2013-2014 Polaris Ranger RZR XP 4 900 Service & Repair Manual

GENERAL INFORMATION 1.1 CHAPTER 1 GENERAL INFORMATION 1 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc. VEHICLE IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 MODEL NUMBER DESIGNATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 ENGINE DESIGNATION NUMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 VEHICLE INDENTIFICATION NUMBER (VIN) DESIGNATION. . . . . . . . . . . . . . . . . . . . 1.2 VEHICLE AND ENGINE SERIAL NUMBER LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . 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 XP 900 / EPS / INT’L . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6 DETAILED: 2013 RANGER RZR XP 900 / EPS / INT’L . . . . . . . . . . . . . . . . . . . . . . . . . . 1.7 GENERAL: 2013 RANGER RZR XP 4 900 / EPS / INT’L . . . . . . . . . . . . . . . . . . . . . . . . 1.8 DETAILED: 2013 RANGER RZR XP 4 900 / EPS / INT’L . . . . . . . . . . . . . . . . . . . . . . . . 1.9 MISC. SPECIFICATIONS AND CHARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.10 CONVERSION TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.10 STANDARD BOLT TORQUE SPECIFICATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.11 METRIC BOLT TORQUE SPECIFICATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.11 SAE TAP / DRILL SIZES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.12 METRIC TAP / DRILL SIZES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.12 DECIMAL EQUIVALENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.12

1.2 GENERAL INFORMATION 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc. VEHICLE IDENTIFICATION Model Number Designation Example: R13XT9EAK Engine Designation Number 1204573 RZRXP 875-13 .................................................... 4-Stroke DOHC Twin Cylinder, Liquid Cooled, Electric Start Vehicle Identification Number (VIN) Designation Example: 4XAXT9EAXDB000000 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 X T 9 E A X D B 0 0 0 0 0 0 * Model Year: A = 2010; B = 2011; C = 2012; D = 2013

1.3 GENERAL INFORMATION 1 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc. Vehicle and Engine Serial Number Location Whenever corresponding about a Polaris ORV, refer to the vehicle identification number (VIN) and the engine serial number. The VIN can be found stamped on a portion of the left rear frame, behind the lower shock mounting location. Refer to Figure 1-1. The engine serial number can be found on a decal applied to the front of the engine crankcase (A) or stamped into the crankcase on the PTO side of the engine (B). Refer to Figure 1-2. VIN Figure 1-1 Figure 1-2 A B

1.4 GENERAL INFORMATION 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 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 XP 900 R13JT87AD, AL, AT 9924093 9924094 2013 RANGER RZR XP 900 EPS R13JT9EAK, AO 9924093 9924094 2013 RANGER RZR XP 900 INT’L R13JT9EFX 9924093 9924094 2013 RANGER RZR XP 4 900 R13XT87AA 9924107 9924108 2013 RANGER RZR XP 4 900 EPS R13XT9EAK 9924107 9924108 2013 RANGER RZR XP 4 900 INT’L R13XT9EFX 9924107 9924109 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 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 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 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc. GENERAL SPECIFICATIONS MODEL: 2013 RANGER RZR XP 900 MODEL NUMBER: R13JT87AD, AL, AT ENGINE NUMBER: 1204573 MODEL: 2013 RANGER RZR XP 900 EPS / INT’L MODEL NUMBER: R13JT9EAK, AO / R13JT9EFX ENGINE NUMBER: 1204573 Category Dimension / Capacity Length 108.4 in. / 275 cm Width 64 in. / 162.5 cm Height 73 in. / 185 cm Wheel Base 81.4 in. / 207 cm Ground Clearance 13 in. / 33 cm Dry Weight 1190 lbs. / 540 kg Gross Vehicle Weight 1930 lbs. / 875 kg Cargo Box Capacity 300 lbs. / 136 kg Maximum Weight Capacity (Payload) 740 lbs. / 335.6 kg (Includes driver, passenger, cargo and accessories) Hitch Towing Capacity This vehicle is not equipped with a hitch for towing loads. Do not use this vehicle for towing. Do not modify the vehicle by adding a hitch. Hitch Tongue Capacity Category Dimension / Capacity Length 108.4 in. / 275 cm Width 64 in. / 162.5 cm Height 73 in. / 185 cm Wheel Base 81.4 in. / 207 cm Ground Clearance 13 in. / 33 cm Dry Weight 1206 lbs. / 547 kg Gross Vehicle Weight 1946 lbs. / 875 kg Cargo Box Capacity 300 lbs. / 136 kg Maximum Weight Capacity (Payload) 740 lbs. / 335.6 kg (Includes driver, passenger, cargo and accessories) Hitch Towing Capacity This vehicle is not equipped with a hitch for towing loads. Do not use this vehicle for towing. Do not modify the vehicle by adding a hitch. Hitch Tongue Capacity

1.7 GENERAL INFORMATION 1 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc. 2013 RANGER RZR XP 900 / EPS / INT’L MODEL NUMBER: 87AD, AL, AT / 9EAK, AO / 9EFX ENGINE NUMBER: 1204573 CLUTCH CHART Engine Platform 4-Stroke DOHC Twin Cylinder, Liquid Cooled, Electric Start Engine Number 1204573 Engine Displacement 875cc Number of Cylinders 2 Bore & Stroke (mm) 93 x 64.4 mm Compression Ratio 10.5:1 Engine Idle Speed 1250 ± 100 RPM Engine Max Operating RPM 8750 RPM Lubrication Wet Sump Oil Requirements PS-4 Plus or Extreme Duty Oil Capacity 2.5 qts. / 2.4 liters Coolant Capacity 4.9 qts. / 4.6 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 43.5 ± 2 psi (300 ± 14 kPa) Fuel Filters See Chapter 4 Fuel Capacity / Requirement 7.25 gal. (27.4 liters) 87 Octane (minimum) Electrical Alternator Rated Output 570 Watts @ 3000 RPM Headlights 2 - Dual Beam LED: Low 27 Watts; High 27 Watts Tail / Brake 2 - 6 Watts / 2 - 27 Watts Starting System Electric Start Ignition System Bosch M17 (ECU Controlled) Spark Plug / Gap RG4YCX / 0.03 in. (0.75 mm) Battery 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 (OPT) Circuit Breaker 20 Amp: Fan Motor Fuses (Fuse/Relay Box) 10 Amp: Drive 10 Amp: Fuel Pump 20 Amp: Lights 20 Amp: EFI 20 Amp: Accessory Fuses (Power Fuse Holder) 30 Amp: EFI 30 Amp: Chassis 30 Amp: EPS (OPT) Drivetrain Transmission Type Polaris Automatic PVT Drive Ratio - Front 3.82:1 Drive Ratio - Final 3.53:1 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 Fluid Type / Capacity Polaris AGL Plus XP 900: 44 oz. (1300 ml) XP INT’L: 41 oz. (1200 ml) Clutching (PVT) Type Drive: Polaris, Basic, Non-Braking Bearing Driven: Team Roller Dampened Clutching (PVT) Center-to-Center Distance 10.5 in. (26.7 cm) PVT Drive Belt 3211148 Steering / Suspension Front Suspension / Shock Independent Dual A-arm FOX™ 2.0 Piggyback Front Travel 13.5 in. / 34.3 cm Rear Suspension / Shock Independent Trailing Arm FOX™ 2.0 Piggyback Rear Travel 14 in. / 35.6 cm Shock Preload Adjustment Front / Rear Threaded Spanner Wrench Adjustment Toe Out 1/8 - 3/16 in. (3.2 - 4.8 mm) Wheels / Brakes Front Wheel Size Front Tire Type / Size 12 x 6 / Cast Aluminum Maxxis Bighorn / 26 x 9 R12 ITP Baja Cross XD / 26 x 9 R12 ITP 900XCT / 27 x 9 R12 Rear Wheel Size Rear Tire Type / Size 12 x 8 / Cast Aluminum Maxxis Bighorn / 26 x 12 R12 ITP Baja Cross XD / 26 x 11 R12 ITP 900XCT / 27 x 11 R12 Tire Air Pressure Front: 12 psi (82.7 kPa) Rear: 14 psi (96.5 kPa) Brakes - Front / Rear Foot Actuated - 4 Wheel Hydraulic Disc Brake Fluid DOT 4 Parking Brake (INT’L Model Only) Hand Actuated (located in center console) Altitude Shift Weight Drive Spring Driven Spring Meters (Feet) 0-1500 (0-5000) 26-59 (1322981) Blue / Yellow (7043766) Red (3234452) 1500-3700 (5000 - 12000) 26-55 (1322982) Blue / Yellow (7043766) Red (3234452)

1.8 GENERAL INFORMATION 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc. MODEL: 2013 RANGER RZR XP 4 900 MODEL NUMBER: R13XT87AA ENGINE NUMBER: 1204573 MODEL: 2013 RANGER RZR XP 4 900 EPS / INT’L MODEL NUMBER: R13XT9EAK / R13XT9EFX ENGINE NUMBER: 1204573 Category Dimension / Capacity Length 134.4 in. / 341.4 cm Width 64 in. / 162.5 cm Height 77 in. / 195.6 cm Wheel Base 107.4 in. / 272.8 cm Ground Clearance 12.5 in. / 31.8 cm Dry Weight 1390 lbs. / 630.5 kg Gross Vehicle Weight 2375 lbs. / 1077 kg Cargo Box Capacity 300 lbs. / 136 kg Maximum Weight Capacity (Payload) 900 lbs. / 408 kg (Includes driver, passengers, cargo and accessories) Hitch Towing Capacity This vehicle is not equipped with a hitch for towing loads. Do not use this vehicle for towing. Do not modify the vehicle by adding a hitch. Hitch Tongue Capacity Category Dimension / Capacity Length 134.4 in. / 341.4 cm Width 64 in. / 162.5 cm Height 77 in. / 195.6 cm Wheel Base 107.4 in. / 272.8 cm Ground Clearance 12.5 in. / 31.8 cm Dry Weight 1406 lbs. / 638 kg Gross Vehicle Weight 2375 lbs. / 1077 kg Cargo Box Capacity 300 lbs. / 136 kg Maximum Weight Capacity (Payload) 900 lbs. / 408 kg (Includes driver, passengers, cargo and accessories) Hitch Towing Capacity This vehicle is not equipped with a hitch for towing loads. Do not use this vehicle for towing. Do not modify the vehicle by adding a hitch. Hitch Tongue Capacity

1.9 GENERAL INFORMATION 1 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc. 2013 RANGER RZR XP 4 900 / EPS / INT’L MODEL NUMBER: R13XT87AA / R13XT9EAK, FX ENGINE NUMBER: 1204573 CLUTCH CHART Engine Platform 4-Stroke DOHC Twin Cylinder, Liquid Cooled, Electric Start Engine Number 1204573 Engine Displacement 875cc Number of Cylinders 2 Bore & Stroke (mm) 93 x 64.4 mm Compression Ratio 10.5:1 Engine Idle Speed 1250 ± 100 RPM Engine Max Operating RPM 8750 RPM Lubrication Wet Sump Oil Requirements PS-4 Plus or Extreme Duty Oil Capacity 2.5 qts. / 2.4 liters Coolant Capacity 9.7 qts. / 9.2 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 43.5 ± 2 psi (300 ± 14 kPa) Fuel Filters See Chapter 4 Fuel Capacity / Requirement 7.25 gal. (27.4 liters) 87 Octane (minimum) Electrical Alternator Rated Output 570 Watts @ 3000 RPM Headlights 2 - Dual Beam LED: Low 27 Watts; High 27 Watts Tail / Brake 2 - 6 Watts / 2 - 27 Watts Starting System Electric Start Ignition System Bosch M17 (ECU Controlled) Spark Plug / Gap RG4YCX / 0.03 in. (0.75 mm) Battery Deka ETX30L / 30 AH 365 CCA / 12 Volt Instrument Type Multifunction Instrument Cluster DC Outlet 2- Standard 12 Volt Relays Chassis / EFI / Fan Fuel Pump / EPS (OPT) Circuit Breaker 20 Amp: Fan Motor Fuses (Fuse/Relay Box) 10 Amp: Drive 10 Amp: Fuel Pump 20 Amp: Lights 20 Amp: EFI 20 Amp: Accessory Fuses (Power Fuse Holder) 30 Amp: EFI 30 Amp: Chassis 30 Amp: EPS (OPT) Drivetrain Transmission Type Polaris Automatic PVT Drive Ratio - Front 3.82:1 Drive Ratio - Final 3.53:1 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 Fluid Type / Capacity Polaris AGL Plus XP 4 900: 44 oz. (1300 ml) XP 4 INT’L: 41 oz. (1200 ml) Clutching (PVT) Type Drive: Polaris, Basic, Non-Braking Bearing Driven: Team Roller Dampened Clutching (PVT) Center-to-Center Distance 10.5 in. (26.7 cm) PVT Drive Belt 3211148 Steering / Suspension Front Suspension / Shock Independent Dual A-arm Walker Evans™ 2.0" Piggyback Front Travel 13.5 in. / 34.3 cm Rear Suspension / Shock Independent Trailing Arm Walker Evans™ 2.5" Piggyback Rear Travel 14 in. / 35.6 cm Shock Preload Adjustment Front / Rear Threaded Spanner Wrench Adjustment Toe Out 1/8 - 3/16 in. (3.2 - 4.8 mm) Wheels / Brakes Front Wheel Size Front Tire Type / Size 12 x 6 / Cast Aluminum Maxxis Bighorn / 26 x 9 R12 ITP 900XCT / 27 x 9 R12 Rear Wheel Size Rear Tire Type / Size 12 x 8 / Cast Aluminum Maxxis Bighorn / 26 x 12 R12 ITP 900XCT / 27 x 11 R12 Tire Air Pressure Front: 14 psi (96.5 kPa) Rear: 16 psi (110.3 kPa) Brakes - 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) 26-59 (1322981) Purple (7043805) Red (3234452) 1500-3700 (5000 - 12000) 26-55 (1322982) Purple (7043805) Red (3234452)

1.10 GENERAL INFORMATION 9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual © Copyright 2012 Polaris Sales Inc. MISC. SPECIFICATIONS AND CHARTS Conversion Table °C to °F: °C x 9/5 + 32 = °F °F to °C: °F - 32 x 5/9 = °C

2013-2014 Polaris Ranger RZR XP 4 900 Service & Repair Manual

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