2013 Polaris RZR / RZR S / RZR 4 Service & Repair Manual (P/N 9924125)

• Official Polaris publication: P/N 9924125, copyright 2012, supplied as a 430-page PDF—416 letter-size service pages plus 14 landscape 11 × 17 wiring-diagram pages. Coverage includes the 2013 RANGER RZR (R13VH76AC, AD, AN, AS), RZR EPS (R13VH7EAI), RZR S (R13VE76AD, AI, AS, AW), RZR S INT’L (R13VE76FI, FX), RZR 4 (R13XE76AD), and RZR 4 EPS (R13XE7EAI).
• Engine and cooling repair: Covers engine removal and transmission separation, cylinder-head and valve service, piston/cylinder and crankcase inspection, camshaft and flywheel/stator work, oil-pump and lubrication testing, water-pump and radiator service, cooling-system bleeding, reassembly, installation, and break-in.
• Bosch M17 EFI and electrical diagnostics: Includes fuel-tank and fuel-line service, injector, pump, ignition, and sensor testing, instrument-cluster trouble-code display, Digital Wrench guided diagnosis and controller reflash coverage, charging and starting tests, EPS troubleshooting, fuse/relay information, and pinouts.
• PVT, transmission, and final drive: Distinguishes non-EBS clutching from the EBS-equipped RZR EPS configuration, with drive-belt, drive/driven-clutch, clutch-offset, and high-altitude setup data. It also covers transfer-case and shift-housing overhaul, Centralized Hilliard AWD diagnosis, CV-joint and propshaft work, and standard versus INT’L rear gearcases.
• Chassis, steering, suspension, and brakes: Details cab and body removal, non-EPS and EPS steering assemblies, A-arms, ball joints, stabilizer bars, toe inspection and adjustment, master-cylinder service, brake bleeding, caliper/pad/disc repair, and brake noise, drag, and pedal-vibration troubleshooting.
• FOX Podium shock coverage: Provides separate factory rebuild data for FOX 1.5 Podium piggyback shocks on RZR S, FOX 2.0 piggyback shocks on RZR 4 L.E. models, and FOX 2.0 top-fill shocks on RZR 4 base models, including disassembly, seal and valving service, IFP setup, filling, and recharging requirements.

Documented Systems and Maintenance Data

The maintenance chapter combines the periodic service schedule with approved lubricants and separate fill data for the main transmission and transfer case using AGL Plus, the front gearcase using Demand Drive Plus, and the standard rear gearcase or RZR S INT’L differential using ATV Angle Drive Fluid. It also covers compression and leakdown testing, cooling-system pressure checks, battery charging and storage, standard spring preload, FOX compression adjustment, brake wear checks, and wheel-bearing and drive-shaft boot inspections. Component torque tables, wear limits, clearances, pressure-test specifications, and electrical test values are placed with the related repair procedures.

Variant-Specific Repair Coverage

The identification pages are especially useful when matching the manual to an engine or chassis. Polaris identifies RZR800-13 as engine designation 1204620; the vehicle specification tables use engine number 1204670 for RZR, RZR EPS, RZR S, and RZR S INT’L, and 1204671 for RZR 4 and RZR 4 EPS. The manual also provides separate maximum-RPM specifications for RZR versus RZR S/RZR 4, accounts for the RZR 4 cooling-system capacity, and includes INT’L-only procedures for the Turf-mode rear differential, differential-solenoid circuit, turn-signal controls, and dedicated rear gearcase.

The clutch and suspension sections carry the same variant detail. The EBS-equipped RZR EPS has its own belt and driven-clutch procedures, while RZR 4 base and L.E. machines use different FOX 2.0 shock constructions. That distinction matters before ordering seals, clutch parts, special tools, or selecting a repair procedure.

Factory Diagnostics, Diagrams, and Workshop Notes

Named technical references include the Oil Flow Chart, EFI System Exploded View, Centralized Hilliard Exploded View, Transmission Exploded View, Cooling System Break-Out Diagram, and EPS System Breakout. The 14 large-format electrical pages provide dedicated schematics for RZR 800, RZR 800 EPS, RZR S 800, RZR S 800 INT’L, RZR 4 800, and RZR 4 800 EPS, plus cargo-box circuits.

The special-tool tables identify the Digital Wrench package PU-47063-B, fuel-pressure kit PU-43506-A with adapter PV-48656, drive-clutch puller PA-48595, cam-gear tooth alignment tool PU-45497-2, and FOX gas-shock recharging kit 2200421. Digital Wrench guided diagnostics and ECU reflash information are included, but the dealer software and SmartLink hardware are separate service tools rather than part of the PDF.

Two easy-to-miss repair traps are called out clearly: the injector-side Bosch connector is bonded to the injector and can damage the injector or harness if separated at the wrong point, while disturbing the factory-calibrated throttle-body stop screw can make throttle-body replacement necessary. Fuel-system components can remain pressurized with the engine off, and FOX shocks contain high-pressure nitrogen; review the manual’s pressure-relief, lifting, and support precautions before teardown.

This PDF is the service manual only. The separately numbered owner’s manual and model-specific parts books referenced in the publication table are separate publications.