Positioning:
The Polaris Ranger RZR lineup, particularly the 800, RZR-S, and RZR-4 variants from 2013, represented a significant segment of the performance-oriented off-road UTV market, known for their agility and power.
Competitors:
Competed directly with other high-performance SxS vehicles from manufacturers like Can-Am (Outlander, Commander), Yamaha (Rhino), and Arctic Cat (Wildcat).
Vehicle Features:
Powerful 800cc engine, long-travel suspension for off-road capability, sharp steering, comfortable seating for 2 or 4 passengers (depending on model), durable construction for rugged terrain.
Value:
This service manual is essential for owners and technicians seeking to perform maintenance, diagnose issues, and execute repairs on these specific RZR models, ensuring optimal performance and longevity. It provides factory-level detail, crucial for accurate and safe servicing.
Primary Coverage:
All aspects of service, repair, maintenance, diagnostics, and troubleshooting for the 2013 Polaris Ranger RZR 800, RZR-S, and RZR-4 models.
Specific Systems Covered:
Engine overhaul/rebuilding, brakes, sunroof (if applicable), timing belt, wiring diagrams, troubleshooting, diagnostics, computer diagnostic trouble codes/charts, engine performance, front end alignment, suspension, transmission removal/installation, air conditioning repair/capacities, transmission in-car servicing, firing orders, maintenance schedules, serpentine belt routing, U-joint/CV-joint repair.
Estimated Page Count:
High (typical service manuals for this complexity are 500+ pages)
Type:
Official Service Manual / Repair Manual
Powertrain:
Engine (800cc liquid-cooled twin-cylinder, ProStar), transmission, driveline, differentials, axles, U-joints, CV-joints.
Chassis And Suspension:
Front and rear suspension systems (dual A-arm, long-travel), shocks, springs, steering, chassis, frame, hubs, wheel bearings.
Braking System:
Hydraulic disc brakes (front and rear), brake fluid specifications, caliper service, rotor replacement, bleeding procedures.
Electrical System:
Ignition system, starting system, charging system, battery, lighting, instrumentation, EFI system, computer diagnostics, full wiring diagrams.
Fuel System:
Fuel injection (EFI), fuel pump, injectors, fuel filter, fuel tank, fuel lines.
Cooling System:
Liquid cooling system, radiator, fan, water pump, coolant specifications, flushing, thermostat.
Lubrication System:
Engine oil, oil filter, oil pump, oil capacities, fluid specifications.
Exhaust System:
Exhaust pipes, muffler, catalytic converter (if applicable).
Bodywork And Trim:
Body panels, seating, roof (sunroof if equipped), doors, lighting covers, interior trim.
Air Conditioning System:
Refrigerant types, capacities, service procedures, diagnostic codes.
Engine Repair:
Complete engine overhaul, rebuilding, component replacement (pistons, rings, valves, bearings), timing procedures.
Transmission Service:
Removal, installation, in-car servicing, clutch service (if applicable), gear inspection, fluid changes.
Suspension And Steering:
Alignment procedures and specifications, shock absorber replacement, spring adjustment, tie rod end replacement, steering column service.
Brake Service:
Pad and rotor replacement, caliper service, brake line bleeding, troubleshooting brake system issues.
Electrical Diagnostics:
Troubleshooting electrical faults using wiring diagrams, diagnostic trouble code (DTC) lookup and interpretation, component testing.
Maintenance Tasks:
Scheduled maintenance, fluid level checks and top-offs, filter replacement (air, oil, fuel), spark plug replacement, belt inspection and replacement.
Driveline Service:
U-joint and CV-joint inspection and replacement, driveshaft service, differential maintenance.
Troubleshooting Guides:
Systematic approaches to diagnosing common problems, fault trees, symptom-based troubleshooting.
Depth:
Comprehensive (covers basic maintenance to complete engine and transmission rebuilds, complex electrical diagnostics, and system troubleshooting).
Diagnostic Capabilities:
Detailed diagnostic trouble codes (DTCs), computer diagnostic trouble tree charts, symptom analysis for EFI and electrical systems.
Specifications:
Complete torque specifications for all fasteners, critical component measurements, fluid capacities, electrical values.
Diagrams And Illustrations:
Hundreds of clear illustrations, detailed wiring diagrams, vacuum diagrams, exploded views of components.
Engine Type:
ProStar 800, Liquid-cooled, 4-stroke, DOHC, Twin-Cylinder
Bore X Stroke:
80 mm x 79 mm (approximate)
Compression Ratio:
10.3:1 (typical for this engine family)
Horsepower:
~52 HP (approximate, varies slightly by model variant)
Torque:
~47 lb-ft (approximate)
Induction:
Electronic Fuel Injection (EFI) with throttle body
Fuel Type:
Unleaded gasoline, minimum 87 octane
Oil Type:
SAE 5W-50 Synthetic (typical recommendation)
Oil Capacity:
Approximately 2.4 US quarts (2.3 liters) with filter change
Coolant Type:
Polaris Premium Long Life Antifreeze/Coolant or equivalent (Ethylene Glycol based, 50/50 mix with distilled water)
Coolant Capacity:
Approximately 5.7 US quarts (5.4 liters)
Type:
Automatic, Polaris Variable Transmission (PVT) with Engine Braking
Drive Modes:
Park, Reverse, Neutral, High, Low
Final Drive:
Shaft Drive with sealed, on-demand, True All-Wheel Drive (AWD) system with VersaTrac Turf Mode
Options:
N/A for this model year's core transmission
Clutch System:
Adjustable clutches for optimal power delivery across varying terrain and loads.
Fluid Type:
Polaris PVT Fluid (or equivalent synthetic CVT fluid)
Fluid Capacity:
Approximately 3.5 US quarts (3.3 liters)
Length:
81.2 - 96.0 inches (RZR 800/S) / 107.0 inches (RZR-4) (approximate)
Width:
50.0 inches (RZR 800/S) / 64.0 inches (RZR-4) (approximate)
Height:
73.4 inches (approximate)
Wheelbase:
61.0 inches (RZR 800) / 77.0 inches (RZR-S) / 81.4 inches (RZR-4) (approximate)
Dry Weight:
Approx. 958 - 1125 lbs (depending on model)
Ground Clearance:
11.5 inches (approximate)
Bed Capacity:
N/A (RZR lineup is not typically equipped with a cargo bed)
Towing Capacity:
N/A (Polaris RZR is not designed for towing)
Tire Size Front:
26x8-12 (e.g., 26x8 R12 All-Terrain)
Tire Size Rear:
26x10-12 (e.g., 26x10 R12 All-Terrain)
Wheel Bolt Pattern:
4x110 mm
Initial Service:
First service typically at 10-20 hours or 100-200 miles (check manual for specific recommendations - usually includes checking fluid levels, bolts, and belt tension).
Regular Maintenance:
Routine checks: every 50 hours/250 miles; oil and filter change: every 100 hours/500 miles; spark plugs: every 100 hours; air filter: clean/inspect every 25 hours, replace as needed; transmission fluid: inspect every 50 hours, change every 100 hours. (These are general guidelines; the manual provides precise intervals).
Engine Oil Spec:
SAE 5W-50 Synthetic (refer to manual for exact spec and API service classification).
Brake Fluid Spec:
DOT 3 or DOT 4 Hydraulic Brake Fluid.
Transmission Fluid Spec:
Polaris PVT Fluid or equivalent synthetic CVT fluid.
Coolant Spec:
Polaris Premium Long Life Antifreeze/Coolant or equivalent (50/50 mix with distilled water).
Common Wear Items:
Drive belts (wear and tear from heavy use), U-joints and CV-joints (especially with aggressive riding), suspension bushings and bearings, brake pads.
Potential Electrical Issues:
Corrosion in connectors, stator/rectifier issues (less common but possible), wiring harness integrity checks.
Engine Longevity:
Proper and timely maintenance is key to the longevity of the ProStar 800 engine. Overheating, lack of lubrication, and ignoring maintenance schedules are primary causes of premature failure.
