2013-2016 Polaris Ranger RZR 800 RZRS RZR4 Service & Repair Manual

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

1.2 GENERAL INFORMATION 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc. VEHICLE IDENTIFICATION Model Number Designation Example: R13VH76AD Engine Designation Number 1204620 RZR800-13...........................................................Twin Cylinder, Liquid Cooled, OHV 4 Stroke, Electric Start Vehicle Identification Number (VIN) Designation Example: 4XAVH76A4DB000000 GROUP MODEL YEAR CHASSIS DRIVELINE ENGINE CATEGORY OPTION REGION 1st digit 2/3rd digit 4th digit* 5th digit* 6th digit* 7th digit* 8th digit 9th digit** 10th digit A = ATV R = RANGER 11 12 13 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 Midsize S = RZR T = Sportsman X2 U = RANGER Fullsize V = RZR W = Multi-pass RGR X = Multi-pass RZR Z = Sportsman XP 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 Displacement in cc divided by 10 and rounded to two digits (i.e. 50 = 498cc) - - - - - - - - - - - - For electric vehicles 08 = 48 Volt 12 = 72 Volt 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. - - OR - - 5 = 550 6 = 570 7 = 760 8 = 850 9 = 875 E = EPS D = Diesel F = D + E * = digits that would transfer to 17 digit VIN and are used in digits 4-8 respectively ** = 9th digit will be used on color/featured versions of models (not including the base) First 3 digits and 9th digit are used in model number only. They are not used with the 17 digit VIN. World Mfg. ID Vehicle Descriptors Vehicle Identifiers Chassis Driveline Engine Size Engine Modifier Category Check Digit Model Year * Mfg. Location Individual Serial No. 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

1.3 GENERAL INFORMATION 1 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc. 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, behind the left rear fender, near the air box (see Figure 1-1). The engine model and serial number can be found on a decal applied to the side of the engine’s cylinder (see Figure 1-2). Figure 1-1 VIN Engine Serial Figure 1-2 Number

1.4 GENERAL INFORMATION 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc. VEHICLE INFORMATION Publication Numbers 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. 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. Model Model No. Owner’s Manual Parts Manual 2013 RANGER RZR R13VH76AC, AD, AN, AS 9924099 9924104 2013 RANGER RZR EPS R13VH7EAI 9924099 9924104 2013 RANGER RZR S R13VE76AD, AI, AS, AW 9924099 9924100 2013 RANGER RZR S INT’L R13VE76FI, FX 9924099 9924101 2013 RANGER RZR 4 R13XE76AD 9924099 9924106 2013 RANGER RZR 4 EPS R13XE7EAI 9924099 9924106 Series# Part Number 20 4010278 21 4010278 22 4010321 23 4010321 27 4010321 28 4010321 31 4110141 32 4110148 67 4010278 68 4010278 Key Series Number KEY COVER P/N 5533534

1.5 GENERAL INFORMATION 1 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc. 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/ . Select “SPX Website - Tools, diagnostics” from the “Service and Warranty” drop down menu

1.6 GENERAL INFORMATION 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc. GENERAL SPECIFICATIONS MODEL: 2013 RANGER RZR MODEL NUMBER: R13VH76AC, AD, AN, AS ENGINE NUMBER: 1204670 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 945 lbs. / 429 kg Gross Vehicle Weight 1727 lbs. / 783 kg Front Storage Capacity 25 lbs. / 11.3 kg Cargo Box Dimension 42 in. x 22 in. / 107 cm x 56 cm Cargo Box Capacity 300 lbs. / 136 kg Maximum Weight Capacity (Payload) 740 lbs. / 335.6 kg (Includes rider(s), cargo, accessories and trailer tongue weight) Hitch Towing Capacity 1500 lbs. / 680 kg Hitch Tongue Capacity 150 lbs. / 68 kg 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 Capacity 25 lbs. / 11.3 kg Cargo Box Dimension 42 in. x 22 in. / 107 cm x 56 cm Cargo Box Capacity 300 lbs. / 136 kg Maximum Weight Capacity (Payload) 740 lbs. / 335.6 kg (Includes rider(s), cargo, accessories and trailer tongue weight) Hitch Towing Capacity 1500 lbs. / 680 kg Hitch Tongue Capacity 150 lbs. / 68 kg

1.7 GENERAL INFORMATION 1 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc. MODEL: 2013 RANGER RZR / EPS MODEL NUMBER: R13VH76AC, AD, AN, AS MODEL NUMBER: R13VH7EAI ENGINE NUMBER: 1204670 CLUTCH CHART (All Non-EPS Models) CLUTCH CHART (EPS Model with EBS) Engine Platform H.O. Domestic Twin Cylinder, Liquid Cooled, 4-Stroke 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 Dual Headpipe / Single Silencer 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 7.25 gal. (27.4 liters) 87 Octane (minimum) Electrical Alternator Max Output 500 Watts @ 3000 RPM Headlights (Halogen) 2 - Halogen: Low 55 W / High 60 W Headlights (LED) 2 - Dual Beam LED: Low 27 Watts; High 40 Watts Tail / Brake 2 - 6 Watts / 2 - 27 Watts Starting System Electric Start Ignition System Bosch M17 (ECU Controlled) Ignition Timing (Variable) 3° - 10° BTDC @ 1200 RPM Spark plug / Gap RC7YC3 / .035 in. (0.9 mm) Battery (RZR) Yuasa YTX20HL / 18 Amp Hr. / 310 CCA / 12 Volt Battery (RZR EPS) Deka ETX30L / 30 AH 365 CCA / 12 Volt Instrument Type Multifunction Instrument Cluster DC Outlet Standard 12 Volt Relays Chassis / EFI / Fan Fuel Pump / EPS Circuit Breaker Fan Motor: 20 Amp Fuses (Fuse/Relay Box) Drive / Fuel Pump: 10 Amp Lights / EFI / Accessory: 20 Amp Fuses (Power Fuse Holder) EFI: 20 Amp Chassis / EPS: 30 Amp 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 Polaris Demand Drive Plus 6.75 oz. (200 ml) Transmission: Main Gearcase Fluid Type / Capacity Polaris AGL Plus 24 oz. (710 ml) Transmission: Transfer Case Fluid Type / Capacity Polaris AGL Plus 14 oz. (414 ml) Rear Gearcase Fluid Type / Capacity Polaris Premium ADF 26 oz. (769 ml) Clutch Type (Standard Model) Standard PVT Clutch Type (EPS Model) PVT with EBS Drive Belt 3211113 Steering / Suspension Front Suspension Independent Dual A-arm w/Anti-Sway Bar 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 Cam Adjustment Toe Out 1/8 - 1/4 in. (3 - 6.4 mm) Wheels / Brakes Front Wheel Type / Size Steel / 12 x 6 Aluminum / 12 x 6 Rear Wheel Type / Size Steel / 12 x 8 Aluminum / 12 x 8 Front Tire Type / Size Ancla / 25 x 8 R12 Maxxis / 25 x 8 R12 Rear Tire Type / Size Ancla / 25 x 10 R12 Maxxis / 25 x 10 R12 Tire Air Pressure - Front / Rear 8 psi (55 kPa) Brake - Front / Rear Foot Actuated - 4 Wheel Hydraulic Disc Brake Fluid DOT 4 Altitude Shift Weight Drive Spring Driven Spring Meters (Feet) 0-1500 (0-5000) 23-62 (5632337) Green (7043789) Blk / Almond (7043167) 1500-3700 (5000 - 12000) 23-58 (B) (1322911) Green (7043789) Blk / Almond (7043167) Altitude Shift Weight Drive Spring Driven Spring Meters (Feet) 0-1500 (0-5000) 23-66 (5632763) Green (7043789) Red (3234452) 1500-3700 (5000 - 12000) 23-62 (5632337) Green (7043789) Red (3234452)

1.8 GENERAL INFORMATION 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc. MODEL: 2013 RANGER RZR S MODEL NUMBER: R13VE76AD, AI, AS, AW ENGINE NUMBER: 1204670 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 1000 lbs. / 454 kg Gross Vehicle Weight 1782 lbs. / 808 kg Front Storage Capacity 25 lbs. / 11.3 kg Cargo Box Dimension 42 in. x 22 in. / 107 cm x 56 cm Cargo Box Capacity 300 lbs. / 136 kg Maximum Weight Capacity (Payload) 740 lbs. / 335.6 kg (Includes rider(s), cargo, accessories and trailer tongue weight) Hitch Towing Capacity 1500 lbs. / 680 kg Hitch Tongue Capacity 150 lbs. / 68 kg 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 Capacity 25 lbs. / 11.3 kg Cargo Box Dimension 42 in. x 22 in. / 107 cm x 56 cm Cargo Box Capacity 300 lbs. / 136 kg Maximum Weight Capacity (Payload) 740 lbs. / 335.6 kg (Includes rider(s), cargo, accessories and trailer tongue weight) Hitch Towing Capacity 1500 lbs. / 680 kg Hitch Tongue Capacity 150 lbs. / 68 kg

1.9 GENERAL INFORMATION 1 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc. MODEL: 2013 RANGER RZR S / INT’L MODEL NUMBER: R13VE76AD, AI, AS, AW MODEL NUMBER: R13VE76FI, FX ENGINE NUMBER: 1204670 CLUTCH CHART Engine Platform H.O. Domestic Twin Cylinder, Liquid Cooled, 4-Stroke 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 Dual Headpipe / Single Silencer 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 7.25 gal. (27.4 liters) 87 Octane (minimum) Electrical Alternator Max Output 500 Watts @ 3000 RPM Headlights (Halogen) 2 - Halogen: Low 55 W / High 60 W Headlights (LED) 2 - Dual Beam LED: Low 27 Watts; High 40 Watts Tail / Brake 2 - 6 Watts / 2 - 27 Watts Starting System Electric Start Ignition System Bosch M17 (ECU Controlled) Ignition Timing (Variable) 3° - 10° BTDC @ 1200 RPM Spark plug / Gap RC7YC3 / .035 in. (0.9 mm) Battery Yuasa YTX20HL / 18 Amp Hr. / 310 CCA / 12 Volt Instrument Type Multifunction Instrument Cluster DC Outlet Standard 12 Volt Relays Chassis / EFI / Fan Fuel Pump Circuit Breaker Fan Motor: 20 Amp Fuses (Fuse/Relay Box) Drive / Fuel Pump: 10 Amp Lights / EFI / Accessory: 20 Amp Fuses (Power Fuse Holder) EFI: 20 Amp Chassis: 30 Amp 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 Polaris Demand Drive Plus 6.75 oz. (200 ml) Transmission: Main Gearcase Fluid Type / Capacity Polaris AGL Plus 24 oz. (710 ml) Transmission: Transfer Case Fluid Type / Capacity Polaris AGL Plus 14 oz. (414 ml) Rear Gearcase Fluid Type / Capacity Polaris Premium ADF 26 oz. (769 ml) Rear Gearcase (INT’L) Fluid Type / Capacity Polaris Premium ADF 22 oz. (650 ml) Clutch Type Standard PVT Drive Belt 3211133 Steering / Suspension Front Suspension / Shock Independent Dual A-arm Standard: Monotube FOX™: PODIUM Front Travel 12 in. / 30.5 cm Rear Suspension / Shock Rolled IRS w/Anti-Sway Bar Standard: Monotube FOX™: PODIUM Rear Travel 12 in. / 30.5 cm Shock Preload Adjustment Front / Rear Standard: Cam Adjustment FOX™: Threaded Spanner Wrench Adjustment 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 ITP “900XCT” / 27 x 9 R12 Maxxis Bighorn / 26 x 9 R12 Rear Tire Type / Size ITP “900XCT” / 27 x 11 R12 Maxxis Bighorn / 26 x 12 R12 Tire Air Pressure - Front / Rear 8 psi (55 kPa) Brake - Front / Rear Foot Actuated - 4 Wheel Hydraulic Disc Brake Fluid DOT 4 Altitude Shift Weight Drive Spring Driven Spring Meters (Feet) 0-1500 (0-5000) 23-62 (5632337) Green (7043789) Blk / Almond (7043167) 1500-3700 (5000 - 12000) 23-58 (B) (1322911) Green (7043789) Blk / Almond (7043167)

1.10 GENERAL INFORMATION 9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual © Copyright 2012 Polaris Sales Inc. MODEL: 2013 RANGER RZR 4 MODEL NUMBER: R13XE76AD ENGINE NUMBER: 1204671 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 1255 lbs. / 569 kg Gross Vehicle Weight 2206 lbs. / 1000 kg Front Storage Capacity 25 lbs. / 11.3 kg Cargo Box Dimension 42 in. x 22 in. / 107 cm x 56 cm Cargo Box Capacity 300 lbs. / 136 kg Maximum Weight Capacity (Payload) 900 lbs. / 408 kg (Includes rider(s), cargo, accessories and trailer tongue weight) Hitch Towing Capacity 1500 lbs. / 680 kg Hitch Tongue Capacity 150 lbs. / 68 kg 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 Capacity 25 lbs. / 11.3 kg Cargo Box Dimension 42 in. x 22 in. / 107 cm x 56 cm Cargo Box Capacity 300 lbs. / 136 kg Maximum Weight Capacity (Payload) 900 lbs. / 408 kg (Includes rider(s), cargo, accessories and trailer tongue weight) Hitch Towing Capacity 1500 lbs. / 680 kg Hitch Tongue Capacity 150 lbs. / 68 kg

2013-2016 Polaris Ranger RZR 800 RZRS RZR4 Service & Repair Manual

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