRILL SIZES
• 17. PERIODIC MAINTENANCE CHART
• 18. PRE-RIDE - 50 HOUR MAINTENANCE INTERVAL
• 19. 100 - 300 Hour Maintenance Interval
• 20. MAINTENANCE QUICK REFERENCE
• 21. MAINTENANCE QUICK REFERENCE, CONTINUED
• 22. GREASE LUBRICATION POINTS
• 23. LUBRICANTS / SERVICE PRODUCTS
• 24. GENERAL VEHICLE INSPECTION AND MAINTENAN...
• 25. FUEL SYSTEM AND AIR INTAKE
• 26. THROTTLE PEDAL INSPECTION
• 27. AIR FILTER SERVICE
• 29. ENGINE
• 30. ENGINE OIL AND FILTER SERVICE
• 31. ENGINE BREATHER HOSE INSPECTION
• 32. EXHAUST - SPARK ARRESTOR
• 33. TRANSMISSION AND GEARCASES
• 36. FRONT GEARCASE LUBRICATION
• 37. REAR GEARCASE LUBRICATION
• 39. COOLING SYSTEM
• 40. COOLANT STRENGTH / TYPE
• 41. RADIATOR
• 42. FINAL DRIVE / WHEEL AND TIRE
• 43. TIRE INSPECTION
• 44. ELECTRICAL AND IGNITION SYSTEM
• 45. BATTERY INSTALLATION
• 46. ENGINE TO FRAME GROUND
• 47. STEERING
• 48. WHEEL TOE ALIGNMENT INSPECTION
• 49. SUSPENSION (STANDARD)
• 50. SUSPENSION (FOX™)
• 51. SHOCK COMPRESSION ADJUSTMENT
• 52. BRAKE SYSTEM
• 54. ENGINE SPECIFICATIONS
• 55. OIL PUMP / GEARS / ENGINE COVER
• 56. STATOR COVER / STARTER / WATER PUMP / LU...
• 57. CYLINDER / CYLINDER HEAD / PISTON
• 58. ENGINE EFI SENSORS / VALVE COVER / GENER...
• 59. ENGINE TORQUE SPECIFICATIONS
• 60. 800 EFI Engine Service Specifications
• 62. SPECIAL TOOLS
• 63. ENGINE COOLING SYSTEM
• 64. COOLING SYSTEM EXPLODED VIEW
• 65. RADIATOR REMOVAL
• 66. COOLING SYSTEM BLEEDING PROCEDURE
• 68. GENERAL ENGINE SERVICE
• 69. OIL FLOW CHART
• 70. ENGINE REMOVAL
• 77. ENGINE / TRANSMISSION SEPARATION
• 78. ENGINE DISASSEMBLY AND INSPECTION
• 79. CYLINDER HEAD REMOVAL
• 80. CYLINDER HEAD INSPECTION / WARP
• 81. CYLINDER HEAD DISASSEMBLY
• 82. VALVE INSPECTION
• 83. COMBUSTION CHAMBER / VALVE SEAT RECONDIT...
• 85. CYLINDER HEAD REASSEMBLY
• 86. VALVE SEALING TEST
• 87. PISTON REMOVAL
• 88. CYLINDER INSPECTION
• 89. CYLINDER HONE SELECTION AND HONING PROCE...
• 90. PISTON-TO-CYLINDER CLEARANCE
• 91. PISTON RING INSTALLED GAP
• 92. FLYWHEEL / STATOR REMOVAL / INSPECTION
• 100. CAMSHAFT INSPECTION
• 101. ENGINE REASSEMBLY
• 110. FLYWHEEL / STATOR INSTALLATION
• 112. OIL PUMP PRIMING
• 113. ENGINE INSTALLATION
• 114. ENGINE BREAK-IN PERIOD
• 115. TROUBLESHOOTING
• 118. GENERAL INFORMATION
• 120. SERVICE NOTES
• 121. EFI SYSTEM EXPLODED VIEW
• 122. EFI SYSTEM COMPONENT LOCATIONS
• 124. FUEL TANK
• 125. FUEL LINE REMOVAL / INSTALLATION
• 127. ELECTRONIC CONTROL UNIT (ECU)
• 128. TEMP / MANIFOLD ABSOLUTE PRESSURE SENSOR...
• 133. FUEL INJECTORS
• 136. FUEL PUMP
• 137. FUEL PUMP TEST
• 138. FUEL PUMP REPLACEMENT
• 141. FUEL TANK REMOVAL (RZR / RZR S)
• 143. FUEL TANK REMOVAL (RZR 4)
• 145. FUEL TANK INSTALLATION
• 146. IDLE AIR CONTROL (IAC)
• 147. THROTTLE POSITION SENSOR (TPS)
• 148. TPS REPLACEMENT
• 150. CAMSHAFT PHASE SENSOR
• 151. ENGINE COOLANT TEMPERATURE SENSOR (ECT)
• 152. IGNITION COIL
• 153. EFI DIAGNOSTICS
• 156. EFI TROUBLESHOOTING
• 157. DIGITAL WRENCH™ OPERATION
• 158. DIGITAL WRENCH™ - DIAGNOSTIC CONNECTOR
• 159. DIGITAL WRENCH™ UPDATES
• 160. DIGITAL WRENCH™ FEATURE MAP
• 161. ENGINE CONTROLLER REPROGRAMMING (REFLASH...
• 167. TORQUE SPECIFICATIONS
• 168. CAB FRAME (RZR / RZR S)
• 170. ASSEMBLY / REMOVAL
• 172. BODY EXPLODED VIEWS
• 173. DASH INSTRUMENTS / CONTROLS / GLOVEBOX
• 174. HOOD / FRONT BODY WORK
• 175. REAR BUMPER
• 176. SEAT ASSEMBLY
• 177. SEAT BELTS / MOUNTING (RZR 4)
• 178. FLOOR / ROCKER PANELS (RZR / RZR S)
• 179. FLOOR / ROCKER PANELS (RZR 4)
• 180. REAR CARGO BOX / FENDERS (RZR / RZR S)
• 181. REAR CARGO BOX / FENDERS (RZR 4)
• 182. CHASSIS / MAIN FRAME (RZR / RZR S)
• 183. CHASSIS / MAIN FRAME (RZR 4)
• 184. BODY COMPONENT REMOVAL
• 185. REAR BUMPER
• 186. REAR FENDER, FLAIR AND TIE DOWN REMOVAL
• 187. CARGO BOX ASSEMBLY REMOVAL
• 189. STEERING ASSEMBLY
• 190. STEERING WHEEL REMOVAL (NON-EPS MODELS)
• 191. STEERING SHAFT BEARING REPLACEMENT
• 192. ELECTRONIC POWER STEERING ASSEMBLY
• 193. UPPER STEERING SHAFT REMOVAL (EPS MODELS...
• 194. STEERING WHEEL REMOVAL (EPS MODELS)
• 195. LOWER STEERING SHAFT REMOVAL (EPS MODELS...
• 196. LOWER STEERING SHAFT INSTALLATION (EPS M...
• 197. UPPER STEERING SHAFT INSTALLATION (EPS M...
• 198. FRONT A-ARMS
• 199. EXPLODED VIEW (RZR)
• 200. BALL JOINT SERVICE
• 201. BALL JOINT INSTALLATION
• 202. FRONT STABILIZER BAR (RZR / RZR S INT'L)
• 205. REAR A-ARMS
• 206. INSTALLATION
• 207. EXPLODED VIEW (RZR)
• 208. REAR STABILIZER BAR (RZR)
• 209. REAR STABILIZER BAR (RZR S / RZR 4)
• 210. SHOCKS / SPRINGS / FASTENERS
• 211. EXPLODED VIEW (RZR 4)
• 212. FOX™ PODIUM PIGGYBACK SHOCK SERVICE
• 213. FOX™ 1.5 PODIUM 'PIGGYBACK - GENERAL SER...
• 214. FOX™ 2.0 PODIUM 'PIGGYBACK' SHOCK (RZR 4...
• 215. FOX™ 2.0 PODIUM 'PIGGYBACK - GENERAL SER...
• 216. FOX™ PODIUM 'PIGGYBACK' REBUILD INFORMAT...
• 218. FOX™ PODIUM 'PIGGYBACK' BODY AND RESERVO...
• 219. FOX™ PODIUM 'PIGGYBACK' COMPONENT REBUIL...
• 220. FOX™ PODIUM 'PIGGYBACK' ASSEMBLY
• 224. FOX™ PODIUM TOP FILL SHOCK SERVICE
• 225. FOX™ 2.0 PODIUM TOP FILL - GENERAL SERVI...
• 226. FOX™ 2.0 PODIUM TOP FILL DISASSEMBLY
• 229. FOX™ 2.0 PODIUM TOP FILL REASSEMBLY
• 236. SPECIAL TOOLS AND SUPPLIES
• 237. DRIVE CLUTCH OPERATION
• 238. OVERHEATING / DIAGNOSIS
• 239. PVT SYSTEM SERVICE
• 240. PVT DISASSEMBLY
• 241. PVT ASSEMBLY
• 242. CLUTCH OFFSET PROCEDURE
• 244. DRIVE BELT (NON-EBS)
• 245. DRIVE BELT (EBS)
• 246. DRIVE CLUTCH SERVICE
• 247. CLUTCH DISASSEMBLY
• 248. DRIVE CLUTCH SPRING INSPECTION
• 249. BUTTON TO TOWER CLEARANCE INSPECTION
• 250. ROLLER, PIN, AND THRUST WASHER INSPECTIO...
• 251. MOVEABLE SHEAVE BUSHING INSPECTION
• 252. BUSHING SERVICE
• 254. CLUTCH ASSEMBLY
• 255. DRIVEN CLUTCH SERVICE (NON-EBS)
• 257. CLUTCH ASSEMBLY
• 259. DRIVEN CLUTCH SERVICE (EBS)
• 261. BUSHING SERVICE
• 263. CLUTCH ASSEMBLY
• 266. EXPLODED VIEW
• 267. TROUBLESHOOTING
• 270. SPECIAL TOOLS
• 271. BEARING REPLACEMENT
• 272. BEARING CARRIER INSTALLATION
• 274. FRONT DRIVE SHAFT
• 275. DRIVE SHAFT / CV JOINT HANDLING TIPS
• 276. INNER PLUNGING JOINT / BOOT REPLACEMENT
• 278. DRIVE SHAFT INSTALLATION
• 279. PROPSHAFT SERVICE
• 280. REMOVAL / INSTALLATION (RZR 4)
• 281. SUPPORT BEARING REPLACEMENT (RZR 4)
• 282. PROPSHAFT U-JOINT SERVICE
• 283. ASSEMBLY
• 284. FRONT GEARCASE / CENTRALIZED HILLIARD
• 285. ALL WHEEL DRIVE OPERATION
• 286. AWD DIAGNOSIS
• 290. GEARCASE ASSEMBLY
• 292. GEARCASE INSTALLATION
• 294. REAR BEARING CARRIER
• 295. BEARING REPLACEMENT
• 296. BEARING CARRIER INSTALLATION
• 297. REAR DRIVE SHAFT
• 298. OUTER CV JOINT / BOOT REPLACEMENT
• 301. INNER PLUNGING JOINT / BOOT REPLACEMENT
• 303. Drive shaft exploded view
• 305. REAR GEARCASE
• 306. GEARCASE DISASSEMBLY
• 308. GEARCASE ASSEMBLY
• 309. GEARCASE INSTALLATION
• 310. GEARCASE EXPLODED VIEW
• 311. REAR GEARCASE (RZR S INT'L)
• 312. GEARCASE REMOVAL
• 313. GEARCASE DISASSEMBLY
• 317. DIFFERENTIAL DISASSEMBLY
• 318. DIFFERENTIAL ASSEMBLY
• 319. GEARCASE ASSEMBLY
• 321. GEARCASE INSTALLATION
• 322. GEARCASE EXPLODED VIEW
• 323. WHEEL HUBS
• 326. TORQUE VALUES / SPECIFICATIONS
• 327. SHIFT CABLE INSPECTION / ADJUSTMENT
• 328. TRANSMISSION SERVICE
• 331. TRANSFER CASE REASSEMBLY
• 335. TRANSMISSION SHIFT HOUSING DISASSEMBLY
• 340. TRANSMISSION SHIFT HOUSING REASSEMBLY
• 344. TROUBLESHOOTING
• 345. TRANSMISSION EXPLODED VIEW
• 349. BRAKE SYSTEM SERVICE NOTES
• 350. HYDRAULIC BRAKE SYSTEM OPERATION
• 351. BRAKE SYSTEM EXPLODED VIEW
• 352. MASTER CYLINDER
• 353. BRAKE BLEEDING / FLUID CHANGE
• 354. FRONT BRAKE PADS
• 355. PAD INSPECTION
• 356. BRAKE BURNISHING PROCEDURE
• 357. FRONT CALIPER SERVICE
• 358. CALIPER REMOVAL
• 359. CALIPER DISASSEMBLY
• 360. CALIPER INSPECTION
• 361. CALIPER ASSEMBLY
• 362. FRONT BRAKE DISC
• 363. DISC REPLACEMENT
• 364. REAR BRAKE PADS
• 365. PAD INSPECTION
• 366. REAR CALIPER SERVICE
• 367. CALIPER DISASSEMBLY
• 368. CALIPER ASSEMBLY
• 370. REAR BRAKE DISC
• 371. TROUBLESHOOTING
• 375. GENERAL INFORMATION
• 376. HEADLAMP SWITCH
• 377. IGNITION KEY SWITCH (INT'L)
• 378. AWD / 2WD / TURF SWITCH (INT'L)
• 379. TRANSMISSION (GEAR POSITION) SWITCH
• 380. THROTTLE RELEASE SWITCH (TRS)
• 382. VEHICLE SPEED SENSOR
• 383. ALL WHEEL DRIVE COIL
• 384. INSTRUMENT CLUSTER
• 385. RIDER INFORMATION DISPLAY
• 388. DIAGNOSTIC MODE
• 389. INSTRUMENT CLUSTER PINOUTS
• 390. HEAD LIGHTS (INCANDESCENT)
• 391. HEADLAMP HOUSING REMOVAL
• 392. HEADLAMP REPLACEMENT
• 393. TAIL / BRAKE LIGHTS
• 394. COOLING SYSTEM
• 395. FAN CONTROL CIRCUIT OPERATION / TESTING
• 396. FUSE BOX: FUSES / RELAYS / CIRCUIT BREAK...
• 397. FUSE BOX DETAIL
• 398. RELAY OPERATION
• 401. CHARGING SYSTEM ALTERNATOR TESTS
• 402. REGULATOR / RECTIFIER
• 403. CHARGING SYSTEM TESTING FLOW CHART
• 404. BATTERY SERVICE
• 405. BATTERY REMOVAL / INSTALLATION
• 406. BATTERY CONDUCTANCE ANALYZER
• 407. STARTING SYSTEM
• 408. STARTER INSTALLATION
• 409. STARTER SOLENOID BENCH TEST
• 410. STARTING SYSTEM TESTING FLOW CHART
• 411. ELECTRONIC POWER STEERING (EPS)
• 412. EPS SYSTEM BREAKOUT
• 415. EPS TROUBLESHOOTING (USING DIGITAL WRENC...