2013-2015 Polaris Ranger 800 4X4 Crew 6X6 Fullsize Service Manual

Description

2013-2015 Polaris Ranger 800 4X4 Crew 6X6 Fullsize Service Manual

This is the full 2013-2015 Polaris Ranger 800 4X4, Crew, and 6X6 Fullsize Service Manual (Polaris publication 9925718), the workshop reference built for the entire full-size Ranger 800 platform across three model years and three body configurations. It is the manual that covers the 760cc H.O. twin-cylinder engine, the Bosch M17 EFI system, the Polaris PVT clutching, the 4X4 transmission with Hilliard front gearcase, the 6X6 mid and rear gearcases, the hydraulic four-wheel disc brakes with hand-actuated parking brake, and the electrical, steering and suspension systems that keep these machines working. Every procedure is written from the technician’s side of the machine, with torque figures, clearance limits, service specifications, exploded views and step-by-step repair sequences spread across eleven chapters of dedicated shop-level content.

File Details

• Manual type: Polaris Service Manual (full workshop reference)
• Brand: Polaris Industries
• Models covered: Ranger 800 4X4 / 4X4 EPS, Ranger Crew 800 / Crew 800 EPS, Ranger 6X6 800 Fullsize
• Model years: 2013, 2014, 2015
• Publication number: 9925718
• Print date: July 2014
• Language: English
• Page count: Approximately 467 pages
• File format: PDF
• Engine covered: 760cc H.O. Twin Cylinder, Liquid Cooled, 4-Cycle OHV, Electric Start
• Engine designation: 1204619 RGR800-13LK / 1204667 (Crew) / 1204668 (6X6)

Chapters Covered

Every chapter below is written for the Ranger 800 Fullsize platform, with procedures, service limits and torque tables integrated throughout:

• Chapter 1 — General Information: model number designation, engine designation, VIN designation, vehicle and engine serial locations, publication numbers, replacement keys, special tools, general specifications (4X4 / Crew / 6X6), conversion table, standard and metric bolt torque specification, SAE and metric tap/drill sizes, decimal equivalents
• Chapter 2 — Maintenance: periodic maintenance chart, break-in period, 25 / 50-100 / 100-300 hour intervals, grease lubrication points, service products and lubricants, fluid maintenance references, component quick reference, pre-ride inspection, shift cable adjustment, fuel system and air intake, engine oil and filter change, transmission and gearcase lubrication, cooling system, final drive and wheel service, electrical and ignition, steering, suspension, brakes
• Chapter 3 — Engine: crankcase exploded view, oil pump and cover, stator cover and starter, cylinder and cylinder head and piston exploded views, EFI sensors and valve cover, engine torque specifications, 800 EFI engine service specifications, cooling system, general engine service, oil pressure test and oil flow chart, engine removal and installation, cylinder head disassembly and inspection, valve service and reconditioning, cylinder and piston removal and inspection, piston ring installation, starter drive bendix, flywheel and stator removal, camshaft inspection, crankcase reassembly, oil pump priming, engine break-in, troubleshooting
• Chapter 4 — Electronic Fuel Injection: component locations, ECU operation and replacement, fuel pump test and replacement, fuel pressure regulator, fuel injectors, T-MAP sensor, crankshaft position sensor, idle air control, throttle position sensor, camshaft phase sensor, engine coolant temperature sensor, ignition coil tests, EFI diagnostics, instrument cluster trouble code display, Digital Wrench operation, engine controller reprogramming, Polaris Mobile Digital Wrench
• Chapter 5 — Body / Steering / Suspension: chassis and main frame exploded views (4X4 / Crew / 6X6), cab frame assembly, body exploded views, dash instruments and controls, hood, cargo box removal and installation, steering assembly, steering wheel and shaft service, power steering (EPS) unit removal and installation, front A-arms and ball joint service, mid/rear A-arms, rear stabilizer bar, shocks and springs, decal replacement
• Chapter 6 — Clutching: high altitude clutch chart, PVT system overview, drive clutch operation, driven clutch operation, PVT break-in, maintenance and inspection, PVT sealing and ducting, drive belt removal/inspection/installation, clutch center distance, clutch offset and alignment, drive clutch service and bushing service, driven clutch service, troubleshooting
• Chapter 7 — Final Drive: front bearing carrier inspection and bearing replacement, front drive shaft, front propshaft (4X4 / 6X6 / Crew), propshaft U-joint service, front gearcase (Centralized Hilliard) exploded view and AWD operation, mid/rear bearing carrier, mid/rear drive shaft, mid propshaft, mid gearcase disassembly and assembly, drive shaft and CV joint service, rear propshaft, rear gearcase (6X6) operation and overhaul
• Chapter 8 — Transmission 4X4: specifications, shift lever removal and installation, shift cable inspection and adjustment, transmission removal, disassembly, snorkel and output gear backlash procedure, transmission assembly, installation, troubleshooting, exploded view (Ranger 4X4 800 PN 1332961 / Ranger Crew 800 PN 1332977)
• Chapter 9 — Transmission 6X6: torque specifications, shift lever, shift cable, transmission removal, disassembly, assembly, installation, troubleshooting, exploded view (Ranger 6X6 800 PN 1332978)
• Chapter 10 — Brakes: general specifications, torque specifications, brake system service notes and troubleshooting, hydraulic brake system operation, brake system exploded view, master cylinder, foot brake pedal, brake bleeding and fluid change, parking brake (4X4/Crew and 6X6 exploded views, cable tension adjustment, caliper service), front brake pads and caliper service, front brake disc, rear brake pads and caliper service, rear brake disc, troubleshooting
• Chapter 11 — Electrical: switches and controls (brake light, headlamp, ignition key, AWD/2WD/Turf, parking brake, transmission gear position), vehicle speed sensor (4X4 and 6X6), rear differential solenoid, instrument cluster pinouts and operation, AWD coils, headlights, tail/brake light, cooling system, EFI diagnostics, fuel sender, fuse box and relay operation, charging system, battery service, starter system, Electronic Power Steering (EPS) troubleshooting

Between these eleven chapters, the Polaris Ranger 800 Fullsize Service Manual covers the platform front to back. It is not a condensed owner’s guide or an abridged third-party reprint; it is the multi-hundred-page workshop manual with the service specifications, torque sequences, exploded assemblies and diagnostic flow charts a working technician actually needs to keep a full-size Ranger 800 running through scheduled maintenance, component overhauls and fault diagnostics.

Model and Engine Coverage

The 2013-2015 Polaris Ranger 800 4X4 Crew 6X6 Fullsize Service Manual spans all three body platforms and their EPS variants across the three model years. Model numbers explicitly addressed in the manual include:

• 2013 Ranger 4X4 800 — R13TH76AG, AH, AK, AR, AZ (AGC, ARC, AZC)
• 2013 Ranger 4X4 800 EPS — R13TH76AG, AK, AZ (AKC, AZC)
• 2013 Ranger Crew 800 — R13WH76AG, AR
• 2013 Ranger Crew 800 EPS — R13WH76AH, AI
• 2013 Ranger 6X6 800 — R13HR76AG, AR
• 2014 Ranger 4X4 800 — R14TH76AA, AC, AR, AS
• 2014 Ranger 4X4 800 EPS — R14TH76AA, AS
• 2014 Ranger Crew 800 — R14WH76AA
• 2014 Ranger 6X6 800 — R14HR76AA, AJ
• 2015 Ranger 6X6 800 — R15HR76AA, AJ

Engine coverage is built around the 760cc H.O. Domestic Twin Cylinder, liquid cooled, 4-stroke with 80 x 76.5 mm bore and stroke and 9.78:1 compression ratio. The same engine platform is documented for the 4X4, Crew and 6X6 with their respective engine numbers (1204397, 1204619, 1204667, 1204668), and the manual distinguishes the systems that vary between configurations, such as the 6X6’s additional mid gearcase and rear gearcase, and the Crew’s front propshaft support bearing arrangement.

Technical Depth

Because the manual is a factory-issue service publication, its content is dense in the areas that matter for real repairs. Torque values are stated to specification with units in ft-lbs and Nm. Service limits for valve stems, cylinder taper, brake disc thickness, pad wear, clutch spring free length, camshaft oil clearance, connecting rod side clearance and crankshaft runout are all given. The EFI chapter includes resistance values for the TPS, IAC, CPS, cam phase sensor, ECT, ignition coil and injector harnesses, plus the diagnostic trouble code table for the ECU. The PVT section includes the shift weight and spring charts by altitude, clutch offset washers and bushing replacement procedures. The transmission chapters include the silent chain service limit and the output gear backlash setting procedure. The electrical chapter includes EPS diagnostic flow charts and the charging system alternator resistance and AC voltage tests.

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What This Manual Enables You To Do

With this manual in hand, you can carry out the full range of scheduled service on a 2013-2015 Ranger 800 Fullsize — engine oil and filter changes, transmission and gearcase lubricant changes, coolant service and bleeding, brake pad replacement and burnishing, air filter and PVT intake service, spark plug service, valve clearance work, and the periodic torque checks the maintenance chart prescribes. Beyond routine maintenance, the manual supports component-level repairs: cylinder head removal and valve seat reconditioning, piston and ring replacement, camshaft and lifter inspection, water pump and mechanical seal replacement, crankshaft and balance shaft removal, oil pump disassembly, drive and driven clutch rebuild, CV joint boot and joint replacement, front gearcase overhaul, mid and rear gearcase overhaul, transmission disassembly with shift fork and shift drum service, and EPS unit replacement with proper diagnostic verification.

On the diagnostics side, the manual gives you the reference values needed to test and isolate faults — the TPS adjustment procedure with both the TPS Tester and Digital Wrench, the CPS resistance test, IAC resistance readings, ECT temperature/resistance chart, fuel pump pressure test and fuel sender resistance values, fan control circuit bypass test, charging system break-even test, voltage drop test for the starter circuit, and the full diagnostic trouble code table. For a technician, the difference between a vague repair and a correct repair is having the right specifications and the right sequence, and that is exactly what this document provides.

Instant PDF Delivery

The 2013-2015 Polaris Ranger 800 4X4 Crew 6X6 Fullsize Service Manual is delivered as an instant-download PDF. There is no shipping, no waiting, and no physical book to keep track of in the shop. Once the purchase is complete, the file is available immediately and can be opened on any device — laptop, tablet, or smartphone — so you can pull it up at the bench, in the garage, or out in the field. Pages can be printed for the job at hand or kept on screen for quick reference while you work. Whether you are a Polaris Master Service Dealer technician following the manual’s own service procedures, an independent shop working on a customer’s Ranger 800, or an owner taking on your own maintenance and repairs, this manual is the reference that keeps the work grounded in the factory’s own specifications.