2013 Polaris Ranger RZR / RZR S / RZR 4 UTV Service Manual (P/N 9924125)

This Polaris service manual covers the 2013 RANGER RZR, RZR S, and RZR 4 800-series models, including EPS and International versions and the RZR 4 Limited Edition suspension. This is the preliminary version of publication P/N 9924125 (copyright 2012 Polaris Sales Inc.).

• Engine repair: Engine removal, cylinder-head and crankcase disassembly, piston and crankshaft inspection, valve seat reconditioning, and cylinder honing.

• Cooling and lubrication: Cooling-system pressure testing and bleeding, radiator and water-pump service, oil-pressure checks, and oil-pump priming.

• EFI diagnosis: Bosch M17 electronic fuel injection diagnostics, fuel pump and injector testing, Idle Air Control (IAC) checks, Throttle Position Sensor (TPS) adjustment, and T-MAP replacement.

• PVT and transmission: Polaris Variable Transmission drive and driven clutch service, belt installation, clutch offset adjustment, shift cable adjustment, and transfer-case and shift-housing repair.

• Final drive: Centralized Hilliard AWD diagnosis and overhaul, armature plate inspection, CV joint replacement, and standard and International rear-gearcase service.

• Chassis and brakes: EPS and non-EPS steering removal, FOX Podium shock rebuilds, suspension alignment, brake bleeding, and caliper overhaul.

• Electrical reference: Model-specific wiring diagrams, instrument-cluster pinouts, stator testing, starting and charging flowcharts, and EPS troubleshooting.

This manual suits experienced repair technicians with measuring equipment and EFI diagnostic tools; Polaris specifies certified Master Service Dealer technicians for PVT service.

Maintenance and Internal Engine Repair

Identification pages cover VIN and engine serial-number locations alongside model-specific chassis specifications. Maintenance charts combine pre-ride checks with hour, mileage, and calendar intervals, plus more frequent service for severe use.

Compression and leakdown tests accompany inspection limits for pistons, rings, crankshaft parts, and camshaft journals. Cylinder-head assembly includes a staged bolt-tightening sequence; cylinder honing is limited to deglazing, with replacement specified for excessively worn plated cylinders.

Crankcase Exploded Views and oil-pump and EFI-sensor assembly drawings support component identification. The Coolant Flow Diagram complements the cooling-system procedures.

Bosch M17 Troubleshooting and Reprogramming

The Diagnostic Trouble Code Table and component tests help distinguish wiring, sensor, and fuel-delivery faults before parts are replaced. Digital Wrench coverage extends to live data, guided diagnostics, and ECU reflashing.

The documented reflash procedure requires separate diagnostic equipment, software, and dealer-site authorization. The injector connector is bonded to the injector; forcing it apart can damage the injector or harness.

PVT, Gearcases, and CV Joints

Separate EBS and non-EBS clutch sections accompany the High Altitude Clutch Charts. Transmission procedures cover internal gears, bearings, and shift components, alongside routine front and rear gearcase maintenance.

RZR S International coverage includes the unlockable rear differential and differential-solenoid service. Rear-gearcase service excludes ring-and-pinion shimming; the manual specifies assembly replacement for damaged matched gear components or housings.

Inner CV-joint and boot replacement is covered, but complete disassembly of the precision-fitted plunging joints is discouraged.

FOX Shocks, Steering, and Brake Service

Shock coverage distinguishes RZR S Piggyback units, RZR 4 Limited Edition Piggyback units, and RZR 4 base-model Top Fill units. Spring-preload settings and the Compression Adjustment Table accompany reservoir, seal, and internal floating-piston work.

EPS procedures separate steering-unit removal from the non-EPS method; impacts to an installed steering wheel or shaft can permanently damage the EPS unit. The EPS System Breakout supports electrical fault tracing.

Brake sections distinguish RZR 4 front calipers and include piston inspection, seal replacement, and disc checks. Use proper lifting equipment and protective gear, and observe the manual's high-pressure nitrogen precautions for FOX shock work.

Examples of TPS Calibration and Mechanical Reference Data

These entries are a small sample of the manual's electrical settings and mechanical service specifications.

For TPS adjustment, Digital Wrench displays 0.46 ± 0.03 Vdc, while TPS Tester PN 2201519-A uses 0.700 ± 0.050 Vdc.

The standard metric-bolt table lists 25 Nm for M8 grade 8.8 fasteners with dry threads. The transmission main gearcase specification is 24 oz. (710 ml) of Polaris AGL Plus.

Search, Bookmarks, and Wiring-Diagram Detail

Finding information: Main service text is searchable, but some tables and diagram labels, including the final wiring sheets, are not. Embedded bookmarks cover chapters, subsections, and wiring sheets. Small wiring labels require zooming, and some diagram linework is faint.

One printable 430-page PDF, comprising 410 service/reference pages, six notes pages, and 14 wiring-diagram pages, all included in the total.