Polaris Ranger 800 4X4, CREW, 6X6 2013 Service Manual (P/N 9923964)

• Fits 2013 Ranger 4x4 800 models R13TH76AG, R13TH76AGC, R13TH76AH, R13TH76AK, R13TH76AR, R13TH76ARC, R13TH76AZ, and R13TH76AZC; 4x4 800 EPS models R13TH7EAG, R13TH7EAK, R13TH7EAKC, R13TH7EAZ, and R13TH7EAZC; Crew 800 models R13WH76AG and R13WH76AR; Crew 800 EPS models R13WH7EAH and R13WH7EAI; and 6x6 800 models R13HR76AG and R13HR76AR.
• Factory publication P/N 9923964, copyright 2012, supplied as a 400-page PDF and marked “Preliminary Version” throughout.
• Engine coverage reaches removal, cooling-system pressure testing and bleeding, cylinder-head and valve service, piston/cylinder inspection and honing, crankcase and gear-train repair, flywheel/stator work, water-pump service, and oil-system priming.
• Bosch M17 EFI sections address the fuel pump, regulator, injectors, T-MAP, CPS, IAC, TPS, cam-phase and coolant-temperature sensors, ignition coil, ECU, instrument-cluster fault codes, and Digital Wrench™ guided diagnostics and reflash functions.
• PVT and transmission chapters document belt service, clutch center-distance and offset checks, high-altitude clutch charts, drive and driven clutch overhaul, 4x4/Crew transmission teardown, and a separate 6x6 transmission repair section.
• Final-drive and brake chapters cover Centralized Hilliard front-gearcase and AWD diagnosis, ring-gear backlash, propshaft and U-joint service, CV-joint/boot work, 6x6 mid and rear gearcases, hydraulic bleeding, caliper repair, and parking-brake variants.
• Body, steering, suspension, and electrical reference includes 4x4/Crew/6x6 exploded views, cargo-box service, EPS and non-EPS steering, A-arms, ball joints, shocks, testing flowcharts, specification tables, special-tool numbers, and model-specific wiring diagrams.

Maintenance, Engine, and EFI Coverage

This is a full-vehicle factory service publication rather than a short engine excerpt. The opening chapters identify VIN, engine-number, and model-code locations, then lay out periodic maintenance, severe-use scheduling, lubrication points, approved fluids, shift-cable adjustment, throttle freeplay, wheel alignment, suspension settings, and brake inspection. Separate quick-reference illustrations identify the engine, transmission, front gearcase, and the additional mid and rear gearcases used on the 6x6.

The engine material is built around the 760 cc liquid-cooled twin-cylinder four-stroke with Bosch M17 EFI and ECU-controlled ignition. The engine chapter distinguishes work that can be completed with the engine installed from repairs that require removal. Flywheel, stator, starter drive, cylinder head, cylinder, piston and rings, camshaft, rocker arms, oil and water pumps, and gear-train components are covered as in-chassis service items. Crankshaft, connecting-rod, counterbalance, main-bearing, and crankcase repair are identified as engine-out work. Factory procedures extend through compression and leakdown testing, oil-pressure diagnosis, valve-seat reconditioning, cylinder honing, piston and ring inspection, cam and balance-gear timing, crankcase reassembly, and break-in reference data.

Two engine repair traps are called out clearly. The water-pump mechanical seal is installed dry; lubricant or contamination can prevent it from bedding and sealing correctly. After internal repair, the oil system must be primed before the first start or internal engine damage may result.

Drivetrain, Brake, and Electrical Repair Scope

The driveline material is configuration-specific. The 4x4/Crew transmission section covers removal, internal disassembly, snorkel/output-gear backlash, reassembly, installation, troubleshooting, and exploded views for transmission P/N 1332961 and 1332977. The 6x6 uses its own transmission chapter and exploded view for P/N 1332978, plus dedicated mid-propshaft, mid-gearcase, rear-propshaft, and rear-gearcase procedures. One important scope limit is stated for the 6x6 rear gearcase: the pinion assembly is not intended for field disassembly, and ring-and-pinion shimming data is not supplied because OEM tooling is required.

EFI and electrical diagnosis goes well beyond basic resistance tables. Digital Wrench™ coverage addresses live engine data, code clearing, guided fault isolation, output-state tests, ECU replacement data transfer, and controller reprogramming. Polaris identifies the software as dealer-only; the manual documents its use but does not provide the software or access. EPS diagnosis is broken into MIL-on, MIL-off, and Digital Wrench paths, supported by system breakouts and flowcharts.

Specifications, Diagrams, and Special Tools

Reference sections provide component-specific torque tables, fluid-capacity and lubricant data, wear limits, clearances, electrical test values, clutch setup charts, and troubleshooting matrices. Notable graphics include the Oil Flow Chart, Cooling System Exploded View, Digital Wrench Feature Map, Front Gearcase - Centralized Hilliard Exploded View, Starting System Testing Flow Chart, and separate 4x4, Crew, 6x6, EPS, and cargo-box wiring diagrams.

Special-tool tables identify equipment such as the Oil System Priming Tool PU-45778, Fuel Pressure Gauge Kit PU-43506-A, Digital Wrench SmartLink Module Kit PU-47471, Clutch Alignment Tool PA-49011, Flywheel Puller 2871043, and Mity Vac™ Pressure Test Tool 2870975. Fuel pressure, hot coolant, rotating PVT parts, brake work, and vehicle support all require the safety precautions and exact factory procedures in the manual before repair begins.