Description
This Official Polaris Ranger 800 Midsize Factory Service Manual provides detailed service information, step-by-step repair instruction and maintenance specifications for 2013-2014 Polaris Ranger 800 Midsize ATVs.
The information printed within this 2013-2014 Polaris Ranger 800 Midsize Service Manual includes the latest product information at time of print. This 2013-2014 Polaris Ranger 800 Midsize 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 2013-2014 Polaris Ranger 800 Midsize Service 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 2013-2014 Polaris Ranger 800 Midsize Service Manual and be familiar with the service procedures before starting any repair. Certain procedures require the use of special tods. 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 2013-2014 Polaris Ranger 800 Midsize Service Manual, contact an authorized dealer for service.
Table of Contents
General Information
Maintenance
Engine
Fuel System – General
Body Steering Suspension
Clutching
Final Drive
Transmission
Brakes
Electrical
Service Manual Index of Topics
A
Air Filter Service
Air Intake Inspection, Engine
Air Intake Inspection, PVT
All Wheel Drive (AWD) Coil
Authorization Key
Authorization, Reflash
AWD, Diagnosis
AWD, Operation
B
Balance Shaft Gear, Removal
Ball Joint, Replacement
Battery Charging
Battery Fluid Level
Battery Installation
Battery Maintenance
Battery Removal
Battery Service
Battery Storage
Battery Terminal Block
Body Component Removal
Brake Disc, Front
Brake Disc, Rear
Brake Fluid Inspection
Brake Hose and Fitting Inspection
Brake Pad and Disc Inspection
Brake Pads, Front
Brake Pads, Rear
Brake Pedal, Installation
Brake Pedal, Removal
Brake System, Bleeding
Brake System, Operation
Brake System, Troubleshooting
Break-In Period
Breather Hose Inspection
c
Cab Frame, Exploded View / Assembly
Caliper, Front
Caliper, Rear
Cam Gear, Reassembly
Cam Gear, Removal
Camshaft Phase Sensor
Cargo Box, Installation
Cargo Box, Removal
Charging System
Charging System, Alternator Tests
Circuit Breaker
Clutch Offset/Alignment
Combustion Chamber
Communication Problems, Digital Wrench
Compression Test
Connector, Digital Wrench
Conversion Table
Coolant Level Inspection
Coolant Strength and Type
Cooling System Bleeding Procedure
Cooling System Hoses
Cooling System Specifications
Cooling System, Troubleshooting
Crankshaft Gear, Removal
Crankshaft Position Sensor (CPS)
CV Shaft Boot Inspection
Cylinder Head Assembly
Cylinder Head Assembly Exploded View
Cylinder Head Disassembly
Cylinder Honing To De-glaze
Cylinder Inspection
D
Dash
Dash / Hood, Exploded View
Dash Instruments and Controls
Decal Replacement
Decimal Equivalent Chart
Diagnostic Codes, Instrument Cluster
Diagnostic Trouble Code Table
Digital Wrench Communication Errors
Digital Wrench Diagnostic Connector
Digital Wrench Diagnostic Software, Overview
Digital Wrench Guided
Digital Wrench Versions
Digital Wrench, Engine Controller Reprogramming
Digital Wrench, Serial Number Location
Digital Wrench, Updates
Digital Wrench, Version and Update ID
Drive Belt, Inspection
Drive Belt, Installation
Drive Belt, Removal
Drive Clutch, Assembly
Drive Clutch, Bushing Service
Drive Clutch, Button to Tower Clearance
Drive Clutch, Cover Bushing Removal /
Installation
Drive Clutch, Disassembly
Drive Clutch, Exploded View
Drive Clutch, Moveable Sheave Inspection
Drive Clutch, Operation
Drive Clutch, Service
Drive Clutch, Shift Weights
Drive Clutch, Spider Removal
Drive Clutch, Spring
Drive Shaft / CV Joint, Handling Tips
Driven Clutch, Assembly
Driven Clutch, Disassembly / Inspection
Driven Clutch, Exploded View
Driven Clutch, Operation
Driven Clutch, Service
E
ECU Replacement
EFI Operation Overview
EFI Priming / Starting Procedure
EFI System, Exploded View
EFI, Component Locations
EFI, Diagnostic Trouble Codes
EFI, Service Notes
EFI, Troubleshooting
Electrical, Cooling System Breakout Diagram
Electronic Control Unit (ECU)
Engine Coolant Temperature Sensor (ECT)
Engine Cooling System
Engine Exploded Views
Engine Installation Notes
Engine Lubrication
Engine Oil and Filter Change
Engine Oil Level
Engine Oil Priming
Engine Oil Pump Installation
Engine Removal
Engine Service Specifications
Engine Temperature Sensor Replacement
Engine Temperature Sensor Test
Engine Torque Specifications
Engine, Accessible Components
Engine, Balance Shaft Removal
Engine, Camshaft Inspection
Engine, Camshaft Installation
Engine, Crankcase Assembly
Engine, Crankshaft Gear Removal
Engine, Crankshaft Installation
Engine, Cylinder Head Assembly
Engine, Cylinder Head Inspection
Engine, Cylinder Head Removal
Engine, Cylinder Head Warp
Engine, Cylinder Honing
Engine, Cylinder Inspection
Engine, Cylinder Installation
Engine, Cylinder Removal
Engine, Flywheel / Stator Installation
Engine, Flywheel / Stator Removal
Engine, Gear(s) Removal
Engine, Gears, Installation
Engine, Oil Flow Chart
Engine, Oil Pressure Test
Engine, Oil Pump Removal
Engine, Piston Installation
Engine, Piston Removal, Inspection
Engine, Piston Ring Installed Gap
Engine, Piston to Cylinder Clearance
Engine, Piston to Rod Clearance
Engine, Push Rod Inspection
Engine, Rocker Arm Inspection
Engine, Starter Drive Removal
Engine, Stator Gear Cover Seal(s) Installation
Engine, Stator Installation
Engine, Troubleshooting
Engine, Valve Inspection
Engine, Valve Lifter Removal, Inspection
Engine, Valve Seal/Spring Service
Engine, Valve Sealing Test
Engine, Valve Seat Reconditioning
Exhaust Pipe
F
Fan Control Circuit Bypass Test
Fan Control Circuit Operation
Floor
Floor, Exploded View
Flywheel / Stator Removal
Flywheel, Removal
Front A-arm, Replacement
Front Bumper
Front Drive Shaft, Installation
Front Drive Shaft, Removal
Front Fascia, Exploded View
Front Fenders
Front Fenders, Exploded View
Front Gearcase – Ring Gear Backlash Adjustment
Front Gearcase Lubrication
Front Gearcase, Assembly / Inspection
Front Gearcase, Centralized Hilliard
Front Gearcase, Coil Resistance
Front Gearcase, Disassembly / Inspection
Front Gearcase, Exploded View
Front Gearcase, Installation
Front Gearcase, Removal
Front Hub
Front Propshaft, Removal
Front Strut, Cartridge Replacement
Front Strut, Exploded View
Fuel Filter
Fuel Injectors
Fuel Lines
Fuel Pressure Regulator
Fuel Pump Assembly
Fuel Pump Replacement
Fuel Pump Test
Fuel Sender Test
Fuel System
Fuel System Diagnostics
Digital Wrench Guided
Fuel Tank, Exploded View
Fuel Tank, Removal
Fuses
G
Gear/Stator Housing Seal Replacement
General Specifications, Brakes
Grease Points
Guided Diagnostics
H
Head Lights
High Altitude Clutch Charts
Hood
Hood / Dash, Exploded View
I
Idle Air Control (IAC)
Ignition Coil
Ignition Coil Replacement
ignition Coil Test
Inner Plunging Joint / Boot Replacement
Instrument Cluster
Instrument Cluster, Installation
Instrument Cluster, Removal
K
Key, Reprogramming Authorization
Keys, Replacement
L
Leakdown Test
Lower Seat Base
Lubrication Grease Points
Lubrication, Stabilizer bar Pivot
M
Maintenance Quick Reference Chart
Maintenance, Brake System
Maintenance, Cooling System
Maintenance, Electrical and Ignition
Maintenance, Engine
Maintenance, Final Drive
Maintenance, Fuel System
Maintenance, General Vehicle Inspection
Maintenance, References
Maintenance, Service Products and Lubricants
Maintenance, Steering
Maintenance, Transmission and Gearcases
Master Cylinder, Installation
Master Cylinder, Removal
Metric Bolt Torque Specification
Model Number
O
Oil Pump Priming
Oil Pump, Disassembly
Oil Pump, Reassembly
Oil Pump, Removal
Outer CV Joint / Boot Replacement
P
Periodic Maintenance Chart
Piston Ring Installed Gap
Piston to Cylinder Clearance
Piston to Rod Inspection
Power Steering Unit, Installation
Power Steering Unit, Removal
Pre-Ride / Daily Inspection
Propshaft, U-Joint Service
Publication Numbers
PVT System, Assembly
PVT System, Disassembly
PVT System, Maintenance
PVT System, Overview
PVT System, Service
PVT Troubleshooting
R
Radiator
Rear A-arm, Replacement
Rear Bearing Carrier
Rear Cargo Box, Exploded View
Rear Drive Shaft, Installation
Rear Drive Shaft, Removal
Rear Fenders, Exploded View
Rear Stabilizer Bar
Reflash Authorization
Regulator / Rectifier Location
Relays
Replacement Keys
Reprogramming Authorization
s
Seat Assembly, Exploded View
Seat Belts
Shift Cable, Adjustment
Shift Cable, Inspection
Shift Lever, Installation
Shift Lever, Removal
Shocks and Springs
Software Version
Solenoid, Rear Differential
Spark Plug Service
Special Tool, Cam Gear Installation Kit
Special Tools
Special Tools, Body/Steering/Suspension
Special Tools, Brakes
Special Tools, Clutching
Special Tools, EFI
Special Tools, Electrical
Special Tools, Engine
Special Tools, Final Drive
Special Tools, Ordering
Special Tools, Transmission
Specification, Balance Shaft Gear Bolt Torque
Specification, Cam Lobe Height
Specification, Cam Thrust Plate Fastener Torque
Specification, Camshaft Gear Bolt Torque
Specification, Coolant Sensor Resistance
Specification, Cylinder Head Warp
Specification, Cylinder Taper Limit
Specification, Cylinder Warp Limit
Specification, Oil Pump Bolt Torque
Specification, Oil Pump Rotor Clearance
Specification, Transmission Silent Chain Length
Specification, Valve Seat Contact Width
Specification, Vaive Spring Free Length
Specification, Valve Stem Diameter
Specification, Valve Stem Guide I D
Specification, Wheel Toe-Out
Specifications, Cam Shaft
Specifications, Cooling System
Specifications, Crankcase Fastener Torque
Specifications, Engine
Specifications, Engine Lubrication
Specifications, Engine Oil Pressure
Specifications, General
Specifications, Oil Baffle Bolt Torque
Specifications, Oil Pick-Up Bolt Torque
Speedometer
Stabilizer bar Pivot Lubrication
Standard Bolt Torque Specification
Starter Drive Removal
Starter Motor, Reassembly / Installation
Starter Motor, Removal
Starter Solenoid, Operation
Starter Solenoid, Test
Starter System, Troubleshooting
Starting System Testing Flow Chart
Stator, Removal
Steering
Steering Shaft, Bearing Replacement
Steering Shaft, Removal (Non-EPS)
Steering Wheel Removal (EPS)
Steering Wheel Removal (Non-EPS)
Steering, Exploded View
Suspension Inspection
Suspension Lubrication Points
Suspension Spring Preload Adjustment
Switch AWD/2WD/TURF
Switch, Brake Light
Switch, Gear Position
Switch, ignition
T
T-MAP Sensor
Tail Lights
Tap/Drill Sizes
Throttle Freeplay Adjustment
Throttle Pedal Inspection
Throttle Position Sensor (TPS)
Tie Rod End and Steering Inspection
Timing Gear Mark Alignment
Tire Inspection
Tire Pressure
Toe Adjustment
Torque Specification, Wheel and Hub
Torque Specifications – Engine
Torque Specifications, Body/Steering/Suspension
Torque Specifications, Brakes
Torque Specifications, Clutching
Torque Specifications, Final Drive
Torque Specifications, Transmission
Transmission Lubrication
Transmission, Assembly
Transmission, Disassembly
Transmission, Exploded View
Transmission, Installation
Transmission, Operation
Transmission, Output Shaft Backlash Procedure
Transmission, Removal
Trouble Codes
Troubleshooting, Brake Noise
Troubleshooting, Clutching
Troubleshooting, Transmission
V
Valve Sealing Test
Valve Seat Reconditioning
Vehicle Identification Number
Vehicle Speed Sensor
Vent Lines
Version, Software
VIN
Voltage Drop Test
W
Wheel Alignment
Wheel Well Panels
Wheel, Installation
Wheel, Removal
