2013 Polaris Ranger 4X4 800 Factory Service & Work Shop Manual

GENERAL INFORMATION 1.1 CHAPTER 1 GENERAL INFORMATION 1 9923964 - 2013 RANGER 800 4X4 / CREW / 6X6 Service Manual © Copyright 2012 Polaris Sales Inc. VEHICLE IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 MODEL NUMBER DESIGNATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 ENGINE DESIGNATION NUMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 VEHICLE INDENTIFICATION 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 GENERAL: 2013 RANGER 4X4 800 / EPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6 DETAILED: 2013 RANGER 4X4 800 / EPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.7 GENERAL: 2013 RANGER CREW 800 / EPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8 DETAILED: 2013 RANGER CREW 800 / EPS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.9 GENERAL: 2013 RANGER 6X6 800 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.10 DETAILED: 2013 RANGER 6X6 800 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.11 MISC. SPECIFICATIONS AND CHARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.12 CONVERSION TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.12 STANDARD BOLT TORQUE SPECIFICATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.13 METRIC BOLT TORQUE SPECIFICATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.13 SAE TAP / DRILL SIZES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.14 METRIC TAP / DRILL SIZES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.14 DECIMAL EQUIVALENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.14 PRELIMINARY VERSION

1.2 GENERAL INFORMATION 9923964 - 2013 RANGER 800 4X4 / CREW / 6X6 Service Manual © Copyright 2012 Polaris Sales Inc. VEHICLE IDENTIFICATION Model Number Designation Example: R13WH7EAH Engine Designation Number 1204619 RGR800-13LK......................................................... Twin Cylinder, Liquid Cooled, 4-Cycle OHV, Electric Start Vehicle Identification Number (VIN) Designation Example: 4XAWH7EA6D2000000 GROUP MODEL YEAR CHASSIS DRIVELINE ENGINE CATEGORY OPTION REGION 1st digit 2/3rd digit 4th digit* 5th digit* 6th digit* 7th digit* 8th digit 9th digit** 10th digit A = ATV R = RANGER 11 12 13 C = Sportsman 6x6 D = Sportsman Tour E = Trail Boss F = Sportsman Youth G = Sport H = RANGER 6x6 J = RZR XP K = Sport Youth M = Sportsman N = Trail Blazer P = Phoenix R = RANGER Midsize S = RZR T = Sportsman X2 U = RANGER Fullsize V = RZR W = Multi-pass RGR X = Multi-pass RZR Z = Sportsman XP A = 2x4 Chain B = 2x4 Shaft C = 4x4 AC Drive E = 4x4 Shaft / IRS G = 4x4 Chain rear / shaft front H = 4x4 Shaft / IRS J = 2x4 Swing arm Manual N = 4x4 Shaft ADC P = 2x4 / IRS Manual R = 6x6 Shaft / IRS T = 4x4 Shaft / Trailing Arm X = 4x4 Shaft EBS Displacement in cc divided by 10 and rounded to two digits (i.e. 50 = 498cc) - - - - - - - - - - - - For electric vehicles 08 = 48 Volt 12 = 72 Volt A = ORV D = Diesel E = EU On-road F = INT’L G = EV L = LSV M = Military S = Scandinavian V = EU On-road C = Calif. - - OR - - 5 = 550 6 = 570 7 = 760 8 = 850 9 = 875 E = EPS D = Diesel F = D + E * = 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. 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 5 6 7 8 9 10 11 12 13 14 15 16 17 4 X A W H 7 E A 6 D 2 0 0 0 0 0 0 * Model Year: A = 2010; B = 2011; C = 2012; D = 2013 PRELIMINARY VERSION

1.3 GENERAL INFORMATION 1 9923964 - 2013 RANGER 800 4X4 / CREW / 6X6 Service Manual © Copyright 2012 Polaris Sales Inc. Vehicle and Engine Serial Number Locations Whenever corresponding about a Polaris RANGER utility vehicle, be sure to refer to the vehicle identification number (VIN) and the engine model number and serial number. The VIN can be found stamped on the lower frame rail on the front LH side of the vehicle (see Figure 1-1). The engine model and serial number can be found on a decal applied to the side of the engine’s cylinder (see Figure 1-2). Figure 1-1 VIN Figure 1-2 Engine Serial Number PRELIMINARY VERSION

1.4 GENERAL INFORMATION 9923964 - 2013 RANGER 800 4X4 / CREW / 6X6 Service Manual © Copyright 2012 Polaris Sales Inc. VEHICLE INFORMATION Publication Numbers (CA): California 50-State Models 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. Model Model No. Owner’s Manual PN Parts Manual PN 2013 RANGER 4X4 800 (CA) R13TH76AG, AH, AK, AR, AZ (AGC, ARC, AZC) 9924160 9924097 2013 RANGER 4X4 800 EPS (CA) R13TH7EAG, AK, AZ (AKC, AZC) 9924160 9924097 2013 RANGER CREW 800 R13WH76AG, AR 9924160 9924210 2013 RANGER CREW 800 EPS R13WH7EAH, AI 9924160 9924210 2013 RANGER 6X6 800 R13HR76AG, AR 9924160 9924092 Series# Part Number 20 4010278 21 4010278 22 4010321 23 4010321 27 4010321 28 4010321 31 4110141 32 4110148 67 4010278 68 4010278 Key Series Number KEY COVER P/N 5533534 PRELIMINARY VERSION

1.5 GENERAL INFORMATION 1 9923964 - 2013 RANGER 800 4X4 / CREW / 6X6 Service Manual © Copyright 2012 Polaris Sales Inc. SPECIAL TOOLS Special tools may be required while servicing this vehicle. Some of the tools listed or depicted are mandatory, while other tools may be substituted with a similar tool, if available. Polaris recommends the use of Polaris Special Tools when servicing any Polaris product. Dealers may order special tools through Polaris’ official tool supplier, SPX Corporation, by phone at 1-800-328-6657 or on-line at http://polaris.spx.com/ . Select “SPX Website - Tools, diagnostics” from the “Service and Warranty” drop down menu PRELIMINARY VERSION

1.6 GENERAL INFORMATION 9923964 - 2013 RANGER 800 4X4 / CREW / 6X6 Service Manual © Copyright 2012 Polaris Sales Inc. GENERAL SPECIFICATIONS MODEL: 2013 RANGER 4X4 800 / EPS MODEL NUMBER: R13TH76AG, AGC, AH, AK, AR, ARC, AZ, AZC MODEL NUMBER: R13TH7EAG, AK, AKC, AZ, AZC (EPS MODELS) ENGINE NUMBER: 1204667 Category Dimension / Capacity Length 114 in. / 289.6 cm Width (cargo box) 60 in. / 152.4 cm Width (tires) 58 in. / 147.3 cm Height 76 in. / 193 cm Wheel Base 76 in. / 193 cm Ground Clearance 12 in. / 30.5 cm Turning Radius 158 in. / 401.3 cm Dry Weight STD: 1237 lbs. / 561 kg EPS: 1257 lbs. / 570 kg Cargo Box Capacity 49-State: 1000 lbs. / 454 kg 50-State: 600 lbs. / 272 kg Cargo Box Dimensions (inside dimensions) 36.5 x 54 x 11.5 in. (93 x 137 x 29 cm) Vehicle Payload (includes weight of operator, passenger, cargo and accessories) 49-State: 1500 lbs. / 681 kg 50-State: 1100 lbs. / 499 kg Hitch Towing Capacity 2000 lbs. / 907 kg Hitch Tongue Capacity 150 lbs. / 68 kg PRELIMINARY VERSION

1.7 GENERAL INFORMATION 1 9923964 - 2013 RANGER 800 4X4 / CREW / 6X6 Service Manual © Copyright 2012 Polaris Sales Inc. MODEL: 2013 RANGER 4X4 800 / EPS 4X4 800 MODELS: R13TH76AG,AGC,AH,AK,AR,ARC,AZ,AZC 4X4 800 EPS MODELS: R13TH7EAG,AK,AKC,AZ,AZC ENGINE NUMBER: 1204667 CLUTCH CHART (B) = Bushed Shift Weight Engine Platform High Output Domestic Twin Cyl, Liquid Cooled, 4-Stroke Engine Number 1204397 Engine Displacement 760 cc H.O. Number of Cylinders 2 Bore & Stroke (mm) 80 x 76.5 mm Compression Ratio 9.78:1 Compression Pressure 165-185 psi Engine Idle Speed 1250 ± 100 RPM Engine Max Operating RPM 6500 RPM Lubrication Pressurized Wet Sump Oil Requirements PS-4 Plus or Extreme Duty Oil Capacity 2 qts. (1.9 L) Coolant Capacity 3.25 qts. (3.1 L) Overheat Warning Instrument Cluster Indicator Exhaust System 2 to 1 Canister Style Fuel System Fuel System Type Bosch M17 EFI Fuel Delivery Electronic Fuel Pump (in tank) Fuel Pressure 58 +/- 2 psi (400 +/- 14 kPa) Fuel Capacity 9 gal. (34 L) Fuel Requirement 87 Octane (minimum) Electrical Alternator Max Output 500 Watts @ 3000 RPM Headlights 2 - Halogen: Low 55 W / High 60 W Tail Lights 0.3 Watts / L.E.D. x 2 Brake Lights 3.1 Watts / L.E.D. x 2 Starting System Electric Start Ignition System Bosch M17 (ECU Controlled) Ignition Timing (Variable) 3° - 10° BTDC @ 1200 RPM Spark plug / Gap RC7YC3 / .035 in. (0.9 mm) Battery / Model / Amp Hr Yuasa YB30L-B / 30 Amp Hr. / 12 Volt Instrumentation Multifunction Instrument Cluster DC Outlets (2) - Standard Relays Chassis / ECM / Fan / Fuel Pump EPS / Rear Diff Circuit Breaker Fan Motor: 20 Amp Fuses Lights / ECM / Drive / Acc: 20 Amp Fuel Pump: 10 Amp EPS: 30 Amp Drivetrain Transmission Type Polaris Automatic PVT Shift Type In Line Shift - H / L / N / R Transmission Gear Ratio: High Low Reverse Front: 3.60:1 / Rear: 11.18:1 Front: 7.70:1 / Rear: 23.91:1 Front: 7.00:1 / Rear: 21.74:1 Front Gearcase Lubricant Requirements Demand Drive Plus 9 oz. (265 ml) Transmission Lubricant Requirements AGL Plus 33.8 oz. (1000 ml) Clutch Type Standard PVT Drive Belt 3211133 Clutch Center Distance 10.05” (255 mm) Steering / Suspension Toe Out 1/8 - 1/4 in. (3.2 - 6.35 mm) Front Suspension Dual A-arm Front Travel 9.6 in. (24.4 cm) Rear Suspension Independent (IRS) Rear Travel 9 in. (22.9 cm) Shock Preload Adjustment Cam Adjustment Wheels / Brakes Front Wheel Type / Size Steel / 12 x 6 Aluminum / 12 x 6 Rear Wheel Type / Size Steel / 12 x 8 Aluminum / 12 x 8 Front Tire Make / Model / Size Carlisle / AT489 / 25 x 10 R12 Carlisle / PXT / 26 x 9 R12 Rear Tire Make / Model / Size Carlisle / AT489 / 25 x 11 R12 Carlisle / PXT / 26 x 11 R12 Tire Air Pressure 8-12 psi (69 kPa) Brake System 4 Wheel Hydraulic Disc Brake Fluid DOT 4 Parking Brake Hand Actuated (in dash) Altitude Shift Weight Drive Spring Driven Spring Meters (Feet) 0-1500 (0-5000) 23-62 (5632337) Black (7043594) Blk / Almd (7043167) 1500-3700 (5000 - 12000) 23-58 (B) (1322911) Black (7043594) Blk / Almd (7043167) PRELIMINARY VERSION

1.8 GENERAL INFORMATION 9923964 - 2013 RANGER 800 4X4 / CREW / 6X6 Service Manual © Copyright 2012 Polaris Sales Inc. MODEL: 2013 RANGER CREW 800 / EPS MODEL NUMBER: R13WH76AG, AR MODEL NUMBER: R13WH7EAH, AI (EPS MODELS) ENGINE NUMBER: 1204667 Category Dimension / Capacity Length 145 in. / 386 cm Width (cargo box) 60 in. / 152.4 cm Width (tires) 58 in. / 147.3 cm Height 76 in. / 193 cm Wheel Base 108 in. / 274 cm Ground Clearance 11.5 in. / 29 cm Turning Radius 255 in. / 648 cm Dry Weight STD: 1495 lbs. / 678 kg EPS: 1515 lbs. / 687 kg Cargo Box Capacity 1000 lbs. / 454 kg Cargo Box Dimensions (inside dimensions) 36.5 x 54 x 11.5 in. (93 x 137 x 29 cm) Vehicle Payload (includes weight of operator, passengers, cargo and accessories) 1750 lbs. / 794 kg Hitch Towing Capacity 2000 lbs. / 907 kg Hitch Tongue Capacity 150 lbs. / 68 kg PRELIMINARY VERSION

1.9 GENERAL INFORMATION 1 9923964 - 2013 RANGER 800 4X4 / CREW / 6X6 Service Manual © Copyright 2012 Polaris Sales Inc. MODEL: 2013 RANGER CREW 800 / EPS CREW 800 MODEL: R13WH76AG, AR CREW 800 EPS MODELS: R13WH7EAH, AI ENGINE NUMBER: 1204667 CLUTCH CHART (B) = Bushed Shift Weight Engine Platform Domestic Twin Cylinder, Liquid Cooled, 4-Stroke Engine Number 1204667 Engine Displacement 760 cc Number of Cylinders 2 Bore & Stroke (mm) 80 x 76.5 mm Compression Ratio 9.78:1 Compression Pressure 165-185 psi Engine Idle Speed 1250 ± 100 RPM Engine Max Operating RPM 6500 RPM Lubrication Pressurized Wet Sump Oil Requirements PS-4 Plus or Extreme Duty Oil Capacity 2 qts. (1.9 L) Coolant Capacity 6.4 qts. (6 L) Overheat Warning Instrument Cluster Indicator Exhaust System 2 to 1 Canister Style Fuel System Fuel System Type Bosch M17 EFI Fuel Delivery Electronic Fuel Pump (in tank) Fuel Pressure 58 +/- 2 psi (400 +/- 14 kPa) Fuel Capacity 9 gal. (34 L) Fuel Requirement 87 Octane (minimum) Electrical Alternator Max Output 500 Watts @ 3000 RPM Headlights 2 - Halogen: Low 55 W / High 60 W Tail Lights 0.3 Watts / L.E.D. x 2 Brake Lights 3.1 Watts / L.E.D. x 2 Starting System Electric Start Ignition System Bosch M17 (ECU Controlled) Ignition Timing (Variable) 3° - 10° BTDC @ 1200 RPM Spark plug / Gap RC7YC3 / .035 in. (0.9 mm) Battery / Model / Amp Hr Yuasa YB30L-B / 30 Amp Hr. / 12 Volt Instrumentation Multifunction Instrument Cluster DC Outlets (2) - Front; (1) - Rear Relays Chassis / ECM / Fan / Fuel Pump EPS / Rear Diff Circuit Breaker Fan Motor: 20 Amp Fuses Lights / ECM / Drive / Acc: 20 Amp Fuel Pump: 10 Amp EPS: 30 Amp Drivetrain Transmission Type Polaris Automatic PVT Shift Type In Line Shift - H / L / N / R Transmission Gear Ratio: High Low Reverse Front: 4.63:1 / Rear: 14.37:1 Front: 7.70:1 / Rear: 23.91:1 Front: 7.00:1 / Rear: 21.74:1 Front Gearcase Lubricant Requirements Demand Drive Plus 9 oz. (265 ml) Transmission Lubricant Requirements AGL Plus 33.8 oz. (1000 ml) Clutch Type Standard PVT Drive Belt 3211133 Clutch Center Distance 10.05” (255 mm) Steering / Suspension Toe Out 1/8 - 1/4 in. (3.2 - 6.35 mm) Front Suspension Dual A-arm Front Travel 9.6 in. (24.4 cm) Rear Suspension Independent (IRS) Rear Travel 9 in. (22.9 cm) Shock Preload Adjustment Cam Adjustment Wheels / Brakes Front Wheel Type / Size Steel / 12 x 6 Aluminum / 12 x 6 Rear Wheel Type / Size Steel / 12 x 8 Aluminum / 12 x 8 Front Tire Make / Model / Size Carlisle / PXT / 26 x 9 R12 Rear Tire Make / Model / Size Carlisle / PXT / 26 x 11 R12 Tire Air Pressure Front: 12 psi (83 kPa) Rear: 16 psi (110 kPa) Brake System Type 4 Wheel Hydraulic Disc Brake Fluid DOT 4 Parking Brake Hand Actuated (in dash) Altitude Shift Weight Drive Spring Driven Spring Meters (Feet) 0-1500 (0-5000) 23-62 (5632337) Black (7043594) Blk / Almd (7043167) 1500-3700 (5000 - 12000) 23-58 (B) (1322911) Black (7043594) Blk / Almd (7043167) PRELIMINARY VERSION

1.10 GENERAL INFORMATION 9923964 - 2013 RANGER 800 4X4 / CREW / 6X6 Service Manual © Copyright 2012 Polaris Sales Inc. MODEL: 2013 RANGER 6X6 800 MODEL NUMBER: R13HR76AG, AR ENGINE NUMBER: 1204668 Category Dimension / Capacity Length 137 in. / 348 cm Width (cargo box) 60 in. / 152.4 cm Width (tires) 58 in. / 147.3 cm Height 76 in. / 193 cm Wheel Base 105 in. / 267 cm Ground Clearance 12 in. / 30.5 cm Turning Radius 243 in. / 617 cm Dry Weight 1551 lbs. / 703.5 kg Gross Vehicle Weight 3701 lbs. / 1679 kg Storage Box Capacity 250 lbs. / 113 kg Cargo Box Capacity 1250 lbs. / 567 kg Cargo Box Dimensions (inside dimensions) 42.5 x 54 x 11.5 in. (108 x 137 x 29 cm) Vehicle Payload (includes weight of operator, passenger, cargo and accessories) 2000 lbs. / 907 kg Hitch Towing Capacity 2000 lbs. / 907 kg Hitch Tongue Capacity 150 lbs. / 68 kg PRELIMINARY VERSION

2013 Polaris Ranger 4X4 800 Factory Service & Work Shop Manual

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