2013-2015 Polaris Ranger 800 4x4 Crew 6x6 UTV Utility Vehicle Service & Repair 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 in electronic format at www.polarisdealers.com. This Service Manual is designed primarily for use by certified Polaris Master Service Dealer ® technicians in a properly equipped shop and should be kept available for reference. 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. Technicians should 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 dealer for service. We value your input and appreciate any assistance you can provide in helping make these publications more useful. Please provide any feedback you may have regarding this manual. Authorized dealers can submit feedback using 'Ask Polaris'. Click on 'Ask Polaris', and then click on 'Service Manual / Service Literature Question'. Consumers, please provide your feedback in writing to: Polaris Industries Inc. ATTN: Service Publications Department, 2100 Hwy 55, Medina, MN 55340. Publication Printed July 2014 (PN 9925718) 2013–2015 RANGER 800 4X4 / CREW / 6X6 FULLSIZE

UNDERSTANDING 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 PRODUCT(S) 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 ofTextron 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 FUEL SYSTEM - GENERAL 5 BODY / STEERING / SUSPENSION 6 CLUTCHING 7 FINAL DRIVE 8 TRANSMISSION - 4X4 9 TRANSMISSION - 6X6 10 BRAKES 11 ELECTRICAL

1 1.1 9925718 - 2013–2015 RANGER 800 4X4 / CREW / 6X6 FULLSIZE Service Manual © Copyright 2014 Polaris Industries 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............................................ 1.4 VEHICLE INFORMATION ................................................................................ 1.5 PUBLICATION NUMBERS ......................................................................... 1.5 REPLACEMENT KEYS............................................................................. 1.5 SPECIAL TOOLS .................................................................................. 1.6 GENERAL SPECIFICATIONS ............................................................................ 1.7 MODEL: 2013–2014 RANGER 4X4 800 / EPS ...................................................... 1.7 MODEL: 2013–2014 RANGER 4X4 800 / EPS ...................................................... 1.8 MODEL: 2013–2014 RANGER CREW 800 / EPS ................................................... 1.9 MODEL: 2013–2014 RANGER CREW 800 / EPS .................................................. 1.10 MODEL: 2013–2015 RANGER 6X6 800 ........................................................... 1.11 MODEL: 2013–2015 RANGER 6X6 800 ........................................................... 1.12 MISC. SPECIFICATIONS AND CHARTS ............................................................... 1.13 CONVERSION TABLE ............................................................................ 1.13 STANDARD BOLT TORQUE SPECIFICATION..................................................... 1.14 METRIC BOLT TORQUE SPECIFICATION ........................................................ 1.14 SAE TAP / DRILL SIZES .......................................................................... 1.15 METRIC TAP / DRILL SIZES ...................................................................... 1.15 DECIMAL EQUIVALENTS ......................................................................... 1.16

1.2 9925718 - 2013–2015 RANGER 800 4X4 / CREW / 6X6 FULLSIZE Service Manual © Copyright 2014 Polaris Industries Inc. VEHICLE IDENTIFICATION Model Number Designation 2014 Example: R14WH76AA GROUP MODEL YEAR CHASSIS DRIVE- LINE ENGINE / MOTOR CODE CATEGORY OPTION REGION 1st 2nd 3rd 4th* 5th* 6th* 7th* 8th* 9th** 10th R 1 4 W H 7 6 A A * = 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. 2015 Example: A15SEA57AD GROUP MODEL YEAR MAKE / CHASSIS CODE ENGINE CODE REGION OPTION 1st 2nd 3rd 4th* 5th* 6th* 7th* 8th* 9th 10th** A 1 5 S E A 5 7 A D * = digits that would transfer to 17 digit VIN and are used in digits 4-8 respectively ** = 10th digit will be used on color/featured versions of models (not including the base) First 3 digits and 10th 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 1204619 RGR800-13LK Twin Cylinder, Liquid Cooled, 4-Cycle OHV, Electric Start Vehicle Identification Number (VIN) Designation 2014 Example: 4XAWH76A6E3000000 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 6 A 6 E 3 0 0 0 0 0 0 * Model Year: A = 2010; B = 2011; C = 2012; D = 2013; E = 2014 GENERAL INFORMATION

1.3 9925718 - 2013–2015 RANGER 800 4X4 / CREW / 6X6 FULLSIZE Service Manual © Copyright 2014 Polaris Industries Inc. 2015 Example: 4XASEA570F3000000 WORLD MFG. ID VEHICLE DESCRIPTORS VEHICLE IDENTIFIERS MAKE / CHASSIS CATEGORY ENGINE SIZE ENGINE MODIFIER 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 S E A 5 7 0 F 3 0 0 0 0 0 0 * Model Year: A = 2010; B = 2011; C = 2012; D = 2013; E = 2014; F = 2015 GENERAL INFORMATION 1

1.4 9925718 - 2013–2015 RANGER 800 4X4 / CREW / 6X6 FULLSIZE Service Manual © Copyright 2014 Polaris Industries 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). GENERAL INFORMATION

2013-2015 Polaris Ranger 800 4x4 Crew 6x6 UTV Utility Vehicle Service & Repair Manual

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