Polaris Ranger 400 & 500 EFI Midsize 2013 Service Manual (P/N 9923949)

• Model coverage: 2013 Polaris RANGER 400 Midsize, 500 EFI Midsize, and 500 EFI CREW Midsize with single-cylinder engines.

• Engine repair: Engine removal and installation, cylinder-head reconditioning, crankcase separation, crankshaft inspection, and camshaft timing.

• Fuel systems: Mikuni CV carburetor overhaul, EFI fuel-pressure testing, sensor diagnosis, throttle-position adjustment, and ECU reflash procedures.

• PVT and transmission: Drive and driven clutch service, belt alignment, internal transmission overhaul, and snorkel/output gear backlash adjustment.

• Final drive: Centralized Hilliard AWD diagnosis, front gearcase overhaul, CV joint service, and CREW prop shaft support-bearing replacement.

• Chassis and brakes: Steering alignment, strut and ball-joint replacement, frame fastener torque specifications, brake bleeding, and caliper repair.

• Electrical troubleshooting: Starting and charging tests, control-module checks, starter motor repair, and chassis, dash, and cargo-box wiring diagrams.

This Polaris OEM service manual, P/N 9923949, is copyrighted 2012 by Polaris Sales Inc. The 403-page PDF contains technical specifications, exploded-view diagrams, torque tables, and maintenance schedules for routine and major servicing.

It is suited to mechanics experienced in engine measurement and electrical testing. Some procedures require dedicated service tools, and Polaris specifies factory-trained, authorized technicians for PVT service and repair.

400 and 500 EFI Engine Identification

The 400 uses the 455 cc EH46PLE engine; the 500 EFI and CREW use the 498 cc EH500PLE engine. These distinctions determine which fuel-system and electrical procedures apply.

Covered model codes are R13RH45AG for the 400; R13RH50AG, R13RH50AR, R13RH50AH, and R13RH50AM for the 500 EFI; and R13WH50AG, R13WH50AR, R13WH50AH, and R13WH50AX for the CREW.

Engine Overhaul and Maintenance Specifications

Engine coverage extends from compression and leak-down testing to valve-seat reconditioning, cylinder honing, piston-ring inspection, and crankshaft end-play adjustment. The Oil Flow Diagram and Camshaft Timing Illustration support lubrication-system diagnosis and timing-system assembly.

Reference data includes compression pressure, ignition timing, intake and exhaust valve clearances, wear limits, and assembly torques. The accessible-components chart distinguishes repairs possible with the engine installed from work requiring engine removal.

Cooling-System Testing and Water-Pump Seal Repair

Cooling procedures cover pressure testing, radiator-cap checks, cooling system bleeding, fan diagnosis, and water-pump mechanical-seal replacement.

The seal section identifies Water Pump Mechanical Seal Puller P/N 2872105 for work with the engine installed. It warns that side-loading the puller can bend the pump shaft, turning a seal repair into engine removal and crankcase separation.

Mikuni Carburetor and Visteon EFI Diagnosis

The Mikuni BST34 CV carburetor section includes disassembly, cleaning, float adjustment, needle-and-seat leakage testing, and jetting guidance for temperature and altitude.

For the Visteon EFI system, the Diagnostic Blink Codes Chart and EFI System Breakout Diagram connect fault codes with component and circuit checks. Together with fuel-pressure and sensor tests, they help distinguish wiring faults from failed components before replacement.

Throttle-position sensor adjustment and ECU replacement/reflashing are documented. Digital Wrench procedures require separate diagnostic software and interface hardware; reflashing also requires dealer authorization.

Clutch, Transmission, and AWD Service

PVT coverage includes clutch inspection, bushing service, offset checks, and center-distance adjustment. The belt-deflection shim procedure is specific to the 400.

Transmission overhaul includes the gear cluster, shift mechanism, and rear differential. Snorkel/output gear backlash work specifies Snorkel Tool PA-50231; lubrication data includes fluid capacities and the documented Full Synthetic AGL Plus transmission-fluid specification.

Front gearcase diagnosis addresses the AWD coil, armature, and roller cage. Separate CREW procedures cover its two-piece prop shaft and carrier bearing.

Steering, Suspension, and Hydraulic Brakes

The workshop manual documents steering inspection, toe specifications and adjustment, front strut service, and rear suspension repair. Chassis sections include cab-frame assembly and body-panel removal.

Brake coverage includes master-cylinder service, disc inspection, and caliper rebuilding. The CREW has separate front-caliper procedures, helping owners select the correct repair section for their vehicle.

Charging, Starting, and Control Circuits

The Charging System Testing Flow Chart and Starting System Testing Flow Chart accompany stator, regulator/rectifier, battery, and starter checks. Electrical coverage distinguishes the 400 ACS/Hub module from the 500 EFI control system and includes instrument-cluster, AWD, and Turf-mode diagnosis.

Always ensure you have the proper tools, a safe work area, and the required mechanical knowledge; follow the manual's precautions for pressurized fuel, hot coolant, and securely supporting the vehicle.

Search, Bookmarks, and Wiring-Sheet Readability

The file has 726 embedded bookmarks spanning all ten chapters and the wiring appendix. Body text is searchable, but many schematic labels and image-based tables are not searchable.

Small wiring labels require magnification for comfortable reading. The page total includes nine wiring sheets, seven notes pages, and two blank divider pages.