Polaris RZR 800 2013 User manual

FOREWORD
The information printed within this publication includes the latest product information at time of print. The most recent
version of this Service Manual is available to Slingshot Dealers in electronic format at www.polarisdealers.com.
This Service Manual is designed primarily for use by trained Slingshot service technicians in a properly equipped shop
and should be kept available for reference in the shop area. All references to left and right side of the vehicle are from
the operator's perspective when seated in a normal riding position.
Some procedures outlined in this manual require a sound knowledge of mechanical theory, tool use, and shop
procedures in order to perform the work safely and correctly. Read the text and be familiar with the service procedures
before starting any repair. Certain procedures require the use of special tools. Use only the proper tools as specified. If
you have any doubt as to your ability to perform any of the procedures outlined in this 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.
Publication Printed July 2013 (PN 9924882)
2013–2014 RZR 800

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. No liability can be accepted for omissions or inaccuracies. Any
reprinting or reuse of the depictions and/or procedures contained within, whether whole or in part, is expressly
prohibited. Printed in U.S.A.
Understanding Manual Safety Labels and
Directions
Throughout this manual, important information is brought to your attention by the following symbols:
WARNING
SAFETY ALERT WARNING indicates a potential hazard that may result in severe injury or death to the operator,
bystander or person(s) inspecting or servicing the vehicle.
CAUTION
SAFETY ALERT CAUTION indicates a potential hazard that may result in minor personal injury or damage to the
vehicle.
CAUTION
CAUTION indicates special precautions that must be taken to avoid vehicle damage or property damage.
NOTE:
NOTE provides key information by clarifying instructions.
IMPORTANT:
IMPORTANT provides key reminders during disassembly, assembly and inspection of components.

TRADEMARKS
POLARIS ACKNOWLEDGES THE FOLLOWING PRODUCTS MENTIONED IN THIS MANUAL:
Loctite, Registered Trademark of the Loctite Corporation
Nyogel, Trademark of Wm. F. Nye Co.
Fluke, Registered Trademark of John Fluke Mfg. Co.
Mity-Vac, Registered Trademark of Neward Enterprises, Inc.
Torx, Registered Trademark of Textron
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.

1
GENERAL INFORMATION
2
MAINTENANCE
3
ENGINE
4
ELECTRONIC FUEL INJECTION
5
BODY / STEERING / SUSPENSION
6
CLUTCHING
7
FINAL DRIVE
8
TRANSMISSION
9
BRAKES
10
ELECTRICAL

1
1.1
9924882 - 2013–2014 RZR 800
© Copyright 2013 Polaris Sales Inc.
GENERAL INFORMATION
CHAPTER 1
GENERAL INFORMATION
VEHICLE IDENTIFICATION..............................................................................1.2
MODEL NUMBER DESIGNATION..................................................................1.2
ENGINE DESIGNATION NUMBER .................................................................1.2
VEHICLE IDENTIFICATION NUMBER (VIN) DESIGNATION ........................................1.2
VEHICLE AND ENGINE SERIAL NUMBER LOCATIONS............................................1.3
VEHICLE INFORMATION ................................................................................ 1.4
PUBLICATION NUMBERS .........................................................................1.4
REPLACEMENT KEYS.............................................................................1.4
SPECIAL TOOLS ..................................................................................1.5
GENERAL SPECIFICATIONS............................................................................ 1.6
MODEL: 2013–2014 RZR 800 ......................................................................1.6
MODEL: 2013–2014 RZR EPS 800 .................................................................1.6
MODEL: 2014 RZR 800 XC.........................................................................1.7
MODEL: 2013–2014 RZR / EPS 800................................................................1.7
MODEL: 2013–2014 RZR S 800 ....................................................................1.9
MODEL: 2013–2014 RZR S INT’L 800 ..............................................................1.9
MODEL: 2013 RZR S / INT’L 800 ..................................................................1.10
MODEL: 2013 RZR 4 800 .........................................................................1.12
MODEL: 2013–2014 RZR 4 EPS 800 ..............................................................1.12
MODEL: 2013 RZR 4 / EPS 800 ...................................................................1.13
MISC. SPECIFICATIONS AND CHARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.15
CONVERSION TABLE ............................................................................1.15
STANDARD BOLT TORQUE SPECIFICATION.....................................................1.16
METRIC BOLT TORQUE SPECIFICATION ........................................................1.16
SAE TAP / DRILL SIZES ..........................................................................1.17
METRIC TAP / DRILL SIZES ......................................................................1.17
DECIMAL EQUIVALENTS .........................................................................1.18

1.2
9924882 - 2013–2014 RZR 800
© Copyright Polaris Sales Inc.
VEHICLE IDENTIFICATION
Model Number Designation
2008–2013 RZR vehicles use model numbers beginning with “R”. Beginning with the 2014 model year, all RZR model
numbers begin with “Z”.
2008–2013 Example: R13XT9EAK
GROUP MODEL
YEAR CHASSIS DRIVE-
LINE
ENGINE /
MOTOR CODE CATEGORY OPTION REGION
1st 2nd 3rd 4th* 5th* 6th* 7th* 8th* 9th** 10th
R 1 3 X T 9 E A K
* = digits that would transfer to 17 digit VIN and are used in digits 4-8 respectively
** = 9th digit will be used on color/featured versions of models (not including the base)
First 3 digits and 9th digit are used in model number only. They are not used with the 17 digit VIN.
Digits 1 through 8 determine Digital Wrench calibration.
2014 Example: Z14VH76AD
GROUP MODEL
YEAR CHASSIS DRIVE-
LINE
ENGINE /
MOTOR CODE CATEGORY OPTION REGION
1st 2nd 3rd 4th* 5th* 6th* 7th* 8th* 9th** 10th
Z 1 4 V H 7 6 A D
* = digits that would transfer to 17 digit VIN and are used in digits 4-8 respectively
** = 9th digit will be used on color/featured versions of models (not including the base)
First 3 digits and 9th digit are used in model number only. They are not used with the 17 digit VIN.
Digits 1 through 8 determine Digital Wrench calibration.
Engine Designation Number
1204620 RZR800-13: Twin Cylinder, Liquid Cooled, OHV 4 Stroke, Electric Start
Vehicle Identification Number (VIN)
Designation
Example: 4XAVH76A4E3000000
World Mfg. ID
Vehicle Descriptors Vehicle Identifiers
Chassis
Driveline
Engine Size
Engine Modifier
Category
Check Digit
Model Year *
Mfg. Location
Individual Serial No.
1 2 3 4 56 7 8 9 10 11 12 13 14 15 16 17
4 X A V H 7 6 A 4 E 3 0 0 0 0 0 0
* Model Year: A = 2010; B = 2011; C = 2012; D = 2013; E = 2014
GENERAL INFORMATION

1.3
9924882 - 2013–2014 RZR 800
© Copyright 2013 Polaris Sales Inc.
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).
The engine model and serial number can be found on a decal applied to the side of the engine’s cylinder (Figure 1-2).
GENERAL INFORMATION
1

1.4
9924882 - 2013–2014 RZR 800
© Copyright Polaris Sales Inc.
VEHICLE INFORMATION
Publication Numbers
Model Model No. Owner’s Manual Parts Manual
2013 RZR 800 R13VH76AC, AD, AN, AS 9924099 9924104
2013 RZR EPS 800 R13VH7EAI 9924099 9924104
2013 RZR S 800 R13VE76AD, AI, AS, AW 9924099 9924100
2013 RZR S INT’L 800 R13VE76FI, FX 9924099 9924101
2013 RZR 4 800 R13XE76AD 9924099 9924106
2013 RZR 4 EPS 800 R13XE7EAI 9924099 9924106
2014 RZR 800 Z14VH76AC, AD 9924707 9924712
2014 RZR EPS 800 Z14VH7EAI, AJ, AK, AL, AW 9924707 9924712
2014 RZR S 800 Z14VE76AD, AL, AS, AV, AW 9924707 9924709
2014 RZR S INT’L 800 Z14VE76FI, FX 9924707 9924708
2014 RZR 4 EPS 800 Z14XE7EAL 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.
Series# Part Number
20 4010278
21 4010278
22 4010321
23 4010321
27 4010321
28 4010321
31 4110141
32 4110148
67 4010278
68 4010278
GENERAL INFORMATION