Polaris Ranger 800 4x4, Crew & 6x6 Service Manual, 2013 (P/N 9923964)

This Polaris factory service manual (P/N 9923964, copyright 2012) covers the 2013 Ranger 800 4x4, Crew, and 6x6, including the 4x4 and Crew EPS models. The service chapters carry a Preliminary Version watermark.

PDF Search, Bookmarks, and Wiring Sheets

Search and diagram detail: The service chapters have searchable text. PDF bookmarks jump to chapters, procedures, and wiring sheets. The wiring sheets have no searchable text layer. Zoom in to read small pin numbers, connector labels, and wire codes.

The ZIP contains one printable PDF with 400 pages. The total includes 392 chapter pages, three of which are notes pages, and eight 11 × 17 in. wiring diagram and wire-termination sheets.

Engine Overhaul, EFI Diagnostics, and Driveline Service

The topics below are selected highlights. The manual also covers speed sensor testing and headlight aim adjustment.

• Engine and cooling: Engine removal, cylinder-head and valve service, piston and cylinder inspection, crankcase and gear-train repair, cooling-system pressure testing, and bleeding.
• Bosch M17 EFI: Fuel pump, regulator, and injector tests, sensor and ignition-coil diagnosis, instrument-cluster fault codes, and Digital Wrench™ guided diagnostics.
• PVT and transmission: Belt service, clutch alignment and overhaul, high-altitude clutch charts, and separate transmission teardown and reassembly procedures for 4x4/Crew and 6x6.
• Final drive: Centralized Hilliard front gearcase service, AWD troubleshooting, ring-gear backlash, propshafts and U-joints, CV joints and boots, and 6x6 mid and rear gearcases.
• Brakes: Hydraulic bleeding, caliper repair, pad inspection and burnishing, and parking-brake procedures for the covered configurations.
• Body, steering, and suspension: Model-specific body exploded views, cargo-box service, EPS and non-EPS steering, A-arms, ball joints, and shocks.
• Electrical diagnosis: Starter voltage-drop tests, charging-system and stator checks, and separate wiring diagrams for 4x4, Crew, 6x6, EPS, and the cargo box.

The manual is suited to technicians and experienced mechanics familiar with safe service procedures and equipped with the specified gauges, meters, and special tools.

Maintenance and Engine Work

The opening chapters show where to find the VIN and engine number. Maintenance coverage includes periodic and severe-use schedules, lubrication points, approved fluids, shift-cable adjustment, throttle free play, wheel alignment, and suspension settings. The fluid quick-reference illustrations identify the engine, transmission, and gearcases, including the 6x6 mid and rear units.

The engine chapter separates in-chassis work on the flywheel, stator, starter drive, top end, pumps, and gear train from engine-out work on the crankshaft, connecting rods, counterbalance, main bearings, and crankcase. It covers compression and leakdown checks, valve-seat reconditioning, cylinder honing, cam and balance-gear timing, and break-in. The Oil Flow Chart and Cooling System Exploded View show how the systems are laid out.

Lubricant or contamination on the water-pump mechanical seal can prevent it from seating and sealing. Skipping oil-system priming after internal repair can damage the engine on the first start.

EFI and Electrical Troubleshooting

Manual EFI checks cover the T-MAP, crankshaft-position, cam-phase, and coolant-temperature sensors, along with the IAC, TPS, and ignition coil. The Digital Wrench™ Feature Map covers live data, fault-code clearing, guided tests, output-state tests where supported, ECU replacement, and engine-controller reflashing. Digital Wrench™ is separate, dealer-only software.

The Starting System Testing Flow Chart helps narrow down a no-crank fault. EPS troubleshooting follows separate paths for the warning lamp on, the warning lamp off, and Digital Wrench™ diagnosis.

Clutch Setup and Transmission Variants

For hard shifting at idle, the clutch chapter gives offset and center-distance checks to help identify clutch drag before opening the transmission. Polaris specifies a trained Master Service Dealer technician for PVT work. The 4x4/Crew transmission section covers snorkel and output-gear backlash and shows assemblies 1332961 and 1332977. The 6x6 section covers assembly 1332978 and has separate mid- and rear-driveline procedures.

For the 6x6 rear gearcase, Polaris calls for assembly replacement if the pinion, bearings, or housing are damaged. The procedure leaves the pinion assembly intact, and ring-and-pinion shimming data is outside its scope.

Reference tables include torque specs, fluid data, wear limits, and tool numbers such as PU-45778 for oil priming, PU-43506-A for fuel pressure, PU-47471 for the SmartLink module kit, PA-49011 for clutch alignment, 2871043 for flywheel removal, and 2870975 for pressure testing. Follow the manual’s precautions for pressurized fuel, hot coolant, rotating PVT parts, brake work, and vehicle support.

Sample Oil Pressure, Injector, and Clutch Specs

The engine oil-pressure test specifies 27–55 psi at 6,000 rpm with the engine at operating temperature and running PS-4 Plus synthetic oil. The Bosch EFI injector test specifies 11.4–12.6 Ω across the two injector harness terminals.

The PVT chapter specifies a clutch center distance of 10.05 in. (255 mm) for checking engine and transmission alignment after installation or mount replacement.