Page 1 Service Manual, contact an authorized Slingshot dealer for service. Comments or suggestions about this manual should be submitted via Ask Polaris. Consumers can direct comments or suggestions to: Service Publications Department, Polaris Sales Inc., 2100 Hwy 55, Medina, MN 55340.
Page 2 Copyright Info All information contained within this publication is based on the latest product information at the time of publication. Due to constant improvements in the design and quality of production components, some minor discrepancies may result between the actual vehicle and the information presented in this publication. Depictions and/or procedures in this publication are intended for reference use only.
Page 3 Hilliard, Trademark of the Hilliard Corporation Warn, Trademark of Warn Industries FOX, Registered Trademark of FOX RACING SHOX RydeFX, Registered Trademark of ArvinMeritor Some Polaris factory publications can be downloaded from www.polarisindustries.com, purchased from www.purepolaris.com or by contacting the nearest Polaris dealer.
Page 5 GENERAL INFORMATION MAINTENANCE ENGINE ELECTRONIC FUEL INJECTION BODY / STEERING / SUSPENSION CLUTCHING FINAL DRIVE TRANSMISSION BRAKES ELECTRICAL...
Page 8: Vehicle Identification
Example: 4XAVH76A4E3000000 Vehicle Descriptors Vehicle Identifiers World Mfg. ID Individual Serial No. * Model Year: A = 2010; B = 2011; C = 2012; D = 2013; E = 2014 9924882 - 2013–2014 RZR 800 © Copyright Polaris Sales Inc.
Page 9: Vehicle And Engine Serial Number Locations
GENERAL INFORMATION 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 (Figure 1-1).
Page 10: Vehicle Information
9924707 9924729 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.
Page 11: Special Tools
Some of the tools listed or depicted are phone at 1-800-328-6657 or on-line at http://polaris. mandatory, while other tools may be substituted with a service-solutions.com/. similar tool, if available. Polaris recommends the use of 9924882 - 2013–2014 RZR 800 © Copyright 2013 Polaris Sales Inc.
Page 12: General Specifications
Capacity (Payload) and trailer tongue weight) Hitch Tongue Capacity 150 lbs. / 68 kg Hitch Towing Capacity 1500 lbs. / 680 kg Hitch Tongue Capacity 150 lbs. / 68 kg 9924882 - 2013–2014 RZR 800 © Copyright Polaris Sales Inc.
Page 13: Model: 2014 Rzr 800 Xc
Battery (RZR) 18 Amp Hr. / 310 CCA / 12 Volt Deka ETX30L / 30 AH Battery (RZR EPS) 365 CCA / 12 Volt Instrument Type Multifunction Instrument Cluster 9924882 - 2013–2014 RZR 800 © Copyright 2013 Polaris Sales Inc.
Page 14 Maxxis / 25 x 10 R12 8 psi (55 kPa) Tire Air Pressure - Front / Rear Foot Actuated - 4 Wheel Brake - Front / Rear Hydraulic Disc Brake Fluid DOT 4 9924882 - 2013–2014 RZR 800 © Copyright Polaris Sales Inc.
Page 15: Model: 2013-2014 Rzr S 800
1500 lbs. / 680 kg Hitch Towing Capacity 1500 lbs. / 680 kg Capacity Hitch Tongue 150 lbs. / 68 kg Hitch Tongue Capacity 150 lbs. / 68 kg Capacity 9924882 - 2013–2014 RZR 800 © Copyright 2013 Polaris Sales Inc.
Page 16: Model: 2013 Rzr S / Int'l 800
Polaris Premium ADF Fluid Type / Capacity 26 oz. (769 ml) 2 - Halogen: Low 55 W / Headlights (Halogen) High 60 W Rear Gearcase (INT’L) Polaris Premium ADF 1.10 9924882 - 2013–2014 RZR 800 © Copyright Polaris Sales Inc.
Page 17 Maxxis Bighorn / 26 x 12 Tire Air Pressure - Front / 8 psi (55 kPa) Rear Foot Actuated - 4 Wheel Brake - Front / Rear Hydraulic Disc Brake Fluid DOT 4 1.11 9924882 - 2013–2014 RZR 800 © Copyright 2013 Polaris Sales Inc.
Page 18: Model: 2013-2014 Rzr 4 Eps 800
Hitch Towing 1500 lbs. / 680 kg 1500 lbs. / 680 kg Capacity Capacity Hitch Tongue Hitch Tongue 150 lbs. / 68 kg 150 lbs. / 68 kg Capacity Capacity 1.12 9924882 - 2013–2014 RZR 800 © Copyright Polaris Sales Inc.
Page 19 26 oz. (769 ml) 2 - Halogen: Low 55 W / Headlights (Halogen) Clutch Type Standard PVT High 60 W Drive Belt 3211133 Headlights (LED) 2 - Dual Beam LED: 1.13 9924882 - 2013–2014 RZR 800 © Copyright 2013 Polaris Sales Inc.
Page 20 Driven Altitude Weight Spring Spring Blk / 23-62 Green 0-1500 Almond (56323- (70437- (0-5000) (704316- ters (Fee- 23-58 Blk / 1500-3700 Green Almond (5000 - (70437- (13229- (704316- 12000) 1.14 9924882 - 2013–2014 RZR 800 © Copyright Polaris Sales Inc.
Page 21: Misc. Specifications And Charts
π (3.14) x Radius² x Height = = cylinder volume °C to °F: 9/5 (°C + 32) = °F °F to °C: 5/9 (°F − 32) = °C 1.15 9924882 - 2013–2014 RZR 800 © Copyright 2013 Polaris Sales Inc.
Page 22: Standard Bolt Torque Specification
37 (50) 55 (75) 103 (140) 151 (205) 177 (240) 59 (80) 85 (115) 159 (215) 232 (315) 273 (370) 81 (110) 118 (160) 225 (305) 321 (435) 376 (510) 1.16 9924882 - 2013–2014 RZR 800 © Copyright Polaris Sales Inc.
Page 23: Sae Tap / Drill Sizes
1 25/32 5/16–18 2–12 1 59/64 5/16–24 2 1/4–4 1/2 2 1/32 3/8–16 2 1/2–4 2 1/4 3/8–24 2 3/4–4 2 1/2 7/16–14 3–4 2 3/4 7/16–20 25/64 1.17 9924882 - 2013–2014 RZR 800 © Copyright 2013 Polaris Sales Inc.
Page 24: Decimal Equivalents
13 mm = 0.5118″ 33/64 0.5156″ 17/32 0.5313″ 0.5469″ 14 mm = 0.5512″ 35/64 9/16 0.5625″ 37/64 0.5781″ 15 mm = 0.5906″ 19/32 0.5938″ 39/64 0.6094″ 0.625″ 16 mm = 0.6299″ 1.18 9924882 - 2013–2014 RZR 800 © Copyright Polaris Sales Inc.
Page 25 ......2.9 POLARIS LUBRICANTS, MAINTENANCE AND SERVICE PRODUCTS GENERAL VEHICLE INSPECTION AND MAINTENANCE ..........2.10 .
Page 27: Periodic Maintenance Chart
▶ = SEVERE USE ITEM: See information provided above. E = Emission Control System Service (California). NOTE: Inspection may reveal the need for replacement parts. Always use genuine Polaris parts. WARNING Improperly performing the procedures marked ■ could result in component failure and lead to serious injury or death.
Page 28: Pre-Ride - 50 Hour Maintenance Interval
▶ Perform these procedures more often for vehicles subjected to severe use. E Emission Control System Service (California) ■ Have an authorized Polaris dealer perform these services. 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 29: 100 - 300 Hour Maintenance Interval
▶ Perform these procedures more often for vehicles subjected to severe use. E Emission Control System Service (California) ■ Have an authorized Polaris dealer perform these services. 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 30: Maintenance Quick Reference
Brake Fluid Polaris DOT 4 Brake Fluid master cylinder reservoir two years * More often under severe use, such as operated in water or under severe loads. 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 31: Maintenance Quick Reference, Continued
Transmission change according to intervals Gearcase Lubricant at the fill hole threads * More often under severe use, such as operated in water or under severe loads. 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 32: Grease Lubrication Points
Grease fittings every of storage, and after Polaris Premium U-Joint A-arm Pivot Bushings 500 miles (800 km). thoroughly washing or Grease submerging the vehicle. Stabilizer Bar Bushings 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 33: Lubricants / Service Products
Dielectric Grease (Nyogel™) 2871329 Coolant 60/40 Coolant (Gallon) (6 Count) 2871323 60/40 Coolant (Quart) (12 Count) 2871534 NOTE: Each item can be purchased separately at your local Polaris dealer. 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 34: General Vehicle Inspection And Maintenance
7. Start engine and shift through all gears to ensure the shift cable is properly adjusted. If transmission still ratchets after cable adjustment, the transmission will require service. 2.10 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 35: Fuel System And Air Intake
EFI System. 2. Be sure fuel line is routed and retained properly. IMPORTANT: Make sure line is not kinked or pinched. 2.11 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 36: Vent Lines
2. Remove cargo box as an assembly (see Chapter 5). Check throttle pedal freeplay periodically in accordance with the Periodic Maintenance Chart. Adjust the freeplay if necessary (see “Throttle Freeplay Adjustment”). 2.12 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 37: Air Filter Service
Inspect the seal. It should adhere tightly to the cover and seal all the way around. 5. Slide back the cable adjuster boot. 3. Remove the air filter assembly. 2.13 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 38 3. Install the filter into the air box and be sure it fits operation for extended periods. tightly. 4. Install air box cap and secure with clips. Air Box / Air Filter Exploded View 2.14 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 39: Engine
8. Reinstall the dipstick and lock the lever. 5. Lift the lever lock, remove dipstick and wipe dry with a clean cloth. 2.15 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 40: Engine Oil And Filter Service
Check to make sure the O-ring is in good condition. CAUTION Oil may be hot. Do not allow hot oil to come into contact with skin, as serious burns may result. 2.16 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 41: Engine Breather Hose Inspection
Engine and Transmission Mounts Periodically inspect engine and transmission mounts for cracks or damage. Refer to Chapter 3 “Engine Assembly and Installation” for mounting fastener torque values. 2.17 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 42 MAINTENANCE 4. Reinstall the arrestor and torque the screw to specification. Spark Arrestor Screw: 40 in-lbs (4.5 Nm) 2.18 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 43: Transmission And Gearcases
5. Reinstall level check plug and torque to specification. 2. Remove the fill plug. 3. Remove the level check plug. Level Check Plug: 30-45 in-lbs (3-5 Nm) 2.19 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 44 2. Place a drain pan under the main gearcase drain plug. Fill / Level Plug: 3. Remove the drain plug and allow to drain completely. 40-50 ft-lbs (54-68 Nm) 2.20 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 45: Front Gearcase Lubrication
7. Check for leaks. Dispose of used lubricant properly. bottom threads of the fill plug hole. 1. Position vehicle on a level surface. 2. Remove the fill plug and check the fluid level. 2.21 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 46: Rear Gearcase Lubrication
5. Reinstall the drain plug with a new O-ring and torque to specification. 6. Add the recommended fluid. Maintain the lubricant level even with the bottom threads of the fill plug hole. 2.22 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 47 7. Reinstall the fill plug and torque to specification. Fill Plug: 40-50 ft-lbs (54-68 Nm) 8. Check for leaks. Dispose of used lubricant properly. 2.23 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 48: Cooling System
7. Remove recovery bottle cap and add coolant using a funnel. Coolant Level Inspection 8. Fill recovery bottle to MAX level with Polaris 60/40 The pressure cap and recovery bottle are located under premix Anti Freeze/Coolant or 50/50 or 60/40 the front hood of the vehicle.
Page 49: Cooling System Pressure Test
2. Slowly remove the pressure cap to relieve any cooling system pressure. 3. Place a suitable drain pan underneath the radiator fitting on the front RH side of the vehicle. 2.25 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 50: Final Drive / Wheel And Tire
4. Attach the wheel nuts and finger tighten them. 5. Carefully lower the vehicle to the ground. 2.26 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 51: Tire Inspection
Front Rear 8 psi (55 kPa) 8 psi (55 kPa) RZR 4 Tire Pressure Inspection (Cold) Front Rear 10 psi (69 kPa) 12 psi (83 kPa) 2.27 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 52: Drive Shaft Boot Inspection
10-30% of full potential. Charge battery according to “Charging Procedure” provided in Chapter 10. Do not use the vehicle’s stator/alternator to charge a new battery. 2.28 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 53: Battery Removal
When reinstalling the battery, install the black (negative) • RZR / RZR S: Remove the driver and passenger cable last. seats. • RZR 4: Remove both rear passenger seats. 2.29 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 54 7. Clean with electrical contact cleaner or a glass bead spark plug cleaner only. CAUTION: A wire brush or coated abrasive should not be used. 2.30 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 55: Engine To Frame Ground
WARNING Due to the critical nature of the procedures outlined in this chapter, Polaris recommends steering component repair and adjustment be performed by an authorized Polaris MSD certified technician. Use only genuine Polaris replacement parts.
Page 56: Tie Rod End / Wheel Hub Inspection
• Replace any worn steering components. Steering should move freely through entire range of travel without binding. 2.32 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 57: Wheel Toe Alignment Inspection
• Shorten or lengthen the tie rod until alignment is as (A) - (B) = 1/8 to 1/4" (0.3 to 0.6 cm) required to achieve the proper toe setting as specified in “Wheel Toe Alignment”. 2.33 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 58: Suspension (Standard)
Shock Spanner Wrench: PN 2871095 4. Each notch of the adjustment will add 6% - 8% more preload to the spring over the primary position. 2.34 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 59: Suspension (Fox™)
(2) clockwise to increase preload or counter-clockwise to decrease preload. IMPORTANT: DO NOT increase the spring preload by more than one inch (25.4 mm) over the factory setting. 2.35 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 60: Shock Compression Adjustment
5. Install the reservoir cap and apply the brake pedal forcefully for a few seconds and check for fluid leakage around the master cylinder fittings and the brake caliper fittings. 2.36 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 61: Brake Pad / Disc Inspection
Brake Hose and Fitting Inspection Check brake system hoses and fittings for cracks, deterioration, abrasion, and leaks. Tighten any loose fittings and replace any worn or damaged parts. 2.37 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 67: Stator Cover / Starter / Water Pump / Lubrication System Exploded View
ENGINE Stator Cover / Starter / Water Pump / Lubrication System Exploded View 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 69: Engine Efi Sensors / Valve Cover / General Components Exploded View
ENGINE Engine EFI Sensors / Valve Cover / General Components Exploded View 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 70: Engine Torque Specifications
* 96 ± 12 (10.85 ± 1.35) 6 mm Water Pump Impeller Nut 108 ± 3 (12 ± 0.35) 8 mm NOTE: * See exploded views for notes or torque sequences. 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 71: 800 Efi Engine Service Specifications
Valve Spring Overall Length - Free Length 1.735" (46.069 mm) Valve Spring Valve Spring Overall Length - Installed Intake - 1.4638" (37.18 mm) Height Exhaust - 1.4736" (37.43 mm) 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 72 0.01181" ± 0.00591" (0.30 ± 0.15 mm) Side Clearance Connecting Rod Big End 0.0015" ± 0.0006" (0.038 ± 0.015 mm) Radial Clearance 0.00236" (0.06 mm) Crankshaft Crankshaft Runout Limit 3.10 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 73: Special Tools
CRANKSHAFT MAIN SEAL SAVER PA-45401 WATER PUMP SEAL SAVER 2870975 MITY VAC™ PRESSURE TEST TOOL PU-45778 OIL SYSTEM PRIMING TOOL Bosch Automotive Service Solutions: 1-800-328-6657 or http://polaris.service-solutions.com/ 3.11 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 74: Engine Cooling System
CAUTION: Using tap water in the cooling system will lead to a buildup of deposits which may restrict coolant flow and reduce heat dissipation, resulting in possible engine damage. Polaris Premium 60/40 Antifreeze/ Coolant is recommended for use in all cooling systems and comes pre-mixed, ready to use.
Page 76: Radiator Removal
5. Allow coolant to completely drain. 6. Remove the front bumper (see Chapter 5). 7. Remove the upper engine outlet hose and recovery hose from the top of the radiator. 3.14 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 78 NOTE: If there is air in the system you will see air bubbles forming through the radiator filler neck. 10. Add Polaris Premium Antifreeze to the radiator filler neck if the level goes down. If no bubbles are seen at the filler neck, the system should be purged of air.
Page 79: General Engine Service
• Crankshaft Main Bearings 3. Start engine and allow it to reach operating temperature, while monitoring the gauge. • Crankcase NOTE: Use only Polaris PS-4 or Extreme Duty Synthetic 4-Cycle Engine Oil. Oil Pressure at 6000 RPM (Engine Hot): Minimum: 27 PSI...
Page 80: Oil Flow Chart
The third oil path flows through a crankcase galley to the MAG side crankshaft journal and also to the front balance shaft journal and onto the crankcase sump. 3.18 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 81: Engine Removal
8. Remove the (2) screws (A) from the rear of the center console (RZR / RZR S only). Because of its design configuration and fastener torque requirements, Polaris recommends removing the engine, transmission and rear gearcase as one assembly. Use the following procedure when engine removal is required.
Page 83 24. Remove the remaining bolt attaching the airbox to 21. Remove the engine breather hose from the valve the frame (see photo). cover. 3.21 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 84 IMPORTANT: Take note of PTO and MAG fuel injector harness connectors before disconnecting them. The harnesses are different and can not be connected incorrectly (PTO - Gray; MAG - Black). 3.22 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 85 (see Chapter “Shift Cable Inspection / Adjustment”). 30. Disconnect the transmission gear indicator switch harness. 33. Disconnect the transmission speed sensor harness. 3.23 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 86 NOTE: Clean area around drive shaft orifices on both sides of rear gearcase and cover orifices using duct tape. This will prevent the lubricant from leaking out during removal. 3.24 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 87 Properly dispose of the engine coolant / antifreeze. 43. Remove the (+) positive battery cable from the starter motor terminal and (-) negative battery cable from the starter motor engine mount. 3.25 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 88 NOTE: Have an assistant help guide the engine in and out of the vehicle while using an engine hoist to prevent personal injury or damage to vehicle components. 3.26 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 89: Engine / Transmission Separation
5. Carefully separate the engine and perform the engine from the assembly. required service (see “Engine Disassembly and Inspection”). 1. Remove the drive belt, drive clutch and driven clutch (see Chapter 6). 3.27 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 90: Engine Disassembly And Inspection
ENGINE ENGINE DISASSEMBLY AND INSPECTION Cylinder Head Assembly Exploded View 3.28 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 91: Rocker Arms
Push rods can also be checked with a dial indicator or rolled across a flat surface to check for straightness. 3.29 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 92: Cylinder Head Inspection
Hook the hose to an air compressor and supply 50 to 100 psi to the hose. This will seat the valves during valve spring removal. Do not remove air supply until reassembly is completed. 3.30 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 93: Cylinder Head Disassembly
IMPORTANT: It is recommended to replace seals whenever the cylinder head is disassembled. Hardened, cracked or worn valve seals will cause excessive oil consumption and carbon buildup. 3.31 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 94: Valve Inspection
“V” blocks and a dial indicator. specifications. Valve Stem Diameter: Intake: 0.2356" ± 0.00039" (5.985 ± 0.01 mm) Exhaust: 0.2351" ± 0.00039" (5.972 ± 0.01 mm) 3.32 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 95: Combustion Chamber
Valve Seat Reconditioning 0.23672" ± 0.000295" (6.0617 ± 0.0075 mm) NOTE: Polaris recommends that the work be done by a local machine shop that specializes in this area. 6. Subtract valve stem measurement from the valve guide measurement to obtain stem to guide NOTE: The cylinder head valve guides cannot be clearance.
Page 96 3. Place 46° cutter on the pilot and make a light cut. 6. Insert valve into guide and tap valve lightly into place a few times. 3.34 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 97 10. Insert the valve into its respective guide and lap using a lapping tool or a section of fuel line connected to the valve stem. 3.35 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 98: Cylinder Head Reassembly
NOTE: To prevent damage to the valve seals, do not compress the valve spring more than necessary to install the keepers. 3.36 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 99: Valve Lifter Removal / Inspection
NOTE: Lifters that are scored, worn, or if the bottom is not smooth should be replaced with new lifters and cam as an assembly. If replacing the lifters, the camshaft should also be replaced. 3.37 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 100: Cylinder Inspection
(B) in the upper oil ring land of the piston. To Remove: A) Remove the top rail first followed by the bottom rail. B) Remove the expander. Cylinder Warp: 0.004" (0.1 mm) Max. 3.38 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 101 0.002" (0.05 mm), the cylinder must be replaced. Cylinder Taper Limit: 0.002" (0.05 mm) Max. Cylinder Out of Round: Limit: 0.002" (0.05 mm) Max. Standard Bore Size (Both Cylinders): 3.1496" (80 mm) 3.39 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 102: Cylinder Hone Selection And Honing Procedure
A hone which will straighten as well as remove material from the cylinder is very important. Using a common spring loaded glaze breaker for honing is not advised for nicasil cylinders. Polaris recommends using a rigid hone orarbor honing machine. IMPORTANT: Clean the cylinder after honing Honing To Deglaze...
Page 103: Piston / Rod Inspection
Replace piston and rings if ring-to- groove clearance exceeds service limits. Piston Pin O.D.: See “800 EFI Engine Service Specifications”, page See “800 EFI Engine Service Specifications”, page 3.41 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 104: Piston Ring Installed Gap
Flywheel Puller (PN 2871043) and remove flywheel. NOTE: Do not thread the puller bolts into the flywheel more than 1/4" or stator coils may be damaged. 3.42 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 105: Flywheel / Stator Removal / Inspection
2. Remove flywheel nut and washer. 5. Remove the bendix (E) if necessary. 3.43 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 106: Engine Crankcase Disassembly / Inspection
(H), and the woodruff key (I) from the crankshaft. The stator does not have to be removed at this point. 3. Remove flywheel nut and washer. 3.44 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 107 10. Inspect the cam gear teeth and check to make sure there is spring tension offsetting the teeth between the two gears. If there is no tension, check the springs inside of the cam gear assembly. 3.45 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 108 12. Remove all three springs using one of the tapered pins from (PU-45497-1). 14. Inspect the gear teeth and the three tabs on the gears for wear. 3.46 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 109 • Perform this procedure with all three tapered pins. • Do not push the pins too far through or the springs will pop out. NOTE: Do not remove the tapered pins at this time. 3.47 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 110 (PN 2871043) to remove the balance shaft gear. NOTE: For ease of installing the Cam Gear Alignment Tool (PU-45497-2), use a twisting motion when pushing down on the tool. 3.48 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 111 25. Install the Flywheel Puller (PN 2871043) and remove replacement rotors will fit into the original oil/ the crankshaft gear, if needed. water pump housing. 3.49 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 112 31. Carefully press the gear off the assembly while supporting the housing assembly. CAUTION Wear appropriate safety gear during this procedure. Protective gloves, clothing and eye wear are required. 3.50 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 113 33. Place the shaft in a press to remove the bearing. 36. Press gear onto shaft while supporting the housing. 34. Press shaft into the new bearing. 3.51 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 115: Camshaft Inspection
3. Measure height of each cam lobe using a micrometer. Compare to specification. Cam Lobe Height Intake (Std): 1.357” (34.477 mm) Exhaust (Std.): 1.342” (34.096 mm) 3.53 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 116 Camshaft Journal Bore I.D.: MAG: 1.656" ± 0.00039" (42.07± 0.010 mm) CTR: 1.637" ± 0.00039" (41.58 ± 0.010 mm) PTO: 1.617" ± 0.00039" (41.07 ± 0.010 mm) 3.54 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 117: Engine Reassembly
2. Install oil baffle weldment (B). Torque bolts to specification. Oil Baffle Weldment and Oil Pick Up Bolt: 60 ± 6 in-lbs (6.8 ± 0.68 Nm) 3.55 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 118 Torque bolts to specification following torque pattern at beginning of this chapter. Crankcase Bolts: 22 ± 2 ft-lbs (30 ± 3 Nm) Torque in sequence 3.56 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 119 12. Orientate the piston rings on the piston before installation into the cylinders. Set the gaps of the rings every 120° (see illustration below). 3.57 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 120 Thrust Plate Screw: 115 ± 12 in-lbs (13 ± 1.35 Nm) 17. Assemble rotors as marked when disassembled. Use a cleaner to remove marks previously made on rotors. 3.58 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 121 NOTE: Before assembly, clean the bolts and bolt holes with Loctite Primer N (commercially available) to remove any debris. This will ensure proper sealing when installing bolts and new Loctite™. 3.59 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 122 NOTE: For assembly of the gears, the cam gear and the crankshaft gear are stamped with “This Side Out”. This indicates the side of the gear that faces outward or away from the case. 3.60 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 124 NOTE: Install the water pump seal (N) with the seal lip facing out (towards the crankcase). Use of a hydraulic press is recommended for this procedure. 3.62 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 125 This helps to prevent coolant leakage. the crankshaft seal (back to front). Leave the seal protector installed. Check the crankshaft seal lips to verify they have not been rolled or damaged. 3.63 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 126 NOTE: Before assembly, clean the bolts and bolt holes with Primer N (commercially available) to remove any debris. This will ensure proper sealing when installing bolts. 3.64 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 127: Flywheel / Stator Installation
Install the starter bendix. NOTE: There are thrust washers on both sides of starter drive. Stator Assembly Bolts: 84 ± 8 in-lbs (9.5 ± 0.9 Nm) 3.65 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 129 Install head bolts (C) and torque to specification in sequence. 5. Lubricate rockers (E) with engine oil. 6. Verify pushrods are engaged in lifters. 3.67 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 130 84 ± 8 in-lbs (9.5 ± 0.9 Nm) Breather Bolts: 20 ± 5 in-lbs (2.5± 0.55 Nm) NOTE: When applying RTV, do not get any RTV inside the reed assembly. 3.68 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 131: Oil Pump Priming
1. After the engine is completely assembled and ready for installation, the engine must be properly primed with engine oil. Fill the oil filter 3/4 full with Polaris PS-4 or PS-4 Extreme Duty Synthetic Engine Oil. Let the oil soak into the filter for 8-10 minutes. Install the filter onto the engine.
Page 132: Engine Installation
2. Remove primer plug from the engine. Install Oil System Priming Adapter (PU-45778) into the oil plug hole. Push 3-5 oz. (approx.) of Polaris PS-4 or PS-4 Engine Assembly and Installation Extreme Duty engine oil into the adapter or until Use the following procedure to reinstall the engine resistance is felt.
Page 133: Engine Break-In Period
CAUTION Use only Polaris PS-4 or Extreme Duty Synthetic 4- Cycle engine oil or an equivalent. Never substitute or mix oil brands. NOTE: If isolator mounts were removed or...
Page 134: Troubleshooting
• Crankcase breather restricted • Restricted breather Engine Idles But Will Not Accelerate • Air filter dirty or contaminated • Spark plug fouled/weak spark • Broken throttle cable 3.72 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 135: Cooling System
• Fuel pump output weak • Electrical malfunction • Water pump failure; loose impeller • Thermistor failure • Cooling fan inoperative or turning too slowly (perform current draw test) 3.73 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 139: General Information
USB-Serial Adaptor cable and SmartLink Module Kit) Digital Wrench® SmartLink Module Kit PU-47471 (PU-47470, PU-47469, PU-47468) Digital Wrench® PU-47470 PC Interface Cable Digital Wrench® PU-47469 Vehicle Interface Cable 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 140 PU-47469 and PC Interface Cable PU-47470. This pressure once you have completed the fuel pressure module kit is used on all 8 pin connector-based Polaris test. EFI systems. This kit is available to Polaris dealers through our tool supplier Bosch Automotive Service Solutions at http://polaris.service-solutions.com or 1-800-...
Page 141: Service Notes
• Always unplug ECU from the wire harness before performing any welding on the unit. IMPORTANT: For the most recent information on Digital Wrench® software and update downloads please visit the website: www.polaris.diagsys.com 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 143: Efi System Component Locations
(RZR 4). 3. Crankshaft Position Sensor (CPS) - Located in the magneto cover between the engine and transmission, just in front of the rear gear case. 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 144 - Located between the rubber air box boot and rubber cylinder head adaptor. 7. Throttle Position Sensor (TPS) - Located on the right-hand side of the throttle body below the IAC motor. 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 145 - Located in the engine block above the oil filter. The 11. Ignition Coil sensor can be accessed through the right rear wheel - Located behind the rear service panel just above well. the outer PVT cover. 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 147: Fuel Line Removal / Installation
2. Pull on the fuel line for removal. 3. To install the line(s), verify the connections are clean and free of debris. 4.11 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 148: Electronic Fuel Injection
"on." This range can vary depending on fuel requirements. The controlled injection of the fuel occurs every other crankshaft 4.12 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 149: Electronic Control Unit (Ecu)
TPS to the throttle body is altered, the TPS must be adjusted. For the purpose of troubleshooting, a known-good ECU from another Polaris RZR EFI of the same model may be used without system or engine component damage. ECU Replacement 1.
Page 150: Pressure Sensor (T-Map)
IMPORTANT: This sensor should only be tested using the Digital Wrench® Diagnostic Software (dealer only). T-MAP Retaining Bolt: 25 ± 2.5 in-lbs (3 ± 0.3 Nm) 4.14 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 151: Crankshaft Position Sensor (Cps)
If the sensor fails or becomes disconnected for any reason, the engine will stop running. CPS Resistance Specification: Yellow to White: 560Ω ± 10% 4.15 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 152: Cps Replacement
4. Remove the (3) bolts retaining the front portion of the mounting bracket to the transmission. Retain the bolts, washers, and spacers for installation. 4.16 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 153 IMPORTANT: When reinstalling the transmission to rear gearcase mount bracket, it is extremely important to torque all (7) fasteners to specification. Refer to the following procedure. 4.17 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 155 Upper Rear Gearcase Bolt limited access to this bolt. Check with the manufacturer of your torque wrench to see if it can be used to tighten left-hand threaded bolts. 4.19 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 156: Fuel Injectors
Cleaning of clogged injectors is not recommended; they should be replaced. Additives and higher grades of fuel can be used as a preventative measure if clogging has been a problem. 4.20 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 157: Fuel Injector Test
(s) by measuring between the two harness pin terminals: Fuel Injector Resistance Specification: 11.4 Ω - 12.6 Ω 4.21 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 158 Separate the fuel injector from the vehicle harness as shown in the illustration below. 6. Thoroughly clean the area around the fuel injectors including the throttle body manifold. 4.22 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 159: Fuel Pump
Disconnect the fuel pump / sending unit connection and measure the resistance. If out of specification, replace the fuel pump assembly. Fuel Sender Resistance Specifications: Full: 6 ± 1 Ω Empty: 90 ± 4.5 Ω 4.23 9924882 - 2013–2014 RZR 800 © Copyright 2013 Polaris Sales Inc.
Page 160: Fuel Pump Test
“3” and “4”' at the white fuel pump connector to check for continuity within the fuel pump. NOTE: If there was no continuity between the pump terminals, replace the fuel pump assembly. 4.24 9924882 - 2013–2014 RZR 800 © Copyright 2013 Polaris Sales Inc.
Page 161: Fuel Pump Replacement
Failure to clean area around fuel pump may lead to debris entering the fuel tank during service. Excessive debris in fuel tank may cause premature wear of fuel pump and/or clogging of internal fuel filters. 4.25 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 162 10. Remove new fuel pump assembly, gasket and PFA nut from packaging. Use care not to bend float arm during un-packaging. Do not lift or carry fuel pump assembly by the float arm. 4.26 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 164: Fuel Tank Removal (Rzr / Rzr
22. Test the fuel pump by turning on the key and listening for the pump to activate. Cycle the key several times to prime the system. 4.28 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 165 7. Remove shift knob and center console from vehicle. 8. Remove the push rivets and screws retaining the RH rocker panel and remove panel from the vehicle (see Chapter 5). 4.29 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 166 12. Remove the (2) tank bracket fasteners that retain the fuel tank in the chassis. Swing the tank brackets clear of the fuel tank for removal. 4.30 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 167: Fuel Tank Removal (Rzr 4)
1. Remove the rear passenger seats along with the rear service panel. 2. Remove the driver’s seat and disconnect the negative battery cable from the battery. 4.31 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 168 (see Chapter 5). the rear seat support. Remove the 7/16” fastener from the left side of the rear seat support. Remove the rear seat support from the vehicle. 4.32 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 169 10. Remove fuel tank vent hose clamp with a suitable pliers and remove vent line from the tank vent fitting. 4.33 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 170: Fuel Tank Installation
Set your meter to read Ohms. Check the resistance values at each of the following pin locations of the IAC. If any of the readings are out of specification, replace the IAC. 4.34 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 171: Iac Replacement
The stop screw controls the air flow calibration of the throttle body. If the stop screw is repositioned or adjusted, the throttle body assembly must be replaced. 4.35 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 172: Tps Resistance Tests
1 - 2 (reference) Reference Voltage Test: ——— 1 - 3 4 kΩ - 6 kΩ • Insert black voltmeter probe into the test port as shown. 4.36 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 173: Tps Replacement
1. Remove the seats, rear service panel and the rear cargo box (see Chapter 5). 2. Loosen the hose clamps retaining the throttle body. 4.37 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 174 Securely tighten the hose 10. Reinstall cargo box, rear service panel and seats clamps. (see Chapter 5). 8. Reinstall cargo box, rear service panel and seats (see Chapter 5). 4.38 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 175: Camshaft Phase Sensor
Cam Phase Sensor Retaining Bolt: 50 ± 5 in-lbs (5.65 ± 0.55 Nm) NOTE: Use Digital Wrench® Diagnostic Software (dealer only) if you suspect this sensor is faulty. 4.39 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 176: Engine Coolant Temperature Sensor (Ect)
ELECTRONIC FUEL INJECTION ENGINE COOLANT TEMPERATURE Refer to Chapter 3 and 10 for additional ECT sensor information. Polaris dealers can test the sensor by using SENSOR (ECT) the Digital Wrench® Diagnostic Software (dealer only). Operation Overview ECT Sensor Resistance Readings Mounted on the cylinder head, the engine temperature Temperature °F (°C)
Page 177: Ignition Coil
3. Remove the fastener retaining the ignition coil and remove it from the vehicle. If replacing the high tension lead(s), remove the other end of the lead(s) from the spark plug. 4.41 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 178: Efi Diagnostics
MODE button to toggle until “CK ENG” displays on the information display area. Secondary Test 2. Press and hold the MODE button to enter the diagnostics code menu. 4.42 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 179 Engine Temperature Sensor (ECT) Temperature Too High P0217 Engine Overheat Shutdown P1217 P0563 Voltage Too High System Power C1063 (Battery Potential / Power Input) Voltage Too Low P0562 4.43 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 180 All Wheel Drive Control Circuit 520207 Driver Circuit Short to B+ P1835 (AWD) Driver Circuit Grounded P1834 Steering Over Current Shut Down Current Above Normal or Grounded 520221 C1050 4.44 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 181 Driver Circuit Open / Grounded P1505 Idle Air Control Valve (IAC) Driver Circuit Short to B+ 520271 P1509 M17; IAC Stepper Pin 1 Driver Circuit Grounded P1508 4.45 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 182: Efi Troubleshooting
• Spark Plug fouled • TPS setting incorrect • Throttle stop screw set incorrectly (out of sync with • Injector failure ECU) • Faulty electrical connection 4.46 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 183: Digital Wrench® Operation
IMPORTANT: Refer to Section 2, 3 and 4 in the Instruction Manual provided in the Digital Wrench® Diagnostic Kit to install the Polaris Digital Wrench® diagnostic software on your computer. The Digital Wrench® diagnostic software allows the technician to perform the following tests and observations: •...
Page 184: Digital Wrench® Communication Errors
ID shown on the lower right side of the Digital Wrench® start-up screen. Located under the dash connected to a sealed plug. 2. Proceed to http://polaris. diagsys. com to see if a newer update is available. Follow these steps to connect the diagnostic interface cable to the vehicle to allow Digital Wrench®...
Page 185: Digital Wrench® Updates
IMPORTANT: Always operate with the latest update. Digital Wrench® Updates Updates are released for Digital Wrench® via the Internet at: http://polaris. diagsys. com. The Digital Wrench® website can also be accessed through the dealer website at: www.polarisdealers.com. NOTE: Only authorized...
Page 187: Engine Controller Reprogramming (Reflash)
Authorization site. The Request Code is automatically generated by Digital Wrench® during the reprogramming • Proceed to http://polaris. diagsys. com for specific process. The Reflash Authorization site is located under information and FAQs on how to troubleshoot the “Service and Warranty”...
Page 188 5. Select the “Special Tests” icon. NOTE: Request Codes and Authorization Keys must be entered EXACTLY as they appear on the screen. 4.52 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 189 PC during the process. once to proceed. 15. Once reprogramming procedure complete, click the ‘Finish’ button on the screen. Verify the reflash was a success by starting the vehicle. 4.53 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 194: Torque Specifications
Steering Gear Box 17 ft-lbs (23 Nm) RZR 4 Main Frame Coupler 38 ft-lbs (52 Nm) M10 Bolts RZR 4 Outer Frame Coupler 17 ft-lbs (23 Nm) M8 Bolts 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 195: Cab Frame (Rzr / Rzr S)
6. To remove the cab frame, reverse the assembly Tighten screws to specification. procedure (steps 1-5). M10-1.5 Bolts: 30 ft-lbs (41 Nm) Tap Screws: 15 ft-lbs (20 Nm) 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 197: Cab Frame (Rzr 4)
M8-1.25 Tap Screws: 15 ft-lbs (20 Nm) M8-1.25 Bolts: 16-18 ft-lbs (22-24 Nm) 1/4-20 Tap Screws: 6-8 ft-lbs (8-11 Nm) 6. To remove the cab frame, reverse the assembly procedure (steps 1-5). 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 211: Body Component Removal
3. Disconnect the front head lamp connectors and remove the front bumper from the vehicle. Rear Console Cover (RZR 4) 1. Remove the rear passenger seats. 5.21 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 212: Rear Bumper
1. Remove the hood as previously described. 6. Disconnect all electrical dash components noting 2. Remove the front bumper (see “BODY COMPONENT their location and wire routing. REMOVAL - Front Bumper”). 5.22 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 213: Rear Fender, Flair And Tie Down Removal
3. Remove the (3) push rivets (RZR) or (8) T27 Torx cargo box assembly from the vehicle. screws (RZR-S / RZR-4) and remove the fender flair. 5.23 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 214: Rocker Panels, Console And Floor
10. Disconnect the 12V outlet and ECU connector. 11. Remove the rear floor from the vehicle. 4. Remove the Torx screws retaining the upper floor to the lower floor. 5.24 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 216: Steering Wheel Removal (Non-Eps Models)
5. Drive the bearings out of the pivot tube using a drift punch. 6. Inspect the pivot tube bearing surfaces for signs of excessive wear or damage. 5.26 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 217 Install the lower portion of the steering shaft onto the steering gear box assembly. Refer to “Steering Shaft Removal (Non-EPS Models)”. Torque the lower pinch bolt to specification. Lower Pinch Bolt: 30 ft-lbs (41 Nm) 5.27 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 218: Electronic Power Steering Assembly
BODY / STEERING / SUSPENSION ELECTRONIC POWER STEERING ASSEMBLY Exploded View (EPS Models) 5.28 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 219: Upper Steering Shaft Removal (Eps Models)
2. Remove the pinch bolt retaining the upper steering shaft to the power steering unit. 5. Remove the steering shaft, pivot tube and steering wheel from the vehicle as an assembly. 5.29 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 220: Steering Wheel Removal (Eps Models)
EPS unit and cause a Power Steering Fault. 2. Disconnect the (2) electrical harnesses from the power steering unit. 4. Place the assembly in a vise. 5.30 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 221: Lower Steering Shaft Removal (Eps Models)
5. Carefully remove the power steering unit and mount bracket from the vehicle as an assembly. 3. Remove the power steering unit (see “Power Steering Unit Removal” procedure). 5.31 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 222: Lower Steering Shaft Installation (Eps Models)
17 ft-lbs (23 Nm) 1. If the power steering unit was removed from the mount bracket, reinstall it prior to vehicle installation. Torque the mounting bolts to specification. 5.32 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 223: Upper Steering Shaft Installation (Eps Models)
7 ft-lbs (10 Nm) Models) IMPORTANT: If steering wheel was removed, follow this procedure to ensure the upper steering shaft is properly positioned on the power steering stub shaft. 5.33 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 224: Front A-Arms
15. Using a soft face hammer, tap on bearing carrier to loosen the lower A-arm ball joint end while pushing downward on the lower A-arm. Completely remove the ball joint end from the bearing carrier. 5.34 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 225 Front Ball Joint Pinch Bolts: 23 ft-lbs (31 Nm) Shock Mounting Bolts: RZR: 37 ft-lbs (50 Nm) RZR S / RZR 4: 37 ft-lbs (50 Nm) 5.35 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 227: Ball Joint Service
- If necessary, remove the lower front shock fastener from the A-arm to gain enough clearance to install ball joint tool (PU-50506) on the lower ball joint. 5.37 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 228: Ball Joint Installation
CAUTION New bolts have a pre-applied locking agent which is destroyed upon removal. Always use new brake caliper mounting bolts upon assembly. 5.38 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 229: Front Stabilizer Bar (Rzr / Rzr S Int
3. Remove the (4) T30 Torx fasteners retaining the front bumper support to the frame. NOTE: Properly support the bumper support and wires that are attached. 5.39 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 230 (4) bolts retaining the upper bushings and replace if needed. radiator mount bracket. 11. Reverse the procedure for installation. Torque the linkage fasteners to specification (see “Exploded View”). 5.40 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 232: Rear A-Arms
3. Examine bushings and pivot tubes (see “Exploded View” on page 5.43). Replace if worn. Discard 3. Remove the fastener (D) attaching the lower A-arm to hardware. the bearing carrier. 5.42 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 233: Installation
6. Attach upper A-arm to bearing carrier. Torque new fastener to specification. 2. Remove the fastener (G) retaining the lower portion of the shock to the lower A-arm. 5.43 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 234: Exploded View (Rzr)
RZR S / RZR 4: 37 ft-lbs (50 Nm) Upper Rear Bearing Carrier Bolts: RZR: 33 ft-lbs (45 Nm) RZR S / RZR 4: 40 ft-lbs (54 Nm) 5.44 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 235: Exploded View (Rzr S / Rzr 4)
2. Remove the retaining nut from the upper portion of the stabilizer bar linkage bushing on each side of the vehicle. 3. Remove the (4) fasteners retaining the stabilizer bar bracket to the frame. 5.45 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 236: Removal / Installation
3. Remove the (4) fasteners retaining the stabilizer bar Stabilizer Mounting Bolts: to the bracket. 18 ft-lbs (24 Nm) 5.46 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 237 5. Inspect the stabilizer bar for straightness. Inspect the bushings and replace if needed. Stabilizer Mounting Bolts: 18 ft-lbs (24 Nm) 5.47 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 238: Decal Replacement
2. Apply the decal on one edge first. Slowly lay down remainder of the decal while rubbing lightly over the decal surface to eliminate any air bubbles during the application. 5.48 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 239: Shock Removal / Installation
(refer to exploded views). Shock Replacement 1. Using a spring compressor, compress the shock spring far enough to remove the spring retainer. 5.49 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 240: Fox™ Podium Piggyback Shock Service
Reservoir End Cap Asm. Spacer Retaining Ring, Wire Piston Asm, Floating (IFP) Damping Adjust Asm., Piston Valving Asm. Damping Adjust Asm., Concentric Bearing Asm. Screw Asm. Bumper 5.50 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 241: Fox™ 1.5 Podium 'Piggyback - General Service Information
0.900 x 0.008 1.100 x 0.010 0.620 x .093 Back-Up 0.620 x .093 Back-Up 0.800 x 0.008 1.000 x 0.010 1.230 x .082 Top-Out 1.230 x .082 Top-Out 5.51 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 242: Fox™ 2.0 Podium 'Piggyback' Shock (Rzr 4 L.e. Models)
Bearing Cap Asm. Bearing, External Bearing Asm. Bumper Valving Asm. Bearing, Spherical Retaining Ring Lock Nut Retaining Ring Reservoir Piston Asm, Floating (IFP) Shock Oil (2870995) 5.52 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 243: Fox™ 2.0 Podium 'Piggyback - General Service Information
1.570 x 0.128 Top-Out 0.950 x 0.015 1.100 x 0.015 1.230 x .082 Top-Out 0.950 x 0.015 0.750 x .100 Back-Up 1.230 x .082 Top-Out 0.750 x .100 Back-Up 5.53 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 244: Fox™ Podium 'Piggyback
Bosch Automotive Service Solutions: 1-800-328- 6657 or http://polaris.service-solutions.com/ 6. Slowly loosen nylon ball retainer from reservoir cap and allow nitrogen to completely escape. 7. Remove the nylon ball retainer. 5.54 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 245 If unsure of order, refer to “Shock Valving” under the “Shock Service Information” provided earlier in this section. 5.55 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 246: Fox™ Podium 'Piggyback
1. Use the appropriate shock body holding tool (PS- 45281-A) to properly secure the shock body Assembly assembly into a vice for service. 1. Apply Loctite® 620™ on primed shock body and reservoir threads. 5.56 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 247: Fox™ Podium 'Piggyback
2. Lubricate NEW O-rings and bearing with shock oil before and after installation onto the piston and cap. 3. Install a new pellet into the reservoir cap. 5.57 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 248: Fox™ Podium 'Piggyback' Assembly
1. Secure the shock rod in a vice using the shock rod holding tool (2872429) so the threaded end is facing 4. Using an arbor press, install a new bearing into the upward. bearing assembly. 5.58 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 249 7. Remove the Shock Seal Protector Sleeve. 14. Fill the reservoir 3/4 full with the proper shock oil. 15. Verify the center screw and O-ring are not installed into the IFP. 5.59 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 250 1/4" (6.35 mm) to work the air bubbles out of the piston and piston ports. 25. Slide the bearing assembly partially into the shock body. 5.60 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 251 50. Adjust external adjusters to the factory settings 43. Install and depress the reservoir cap past the 51. Install shock onto the vehicle and torque fasteners to retaining ring groove. specification. 5.61 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 252: Fox™ Podium Top Fill Shock Service
Spherical Bearing Shaft .620” O.D. Eyelet Spiral Retaining Ring Bearing Cap Asm. Shock Oil (2870995) Bearing Asm. Valving Asm. Lock Nut Piston Asm. Floating Preload Ring 5.62 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 253: Fox™ 2.0 Podium Top Fill - General Service Information
0.950 x 0.010 0.950 x 0.012 1.230 x 0.082 Top-Out 1.570 x 0.128 Top-Out 1.230 x 0.082 Top-Out 0.750 x 0.100 Back-Up 0.750 x 0.100 Back-Up 5.63 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 254: Fox™ 2.0 Podium Top Fill Disassembly
5. Locate the retaining rings holding the spheical bearing in the ear of the body cap assembly. 5.64 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 255 DO NOT RE-USE OIL SHOCK OIL. 14. Mount the shock body using body clamp tools in the bench vise with the bearing cap assembly upwards. 5.65 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 256 22. Remove the piston/wear band (if still attached). Discard wear band. Note the orientation of the rebound and compression sides of the piston. 5.66 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 257: Fox™ 2.0 Podium Top Fill Reassembly
50 ft-lbs (68 Nm) 4. Mount the shock shaft eyelet in a bench vise with the threaded end upwards. 5. Install the bumper; narrow end upwards. 5.67 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 258 NOTE: The last compression valve shim is the air bleed shim. The shim must be orientated correctly with the piston valve to allow air to bleed through the assembly during installation. 5.68 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 259 Shock Shaft Lock Nut: 22 ft-lbs (30 Nm) 13. Replace the IFP o-ring. Apply a thin layer of low temperature grease to the IFP. 5.69 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 260 8” from the top of the shock body. Pass a propane torch quickly over the shock body to eliminate any air bubbles. Polaris Gas Shock Oil - 5 wt. PN 2870995 - qt. PN 2872279 - 2.5 gal. 22. Slide the piston valve and bearing as an assembly down against the shock shaft valve stack (Fig.
Page 261 IFP position must be reset. SLOWLY initially to ensure the shock and the vehicle’s suspension is performing correctly. 26. Secure the shock assembly in a bench vise. 5.71 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 262: Walker Evans™ Shock Exploded Views
Reservoir End Cap Shock Body Reservoir Body Spring Adjustment Nut Washer (1.50" x 0.125" x 0.348") Shaft, Chrome Crimp Nut (7/16") 2-Piece Piston Asm. Snap Ring 5.72 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 263: Walker Evans™ Shock Service
Extended Length 16.313” (414.4 mm) 3.00 ± 0.13” (76.2 ± 3.3 IFP Location Nitrogen Pressure 100 psi (689 kPa) ± 10% 2874124 (qt.) Gas Shock Oil 5.73 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 264: Rear Shock Service Information
Extended Length 18.035” (458 mm) 3.00 ± 0.13” (76.2 ± 3.3 mm) IFP Location Nitrogen Pressure 100 psi (689 kPa) ± 10% 2874124 (qt.) Gas Shock Oil 5.74 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 265: Walker Evans™ Shock Rebuild Information
Piston Orientation The face of the piston with the greater number of relief ports will always face the rebound valve stack. 5.75 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 266: Walker Evans™ Shock Disassembly
Shock Body Holding Tool: PU-50979 4. Remove the valve cap from the valve fitting on the top of the reservoir. 5.76 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 267 13. Use the appropriate shock rod holding tool and a vise to mount the shock rod vertically with the threaded end upward. Shock Rod Holding Tool: 2872429 5.77 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 268: Walker Evans™ Shock Assembly
6. Place the compression valve stack on the rod in the properly secure the shock assembly into a vice for reverse order of disassembly. service. Shock Body Holding Tool: PU-50979 5.78 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 269 11. Use the appropriate shock body holding tool to properly secure the shock assembly into a vice for service. Shock Body Holding Tool: PU-50979 5.79 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 270 • Be sure to bottom out piston in the reservoir body. • Allow time for the bubbles to dissipate. • Repeat the process until all air has been removed. 5.80 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 271 This opens screw. the valves on the damping piston. You will see the released air bubbles come to the surface of the oil. 5.81 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 272 35. Reinstall the valve cap. 36. Clean all oil residue from the shock and reservoir with solvent, and dry with low pressure compressed air in a well ventilated area. 5.82 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 273 42. Reinstall spherical bearing O-rings and polyurethane bushings. NOTE: After installation, be sure to RIDE SLOWLY initially to ensure the shock and the vehicle’s suspension is performing correctly. 5.83 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 277: Special Tools And Supplies
Piston Pin Puller 2870910 Roller Pin Tool Universal Clutch Compressor PU-50518 Bosch Automotive Service Solutions: 1-800-328- 6657 or http://polaris.service-solutions.com/ Special Supplies Part Number Loctite™ 609 8560054 RTV Silicone Sealer 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 278: High Altitude Clutch Charts
(323445- (5000 - (56323- (70437- clutch upshift and backshift. During the development of 12000) the Polaris vehicle, the PVT system is matched first to the engine power curve; then to average riding conditions vehicle’s intended usage. Therefore, modifications or variations of components at random are never recommended.
Page 279: Driven Clutch Operation
10 hours as recommended (see Chapter 3 “Engine Break-In Period” for break-in example). Pull only light loads. Avoid aggressive acceleration and high speed operation during the break-in period. 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 280: Overheating / Diagnosis
10 seconds. Clutch seals should be inspected for damage if repeated leaking occurs. Clutch component inspection should be performed by a Polaris MSD certified technician. Clutch malfunction. Fouled spark plugs, foreign material in fuel tank, restricted fuel lines, or faulty fuel pump may Poor engine performance.
Page 282: Pvt Disassembly
5. Loosen the hose clamp on the clutch outlet duct. 6. Remove outer clutch cover screws and clutch cover. 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 283: Pvt Assembly
10. Install the Drive Clutch Holder (PN 9314177) (A). PVT Assembly 1. Inspect inner clutch cover. Replace if cracked or damaged. 2. Inspect the seal on the transmission input shaft. Replace if damaged. 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 284 10. Install the driven clutch, washer, lock washer, and retaining bolt. Torque to specification (see next page). 11. Clean end of taper on crankshaft and the taper bore inside drive clutch. 6.10 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 285: Clutch Offset Procedure
17 ft-lbs (23.5 Nm). Be sure to rotate the driven clutch counterclockwise several times to ensure the belt is tight and riding at the proper height in the clutch. 6.11 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 286 Allow the engine to idle for five minutes to break in the drive clutch hub bearing. CAUTION Do not leave the vehicle unattended. 6.12 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 287: Drive Belt (Non-Ebs)
5. Install outer PVT cover as described in “PVT SYSTEM SERVICE - PVT Assembly”. See “PVT Break-In (Drive Belt / Clutches)”, page 6.5 6.13 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 288: Drive Belt (Ebs)
4. Rotate the tool towards the clutch to open the sheaves. 5. Walk the belt out of the driven clutch and drive clutch. Remove the belt from the vehicle. 6.14 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 290: Clutch Disassembly
Cover Bushing Inspection: Replace the cover bushing if more brass than Teflon™ is visible on the bushing. Refer to bushing replacement in this chapter. 6.16 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 291: Drive Clutch Spring Inspection
2.72 in. (6.90 cm) NOTE: A damaged shift weight is usually caused by a damaged or stuck roller in the spider assembly. See “Roller, Pin and Thrust Washer Inspection”. 6.17 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 292: Button To Tower Clearance Inspection
NOTE: To maintain proper clutch balance and worn, damaged or cracked. belt-to-sheave clearance, be sure to reinstall the original quantity and thickness of washers/ spacers beneath the spider during assembly. 6.18 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 293: Roller, Pin, And Thrust Washer Inspection
Roller Pin Tool (PN 2870910) to replace rollers and pins. Take care not to damage roller bushing or bearing surface of the new pin during installation. 6.19 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 294 5. Visually inspect PTFE thrust washers for damage. Measure the thickness and compare to specification. Replace if worn or damaged. PTFE Washer Thickness Standard: .030” (.76 mm) Service Limit: .025” (.64 mm) 6.20 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 295: Moveable Sheave Bushing Inspection
Additional Special Tools Qty. Tool Description Part # Clutch Bushing Replacement Tool Kit 2871226 2870386 Piston Pin Puller *Clutch Bushing Replacement Tool Kit (PN 2871226) 6.21 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 296 Turn puller barrel to increase tension on sheave if needed. Using a hand held propane torch, apply heat around outside of bushing until tiny smoke tailings appear. 6.22 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 297: Clutch Assembly
6. Remove nut from puller rod. Take installation tool and clutch cover off rod. Clutch Assembly NOTE: The Teflon™ bushings are self-lubricating. 6.23 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 298 “X” or the marks that were made earlier on the cover. 9. Torque cover bolts evenly to specification. Cover Screw: 90 in-lbs (10.4 Nm) 6.24 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 299: Driven Clutch Service (Non-Ebs)
Use caution when removing, the snap ring pressure is loaded by the compression spring. 1. Remove driven clutch from transmission input shaft. 6.25 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 300 (B), compression spring (C), spacer (D), and inner spring retainer (E). 7. Inspect the inner spring retainer for wear and replace as needed. 6.26 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 301: Clutch Assembly
11. Clean and inspect splines on helix and transmission input shaft. 12. Lube splines with a light film of grease. Do not lubricate the bearings! 3. Install the spring into the inner retainer. 6.27 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 302: Driven Clutch Service (Ebs)
X’s on the components for reference. This will aid in reassembly and helps to maintain clutch balance after reassembly. 6.28 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 303 4. Place the driven clutch into the Universal Clutch Compressor PU-50518. 6. Remove the spider assembly and spring (B). NOTE: Spring is compression only and has no torsional wind. 6.29 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 305: Bushing Service
Instructions Additional Special Tools Qty. Tool Description Part # Clutch Bushing Replacement Tool Kit 2871226 2870386 Piston Pin Puller *Clutch Bushing Replacement Tool Kit (PN 2871226) 6.31 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 306: Clutch Assembly
NOTE: Press only on the outer race of the bearing during installation to prevent damaging the bearing. 3. Apply Loctite™ 609 evenly to bushing bore inside moveable sheave. 6.32 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 307 8. Install the clutch rollers (D) onto each side of the outside spider. Install the washers (E) and E-clips (F) to secure the rollers. The rollers should spin freely. 6.33 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 308 Once the spider passes the retaining ring notch on the shaft, install the retaining ring. 11. Place the driven clutch into the Universal Clutch Compressor PU-50518. 6.34 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 309 (helix) side down. Press down on the moveable sheave belt face with both hands and the helix will release. Helix Retaining Screws: 42-52 in-lbs (4.75 - 5.88 Nm) 6.35 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 311: Troubleshooting
Belt burnt, thin -Dragging brake -Inspect brake system spots -Slow, easy clutch engagement -Fast, effective use of throttle for efficient engagement 6.37 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 312 -Replace belt; Refer to belt burnt troubleshooting Engagement -Thin spots on belt, worn belt and instruct operator erratic or stabby -Drive clutch bushings stick -Inspect and repair clutches 6.38 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 315: Special Tools
Steel Wheels 6657 or http://polaris.service-solutions.com/ 27 ft-lbs (37 Nm) (Black / Camo) Front Hub 80 ft-lbs (108 Nm) Castle Nut Rear Hub 80 ft-lbs (108 Nm) Castle Nut 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 316: Front Bearing Carrier
3. Remove the (4) wheel nuts and remove front wheel. 4. Remove the cotter pin and loosen the front wheel hub castle nut. Remove the nut, and (2) cone washers from the front wheel hub assembly. 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 317: Bearing Replacement
NOTE: Use care to not allow any of the Loctite ® compound to get in the bearing. 8. Wipe the housing clean of any excess compound and install the snap ring. 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 318: Bearing Carrier Installation
2. Install the upper and lower ball joint ends into the front bearing carrier. Ball Joint Pinch Bolts: 23 ft-lbs (31 Nm) 4. Apply grease to drive shaft axle splines. 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 319 8. Torque the tie rod end fastener to specification and install a new cotter pin. Tie Rod End Fastener: 42.5 ft-lbs (58 Nm) 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 320: Front Drive Shaft
CAUTION: Do not hang the caliper by the brake line. Use wire to hang caliper to prevent damage to the brake line. 5. Remove the front wheel hub assembly. 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 321: Drive Shaft / Cv Joint Handling Tips
3. Use a soft-faced hammer or brass drift to separate the outer CV joint from the drive shaft. NOTE: If using a brass drift, be sure to tap on the inner race of the joint only. 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 322: Inner Plunging Joint / Boot Replacement
2. Remove and discard the boot clamps. Boot Replacement Grease Requirement: CV Boot Clamp Pliers Outer CV Joint Capacity: 80g Earless Type: 8700226 Grease Service Kit: PN 1350047 (50g) 7.10 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 323 Slide a straight O-ring pick or a small slotted screw driver between the large end of the boot and joint housing and lift up to equalize air pressure in the boot. 7.11 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 324: Drive Shaft Installation
Use a rubber mallet to tap on the outboard end of the drive shaft if necessary 3. Install drive shaft into the front bearing carrier. 7.12 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 325 6. Apply grease to drive shaft axle splines. 9. Install brake caliper mounting bolts and torque to specification. Front Caliper Mounting Bolts: 31-34 ft-lbs (42-46 Nm) 7.13 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 326: Propshaft Service
3. Remove the Torx screws retaining the center console to access the propshaft. 4. Slide prop shaft back far enough to remove it from the front gearcase input shaft. 7.14 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 327: Removal / Installation (Rzr 4)
4. Remove the retaining screw and the gear selector handle. 5. Remove the fasteners retaining the center console to access the propshaft support bearing. 7.15 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 328 (upper & lower half) from the shaft. Support Bearing Fasteners: 16-18 ft-lbs (22-24 Nm) IMPORTANT: When installing the front portion of the propshaft, use a NEW roll pin. 7.16 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 329: Support Bearing Replacement (Rzr 4)
NEW roll pin. 5. Install a new retaining ring and slide the bearing tight against the retaining ring. 11. Reinstall the center console, selector handle and front seats. 7.17 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 330: Propshaft U-Joint Service
1. Install new bearing caps in yoke by hand. Carefully install U-joint cross with grease fitting properly positioned inward toward center of shaft. Take care not to dislodge needle bearings upon installation of cross joint. 7.18 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 331 4. Install snap ring to contain bearing cap just installed. Repeat procedure for other side. 5. Install outer yoke, aligning marks made disassembly and repeat Steps 1-3 to install bearing caps on outer yoke. 7.19 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 332: Front Gearcase / Centralized Hilliard
Armature Plate Cover Plate Assembly AWD Coil Gearcase Housing Fill Plug Clutch Housing (Ring Gear) Drain Plug, Magnetic Roll Cage Retaining Ring, External Hub / Race Assembly 7.20 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 333: All Wheel Drive Operation
The front drive will remain engaged until the torque requirement goes away (i. e. rear wheels regain traction). 7.21 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 334: Awd Diagnosis
6. Inspect the rollers for nicks and scratches. The rollers must slide up, down, in and out freely within the roll cage sliding surfaces and H-springs. 7.22 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 335: Gearcase Removal
4. Disconnect the wire harness above the front gearcase and remove the harness from the retaining dart. 5. Remove the vent line from the front gearcase. 7.23 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 336: Gearcase Disassembly / Inspection
Remove any metal particles from the drain plug magnet. 2. Remove the (7) cover screws and remove the cover plate assembly. NOTE: Nylon spacer is non-serviceable and should not be removed. 7.24 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 337 5. Remove the torsion spring retainer and torsion 7. Remove the RH output hub assembly from the spring from the top of the ring gear. gearcase housing. 7.25 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 338 13. Inspect clutch housing ring gear (C) for a consistent wear pattern. Inspect the ring gear for chipped, broken, or missing teeth. 7.26 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 339: Gearcase Assembly
4. Install the RH output hub into the gearcase housing. 16. Clean and inspect all remaining front gearcase components. Check each for excessive wear or damage. 7.27 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 341 NOTE: Be sure the square O-ring is placed flat 7-11 ft-lbs (10-15 Nm) on the cover surface. If the O-ring is twisted fluid leakage may occur. 7.29 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 342: Gearcase Installation
30 ft-lbs (41 Nm). (PN 2877922) 4. Install the vent line. Front Housing Capacity 6.75 fl. oz. (200 ml) Front Gearcase Mounting Bolts: 30 ft-lbs (41 Nm) 7.30 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 343: Rear Bearing Carrier
Remove the nut, and (2) cone washers from the rear wheel hub assembly. 7. Remove the bolts that attach the rear bearing carrier to the upper and lower A-arms. 7.31 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 344: Bearing Replacement
6. Support the bottom of the bearing carrier housing. Bearing Replacement Bearing Removal CAUTION 1. Remove outer snap ring. Use an arbor and press only on the outer race, otherwise bearing damage may occur. 7.32 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 345: Bearing Carrier Bushing Replacement
8. Wipe the housing clean of any excess compound and install the snap ring. 1. Install drive shaft axle through the backside of the bearing carrier. Be sure bushings and pivot tubes are installed. 7.33 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 346 3. Apply grease to drive shaft axle splines. 4. Install rear wheel hub assembly, cone washers, and hand tighten the castle nut. Install washers with domed side out. 7.34 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 347: Rear Drive Shaft
8. Rotate wheel and check for smooth operation. Bend Use wire to hang caliper to prevent damage to the both ends of cotter pin around end of spindle in brake line. different directions. 7.35 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 348: Outer Cv Joint / Boot Replacement
7. Slide the rear drive shaft out of the bearing carrier by pulling the bearing carrier assembly outward and tipping it down to remove the shaft. 7.36 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 349 7. Thoroughly clean the joint with an appropriate solvent and dry the joint to prevent any residual solvent from being left in the joint upon reassembly. 7.37 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 350 RZR - 80g RZR S / RZR 4 - 90g Grease Only Service Kit: PN 1350047 (50g) Axle Boot Clamp Tool: PU-48951 CV Boot Clamp Pliers: 8700226 7.38 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 351: Inner Plunging Joint / Boot Replacement
3. Clean the grease from the face of the joint and place the drive shaft in a soft-jawed vise. Axle Boot Clamp Tool: PU-48951 CV Boot Clamp Pliers: 8700226 7.39 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 353 CV Boot Clamp Pliers: 8700226 17. Remove excess grease from plunging joint’s external surfaces and place the excess grease in the boot. 7.41 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 354: Drive Shaft Exploded View
3. Slide the rear drive shaft into the rear bearing carrier. Drive Shaft Installation 1. Install new spring ring on drive shaft. Apply anti- seize compound to splines. 7.42 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 355 6. Install rear wheel hub assembly, cone washers, and destroyed upon removal. Always use new brake caliper hand tighten the castle nut. Install washers with mounting bolts upon assembly. domed side out. 7.43 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 356: Rear Gearcase
(4) bolts retaining it to the rear suspension plate (see photo). Wheel Nuts: Steel Wheels: 27 ft-lbs (37 Nm) Aluminum Wheels: 30 ft-lbs + 90° (1/4 turn) 7.44 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 357: Gearcase Disassembly
In the event damage to the gears or housing requires replacement, the entire assembly must be replaced. 1. Drain and properly dispose of used gearcase fluid. 7.45 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 358 NOTE: Record the thickness of the shim pack located under each bearing. Keep the shims together for reassembly. 7.46 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 359 6. Remove the seals from each side of the gearcase teeth. If damaged, replace the gearcase assembly. housing. NOTE: In the event damage to the gears or housing requires replacement, entire assembly must be replaced. 7.47 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 360: Gearcase Assembly
NOTE: In the event damage to the gears, pinion bearings or housing requires replacement, the entire assembly must be replaced. 7.48 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 361 (2871557) to gearcase mating surfaces press. upon cover installation. WARNING Wear the appropriate safety equipment while installing bearing races to reduce the risk of injury. 7.49 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 362 The bearings are a slip-fit and will slide onto the axle spool. 5. Install ring gear/axle spool assembly into the housing. Cover Screws: 23-27 ft-lbs (31-37 Nm) 7.50 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 363: Gearcase Installation
FINAL DRIVE Gearcase Installation 2. Add Polaris ATV Angle Drive Fluid to rear gearcase. Refer to maintenance information in Chapter 2 for 1. Install the rear gearcase by reversing the procedure more details. Torque drain and fill plugs to listed under “REAR GEARCASE - Gearcase specification.
Page 364 Mount, Rear Seal, Oil Nut, Flanged Screw, Flange Head Assembly, Rear Housing, RH Screw Dowel Assembly, Tapered Roller Bearing Plug, Drain w/O-Ring Plug, Fill w/O-Ring Shim 7.52 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 366: Gearcase Removal
3. Remove upper A-arm bolts, lower rear A-arm bolts and suspension plate. NOTE: If accessory rear rack cab frame is installed, remove the (4) bolts retaining it to the suspension plate (see photo). 7.54 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 368: Gearcase Disassembly
3. Remove the differential assembly from the housing. 6. Remove the shim (s) from the differential assembly. Be sure to keep the shims together for reassembly. 7.56 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 369 9. Inspect each differential bearing and race for signs of wear or damage. If bearing replacement is required, use standard bearing puller tools to remove the bearing races. 7.57 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 370 14. If the solenoid was removed for servicing, inspect the tip of the solenoid for wear. If the tip of the solenoid is flattened, the solenoid must be replaced. 7.58 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 371 OEM tooling in order to properly reassemble. If there is any damage to the pinion gear, bearings or case, the gearcase assembly must be replaced. 7.59 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 372: Differential Disassembly
2. Use a brass punch in the recessed area as shown to punch to remove the roll pin from the differential remove the differential cover. case. 3. Remove the upper differential gear. 7.60 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 373: Differential Assembly
3. Install the side differential gears and thrust washers and slide the cross pin into position with the hole side facing the hole in the differential case. 4. Install a new roll pin. 7.61 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 374: Gearcase Assembly
6. Install the ring gear and torque the retaining bolts to specification. Ring Gear Bolts: 70-80 ft-lbs (95-108 Nm) NOTE: Grease all seals with Polaris All Season Grease (PN 2871322) upon assembly. Gearcase Assembly 1. Replace all worn components. 3. Install new seals into the gearcase housing and gearcase cover using a standard seal installer or other suitable method.
Page 375 Install the bearings by hand as they are a slip-fit. 9. Install the shift yoke assembly with the shift return springs (C), facing down in the housing. 7.63 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 376 12. Assemble the gearcase halves and install the bolts that secure the cover to the housing. Torque the bolts in a criss-cross pattern to 23-27 ft-lbs (31-37 Nm). 7.64 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 377: Gearcase Installation
FINAL DRIVE Gearcase Installation 2. Add Polaris ATV Angle Drive Fluid to rear gearcase. Refer to maintenance information in Chapter 2 for 1. Install the rear gearcase by reversing the procedure more details. Torque drain and fill plugs to listed under “REAR GEARCASE - Gearcase specification.
Page 378: Gearcase Exploded View
Gear, Diff, Pinion Mate Yoke, Shift Gear, Diff Side Thrust Washer, Side Gear Cover Asm., Rear Case, Diff Half Pin, Diff, Cross Screw Seal, Oil Pin, Spring Screw, Flanged 7.66 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 382: Torque Values / Specifications
26 oz. (769 ml) ADF PN 2871653 Rear Gearcase Fluid Capacity (INT’L) 22 oz. (650 ml) 5. Lift the gear shift selector out of mounting bracket and away from frame. 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 383: Installation
Tighten the lower jam nut against the mount. 2. Inspect shift cable, clevis pin, pivot bushings, and dust boot. Replace if worn or damaged. 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 384: Transmission Service
NOTE: Exploded views are located at the end of this chapter for additional information. 1. Place the transmission in the neutral position. 2. Drain both the transfer case and transmission case halves. 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 385 5. Inspect the driveshaft splines for wear and the O- rings for damage. Replace if found to be worn or damaged. 6. Remove the LH front isolator mount bracket. Refer to Chapter 3. 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 386 Note the alignment dowels (circled) for installation. damage and replace as needed. The shaft can be disassembled as shown using a press and standard bearing removal tools. 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 387 21T main pinion gear and remove the gear. and standard bearing removal tools. 15. Remove the lower snap ring from under the gear. 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 388: Transfer Case Reassembly
1. Install the intermediate shaft seal (circled) flush or slightly below the case. Install circlips and gear onto the input intermediate shaft as shown. 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 389 Proceed to step 18. 9. Remove the three bolts and the output pinion shaft bracket from the transfer case. 10. Remove the slip fit bearing race and shim(s). 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 390 15. Rotate output shaft 5-10 times both clockwise and output shaft rolling torque is within specification. counter clockwise. 18. Reinstall the intermediate pinion shaft assembly and bearing cup. 8.10 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 391 To Case Mating Surfaces Transfer Case Cover Screws: 23-27 ft-lbs (31-37 Nm) 21. With the transmission in neutral, rotate the output shaft 5-10 times both clockwise and counter- clockwise. 8.11 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 392 .030” (.762mm) 27. Install selected shim(s) and slip fit bearing race into transfer case cover. Coating shim (s) and bearing race with Polaris All Purpose Grease may be necessary to hold the assembly together during installation. 28. Apply a thin coat of sealant to the case mating surfaces.
Page 393 24-30 until within specification. B) If the torque required to rotate the output shaft is within specification, no adjustment is needed and the transfer case reassembly is complete. 8.13 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 394: Transmission Shift Housing Disassembly
3. Remove the retaining ring and retaining plate. NOTE: Shift cable bracket removal is required. 4. Remove the reverse clutch gear assembly from the housing. Inspect these components and replace if needed. 8.14 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 395 8. Remove the input shaft seal and clutch intermediate shaft seal using a seal puller or punch. NOTE: Do not pull bearing from case for inspection, as the removal process damages the bearing. 8.15 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 396 DO NOT remove the detent sleeve assembly before removing the outer detent screw. Removing the detent sleeve first will allow the detent ball and spring to fall into the shift housing. 8.16 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 397 16. Inspect the ball bearing channels on both ends of the shift collar for excessive wear or damage. 17. Remove the sliding shoes from the clutch yoke. 8.17 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 398: Transmission Shift Housing Reassembly
Replace the shaft if required. Transmission Shift Housing Reassembly 1. Install a new shift cable lever seal and press it flush with the case. Apply lubricant to the seal lip. 8.18 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 399 15-20 ft-lbs (20 - 27 Nm) 3. Assemble the input shaft with new ball bearings (if required). NOTE: Install new bearings and seals by pressing on the inner race only. 8.19 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 400 TIME. PLACE THE TRANSMISSION IN NEUTRAL. Detent Sleeve Assembly: 40-45 ft-lbs (54-61 Nm) 8. Install the clutch shaft into the transmission housing. 9. Install the sliding shoes onto the clutch yoke. 8.20 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 401 15. Install a new shaft bearing (if required). Apply Lubricant to shift drum components. Gear Position Sensor Screws: 25-40 in-lbs (3-5 Nm) 8.21 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 403 Shift Housing Screws: 23-27 ft-lbs (31-37 Nm) Shift Housing Screws: 23-27 ft-lbs (31-37 Nm) 23. Proceed with transfer case reassembly. See “Transfer Case Reassembly”, page 8.8 8.23 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 404: Troubleshooting
If transmission problem remains, disassemble transmission and inspect all gear dogs for wear (rounding), damage. Inspect all bearings, circlips, thrust washers and shafts for wear. 8.24 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 405: Transmission Exploded View
TRANSMISSION TRANSMISSION EXPLODED VIEW Shift Housing / Transfer Case Exploded View 8.25 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 409: General Specifications
0.298 ± 0.007" (7.57 ± 0.178 mm) 0.180" (4.6 mm) Rear Brake Disc Thickness 0.188" (4.78 mm) 0.170" (4.32 mm) Rear Brake Disc Runout 0.010" (0.254 mm) 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 410: Torque Specifications
(Master Cylinder Attachment) Front Brake Disc to Hub Bolts Rear Brake Disc to Hub Bolts Brake Switch 12-15 16-20 Master Cylinder to Frame Brake Pedal Mounting Bracket to Frame 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 411: Brake System Service Notes
• DO NOT lubricate or clean the brake components with aerosol or petroleum products. Use only approved brake cleaning products. 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 412: Brake Noise Troubleshooting
If noise does not change when brake is applied check other sources. Noise is from other source (axle, hub, disc or wheel) Inspect and repair as necessary Wrong pad for conditions Change to a softer or harder pad 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 413: Hydraulic Brake System Operation
BRAKES HYDRAULIC BRAKE SYSTEM OPERATION The Polaris brake system consists of the following components or assemblies: brake pedal, master cylinder, hydraulic brake lines, brake calipers, brake pads, and brake discs, which are secured to the drive line. When the foot activated brake lever is applied it applies pressure on the piston within the master cylinder.
Page 415: Master Cylinder
Refer to the torque specifications in the illustration. 2. After installing the foot brake check pedal freeplay. Pedal freeplay should not exceed .090” (2.286 mm). 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 416: Brake Pedal Lever
Attach a clean, clear hose to fitting and place the other end in a clean container. Be sure the hose fits tightly on fitting. 9.10 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 417: Front Brake Pads
Check for proper braking action and pedal reserve. With pedal firmly applied, pedal reserve should be no less than 1/2"(1.3 cm). 13. Check brake system for fluid leaks. 9.11 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 419: Pad Inspection
RZR/RZR S: .300” ± .007” (7.6 mm ± .178 mm) RZR 4: .297 ± .007" (7.5 ± .178 mm) Service Limit: .180” (4.6 mm) Front Caliper Mount Bolt: 31-34 ft-lbs (42-46 Nm) 9.13 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 420: Brake Burnishing Procedure
Repeat this procedure 10 times. Do not make more than 3 stops per 1 mile (1.6 km). 9.14 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 421: Front Caliper Service
BRAKES FRONT CALIPER SERVICE Caliper Exploded View (RZR / RZR S / RZR S INT’L) Caliper Exploded View (RZR 4) 9.15 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 422: Caliper Removal
Remove brake line from caliper. 6. Remove the two caliper mounting bolts and remove the caliper assembly from the front hub. 9.16 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 423: Caliper Disassembly
O-rings from the caliper. O-rings should be replaced during caliper service. 3. Thoroughly clean the caliper before disassembly and prepare a clean work area for disassembly. 9.17 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 424: Caliper Inspection
RZR 4: Front Caliper Piston Bore I.D.: Standard: 1.373” (34.87 mm) Service Limit: 1.375” (34.93 mm) NOTE: Be sure to clean seal grooves in caliper body. 9.18 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 425: Caliper Assembly
2. Coat pistons with clean Polaris DOT 4 Brake Fluid. Install pistons with a twisting motion while pushing RZR / RZR S: Front Caliper Piston O.D.: inward.
Page 426: Caliper Installation
4. Install the adjustment set screw and turn clockwise until stationary pad contacts disc, then back off 1/2 turn (counter-clockwise). 5. Perform brake bleeding procedure as outlined earlier in this chapter. 9.20 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 427: Front Brake Disc
If the brake drags, re-check assembly and installation. NOTE: If new pads are installed, refer to “FRONT BRAKE PADS - Brake Burnishing Procedure”. Brake Disc Runout: Service Limit 0.010” (0.254 mm) 9.21 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 428: Disc Inspection
Service Limit: 0.002” (0.051 mm) difference between measurements CAUTION Always use new brake disc mounting bolts. The bolts have a pre-applied locking agent which is destroyed upon removal. 9.22 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 429: Rear Brake Pads
NOTE: When removing caliper, be careful not to damage brake line. Support caliper so as not to kink or bend brake line. 9.23 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 430: Pad Inspection
6. Push caliper mounting bracket inward and slip outer brake pad past the edge to remove. Rear Brake Pad Thickness: Standard: 0.298 ± 0.007” (7.57 ± 0.178 mm) Service Limit: 0.180” (4.6 mm) 9.24 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 431: Pad Assembly / Installation
Repeat this procedure 10 times. Do not make more than 3 stops per 1 mile (1.6 km). 3. Install caliper and torque bolts to specification. Rear Caliper Mount Bolt: 18 ft-lbs (24 Nm) 9.25 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 432: Rear Caliper Service
2. Remove the (4) wheel nuts and rear wheel. 3. Clean caliper area before removal. 5. Loosen the brake pad adjustment set screw to allow brake pad removal after the caliper is removed. 9.26 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 433: Caliper Disassembly
2. Push upper pad retainer pin inward and slip brake body. pads past the edge and remove from the caliper. 3. Remove mount bracket (B) and dust boots (G and 9.27 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 434: Caliper Inspection
3. Inspect the brake disc and pads as outlined in this RZR 4: Rear Caliper Piston Bore I.D.: chapter. Standard: 1.505” (38.23 mm) Service Limit: 1.507” (38.28 mm) 9.28 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 435: Caliper Assembly
Be sure groove is clean and free of residue or brakes Torque mounting bolts to specification. may drag upon assembly. 2. Coat piston with clean Polaris DOT 4 Brake Fluid. Install piston (D) with a twisting motion while pushing inward. Piston should slide in and out of bore smoothly with light resistance.
Page 436: Rear Brake Disc
Slowly rotate the disc and read total runout on the dial indicator. Replace the disc if runout exceeds specifications. Brake Disc Runout: Service Limit 0.010” (0.254 mm) 9.30 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 437: Disc Replacement
4. Clean the wheel hub mating surface and install new installation. disc on wheel hub. 5. Install new bolts and torque to specification. Brake Disc Mounting Bolts: 28 ft-lbs (38 Nm) 9.31 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 438: Troubleshooting
• Residue build up under caliper seals • Operator riding brakes Brakes Lock • Alignment of caliper to disc • Caliper pistons sticking • Improper assembly of brake system components 9.32 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 441: General Information
(K, M, etc.) and the position of the decimal point. • For resistance readings, isolate the component to be tested. Disconnect it from the wiring harness or power supply. 10.3 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 442: Switches / Controls
0.5 ohms, clean the switch terminals. Re-test and replace switch if necessary. NOTE: Pins 7 and 8 provide power and ground to light the switch lamp. 10.4 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 443: Ignition Key Switch
C and D; E and F. • Turn the ignition key to START. There should be continuity between pins A and B; C and D; E and 10.5 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 444: Awd / 2Wd Switch
• Move the switch to 2WD. There should be no continuity between any pins. • Move the switch to TURF. There should be continuity between switch pins 1 and 2; 4 and 5. 10.6 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 445 2 and 3. tests fail, replace the switch assembly. • Move switch to NONE / OFF. There should be no continuity between switch legs or pins. 10.7 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 446: Transmission (Gear Position) Switch
Throttle Release Switch (TRS) TRS System Operation This vehicle is equipped with a throttle release switch (TRS) to detect when the throttle pedal has returned to the rest position. 10.8 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 447 TRS slot. 5. Connect the negative (-) battery cable and install the drivers seat. 3. Remove the TRS from the vehicle. 10.9 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 448: Vehicle Speed Sensor
Harness to the sensor 3 pin connector using the Hall Sensor Probe Harness (PN 2460761). 3. Pass a screwdriver back and forth in front of the sensor tip. 10.10 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 449: Rear Diff Solenoid (Int'l)
• Check the AWD / 2WD / TURF Switch wires for loose connections. • Remove solenoid from rear differential and ensure the solenoid plunger is actuating. 10.11 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 451: Instrument Cluster
Do not use alcohol to clean the instrument cluster. Do not allow insect sprays to contact the lens. Immediately clean off any gasoline that splashes on the instrument cluster. 10.13 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 452: Rider Information Display
TURF position (INT’L Models Only). 12. Neutral Gear Indicator - LED icon illuminates when gear selector is in the neutral (N) position. 10.14 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 453 MODE button until “OFF” is displayed. Engine temperature can be displayed in ° F or ° C. Refer to “Units of Measurement” to change the format. 10.15 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 454 1. Turn the key to the OFF position. 2. Press and hold the MODE button while turning the key to the ON position. 10.16 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 455: Diagnostic Mode
4. Use the trouble code reference table in the EFI Chapter for a description of each code. 5. If more than one code exists, press the MODE button to advance to the next trouble code. 10.17 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 456: Instrument Cluster Pinouts
Twist the instrument cluster gently in a clockwise motion to properly seat the instrument cluster into the rubber mount. Apply pressure on the bezel while pressing down on the instrument cluster. 10.18 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 457: Head Lights (Incandescent)
4. Repeat steps 1-3 if replacing daytime running lights (INT’L Only) also located in the headlamp housing. NOTE: Make sure the tabs on the bulb locate properly in the housing. 10.19 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 458: Headlight Adjustment
(A) on both sides of the headlamp and install the adjustment screw (B). 3. Reconnect wire harness or re-insert bulb if previously removed. 4. Adjust headlights using the “Headlight Adjustment” procedure in this section. 10.20 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 459: Headlamp Replacement
1. Disconnect wire harness from headlamp assembly. Be sure to pull on the connector, not on the wiring. 3. Carefully lift and remove headlamp assembly from the bumper. 10.21 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 460: Headlamp Installation
3. Connect the wire harness. 4. Test the tail light, brake light and turn signal (INT’L Only) to verify it is working properly. 10.22 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 461: Efi Diagnostics
All EFI component information and diagnostic testing procedures are located in Chapter 4. Refer to Chapter 4 “Electronic Fuel Injection System (EFI)” when diagnosing an EFI system or component. 10.23 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 462: Fan Control Circuit Operation / Testing
2.5 k Ω ± 6% 212 °F (100 °C) 186 Ω ± 2% NOTE: If the coolant temperature sensor or circuit malfunctions the radiator fan will default to 'ON'. 10.24 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 463: Fuse Box: Fuses / Relays / Circuit Breaker
20-amp circuit breaker protects the fan motor circuit. A separate relay located under the dash, operates the high beam and low beam headlights on INT’L models. 10.25 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 465: Relay Operation
Dark Green / Yellow 20-Amp fuse protected 12 Vdc constant Red / White battery voltage. Provides 12 Vdc power for EFI system Red / Dark Blue circuits. 10.27 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 466: Charging System
(lights, etc.) and begins to charge the battery. Depending on battery condition and system load, the break even point may vary slightly. The battery should be fully charged before performing this test. 10.28 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 467: Charging System Alternator Tests
‘leg’ of the stator by connecting the meter leads to the wires leading from the alternator (Y1 to Y2, Y1 to Y3, Y2 to Y3). 10.29 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 468: Regulator / Rectifier
80 VAC ± 25% Regulator / Rectifier The Regulator / Rectifier is located behind the radiator cooling fan and can be accessed through the front left wheel well. 10.30 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 469: Charging System Testing Flow Chart
Whenever charging system problems are suspected, proceed with the following system check after verifying that all wires are in good condition, connected and not exposed or pinched. 10.31 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 470: Battery Service
Refer to OCV table (see “OCV - Open Circuit Voltage Test”). 3. Charge the battery as recommended (see “Charging Procedure”). 10.32 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 471: Battery Removal / Installation
11.8 V or less NOTE: Battery charge can be maintained by using a Polaris battery tender charger or by charging once a Load Test month to make up for normal self-discharge. Battery tenders can be left connected during the storage...
Page 472: Charging Procedure
Always watch charging times carefully. Stop charging if the battery becomes very warm to the touch. Allow it to cool before resuming charging. 10.34 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 473: Starting System
.1 DC volts per connection Starter Motor Mounting Bolts: 7 ft-lbs (9.5 Nm) Starter Motor Removal 1. Disconnect the negative (-) battery cable and remove the seat base. 10.35 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 474: Starter Drive Bendix
5 seconds. With the solenoid energized, resistance should read about 0 - 0.5Ω between terminals (A) and (B). If resistance measurement is out of specification, replace the starter solenoid. 10.36 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 475: Starting System Testing Flow Chart
ELECTRICAL STARTING SYSTEM TESTING FLOW CHART Condition: Starter fails to turn over the engine. 10.37 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 476: Electronic Power Steering (Eps)
EPS unit. If not, update to the latest to a normal mechanically coupled steering system. The version for each and follow the guided diagnostic system is Polaris Digital Wrench® compatible for procedure(s) available in Digital Wrench®. simplified diagnostics...
Page 479: Eps Troubleshooting (Power Steering Non-Functional With Mil Off)
ELECTRICAL EPS Troubleshooting (Power Steering Non-Functional with MIL OFF) 10.41 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 481 Driven Clutch, Service (Non-EBS)......6.25 Centralized Hilliard, Exploded View......7.20 Driveshaft / CV Joint, Handling Tips ......7.9 Charging System ..........10.28 Charging System, Alternator Tests ......10.29 IX.1 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 482 Engine, Piston Ring Installed Gap ......3.42 Fuses ..............10.25 Engine, Piston to Cylinder Clearance ...... 3.40 Engine, Piston to Rod Clearance ......3.41 Engine, Push Rod Inspection........3.29 IX.2 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 483 Replacement ............7.39 Metric Bolt Torque Specification ......1.15 Rear Driveshaft, Installation........7.42 Rear Driveshaft, Removal ........7.35 Rear Fender, Flair, and Tie Down Removal....5.23 IX.3 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 484 Shocks and Springs ..........5.48 Steering, Inspection ..........2.31 Software Version ........... 4.47 Suspension, (FOX) ..........2.35 Solenoid, Rear Differential (INT’L)......10.11 Suspension, Compression Adjustment (FOX) ..2.36 IX.4 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 485 Upper Steering Shaft Removal (EPS)...... 5.29 Upper Steering Shaft, Installation (EPS) ....5.33 Valve Seal/Spring Service ........3.30 Valve Sealing Test ..........3.36 Valve Seat Reconditioning........3.33 Vehicle Information IX.5 9924707 - 2013–2014 RZR 800 Service Manual © Copyright 2013 Polaris Sales Inc.
Page 487 2013-2014 RANGER RZR 800...
Page 488 2013-2014 RANGER RZR 800...
Page 489 2013-2014 RANGER RZR 800 (EPS)
Page 490 2013-2014 RANGER RZR 800 (EPS)
Page 491 2013-2014 RANGER RZR S 800...
Page 492 2013-2014 RANGER RZR S 800...
Page 493 2013-2014 RANGER RZR S 800 INT’L...
Page 494 2013-2014 RANGER RZR S 800 INT’L...
Page 495 2013-2014 RANGER RZR 4 800...
Page 496 2013-2014 RANGER RZR 4 800...
Page 497 2013-2014 RANGER RZR 4 800 (EPS)
Page 498 2013-2014 RANGER RZR 4 800 (EPS)
Page 499 2013-2014 RANGER RZR / RZR S / RZR 4 (CARGO BOX)
Page 500 2013-2014 RANGER RZR S 800 INT’L (CARGO BOX)

This manual is also suitable for:

Rzr 800 2014

Polaris RZR 800 2013 Manual

Chapter 1 1 General Information

Chapter 2 Maintenance

Chapter 3 Engine

Chapter 4 Electronic Fuel Injection

Chapter 5 Body / Steering / Suspension

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Chapters

Troubleshooting

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Summary of Contents for Polaris RZR 800 2013