Polaris 800 EFI manual

PMS 419 Owner's Manual for Maint enance and Safety R ANGE R ® 800 EFI R ANGE R ® 800 EPS R ANGE R CR EW ® 800 EFI R ANGE R ® 6X6[...]

W ARNING Read, understand, and follo w all of the in structions and safety precautions in this manual and on all produ ct labels. Failure to follow the safety precautions could result in serious injury or dea th. W ARNING The engine exhaust from this product contains chemicals known to the S tate of California to cause cancer , birt h defect s or o[...]

1 WELCOME Thank you for purchasing a POLARIS vehicle, and welcome to our world-wide family of POLARIS enthusiasts. Be sure to visit us online at www .polaris.com for the latest news, new product introductions, upcoming events, career opportunities and more. Here at POLARIS we proudly produce an exciting line of utility and recreational products. ?[...]

2 POLARIS®, RANGER ® and RANGE R CREW® are registered trademarks of POLARIS Industries Inc. Copyright 2013 POLARIS Sales Inc. All information contained within this publication is based on the latest product information at the time of publication. Due to constant improvements in the d esign and quality of production components, some minor discrep[...]

3 T ABLE OF CONTENTS Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Features and Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Operation . . . . . . . . . . . . . . . . . . . [...]

4 INTRODUCTION The RANGER is an of f-road vehicle. Familiarize yourself with all laws and regulations concerning the operation of this vehicle in your area. The following signal wo rds and symbols appear throughou t this manual and on your vehicle. Y our safety is involved when these words and symbols are used. Become familiar with their meanings b[...]

5 INTRODUCTION Failure to follow the warnings con tained in this manual can resul t in seve re injury or death. Y our POLARIS RANGER is not a toy and can be hazardous to op erate. This vehicle handles di fferently than other vehicles, such as cars, trucks or other off-road vehicles. A collision or rollover can occur quickly , even during rou tine m[...]

6 INTRODUCTION V ehicle Identification Numbers Record your vehicle's identification numbers and key number in the spaces provided. Remove the spare key and store it in a safe place. An ignition key can be duplicated only by ordering a POLARIS key blank (using your key number) and mating it with one of your existing keys. The ignition switch mu[...]

7 INTRODUCTION European Vi bration and Noise The driver-perceived noise and hand/arm and whole body vibration leve ls of this machinery is measured per prEN 15997. The operating conditions of the machinery during testing: The vehicles were in like-new condition. The environment was controlled as indicated by the test procedure(s). The uncertainty o[...]

8 SAFETY Safe Riding Gear The driver and all passengers must wear helm et, eye protection, gloves, long-sleeve shirt, long pants, over-the-ankle boots and seat belt at all times. Protective gear reduces the chance of injury . Helmet W earing a helmet can prevent a severe head inj ury . Whenever riding this POLARIS vehicle, always wear a helmet that[...]

9 SAFETY Safe Riding Gear Eye Protection Do not depend on eyeglasses or sunglasses for eye protection. Whenever riding this POLARIS vehicle, always wear shatterproof goggles or use a shatterproof helmet face shield. POLARIS recommends wearing approved Personal Protective E quipment (PPE) bearing markings such as VESC 8, V -8, Z87.1, or CE. Make sur[...]

10 SAFETY Safety Labels and Locations W arning labels have been placed on the vehi cle for your protection. Read and follow the instructions of the labels on the vehicle carefully . If any of the labels depicted in this manual differ from the labels on your vehicle, always read and follow the instructions of the labels on the vehicle . If any label[...]

11 SAFETY Safety Labels and Locations Seat Belt/Drive Responsibly W arning W ARNING Improper vehicle use can result in SEVERE INJURY or DEA TH Be Prepared • Fasten seat belts. • Wear an approved helmet and protective gear . • AL WA YS use vehicle cab nets and/or doors. • Each rider must be able to sit with back against seat, feet flat on th[...]

12 SAFETY Safety Labels and Locations Load/Passenger/Tire Pressure W arning S torage Box Load 250 lbs. (1 13 kg) W ARNIN G • Never carry passengers in cargo box. • Passengers can be thrown of f. This can cause serious injury or death. IMPROPER TIRE PRESSURE OR OVERLOADING CAN CAUSE LOSS OF CONTROL RESUL TING IN SERIOUS INJURY OR DEA TH. • Red[...]

13 SAFETY Operator Safety Serious injury or death can result if you do not follow these instructions and proce dures, which are outlined in further detail within your owner's manual. • Read this entire manual and all labels carefully . Follow the operating procedures described. • Never allow anyone under the age of 16 to oper ate this vehi[...]

14 SAFETY Operator Safety • Always travel slowly and use extra caution when operating on unfamiliar terrain. Be alert to changing terrain. • Never operate on excessively rough, slippery or loose terrain. • Always follow proper procedures for turning. Practice turning at slow speeds before attempting to turn at faster speeds. Never turn at exc[...]

15 SAFETY Operator Safety • Always use the proper size and type of tires specified in this manual. Always maintain proper tire pressure as specified on safety labels. • Never modify this vehicle through improper installation or use of non-POLARIS- approved accessories. • Never exceed the stated load capacity for this vehicle. Cargo should be [...]

16 SAFETY Operator Safety Failure to operate the RANGER properly can result in a collision, loss of control, accident or rollover , which may result in serious injury or death. Heed all safety warning s outlined in this section of the owner ’s manual. See the OPERA TION section of the owner ’s manual for proper operating proced ures. Age Restri[...]

17 SAFETY Operator Safety Cab Net s Riding in this vehicle without usin g the cab nets (or doors, if equipped) increases the risk of serious injury or death in the event o f an accident or rollover . Always use the cab ne ts (or doors) while riding in this vehicle. Always keep hands and feet inside the vehicle at al l times. Failure to Inspect Befo[...]

18 SAFETY Operator Safety Handling Gasoline Gasoline is h ighly flammable and explosive under certain conditions. • Always exercise extreme caution w henever handling gasoli ne. • Always turn off the engine when refueling. • Always refuel outdoors or in a well ventilated area free of any source of flame or sparks. • Always use an approved g[...]

19 SAFETY Operator Safety T urning Improperly T urning improperly could cause loss of traction, loss of control, accident or rollover . Always follow proper procedures for turning as descri bed in this owner ’s manual. Never turn abruptly or at sharp angles. Never turn at high speeds. Practice turn ing at slow speeds before attempting to turn at [...]

20 SAFETY Operator Safety Improper Tire Maintenance Operating this vehicle with improper tires or with im proper or uneven tire pressure could cause loss of control or accident. Always use the size and type of tires specified for your vehicle. Alwa ys maintain proper tire pressure a s described in the owner's manual and on safety labels. Opera[...]

21 FEA TURES AND CONTROLS Component Locations Y our vehicle is equipped with cab nets on both sides of the vehicle. Cab nets (or doors, if equipped) must be used by both operator and passengers at all times. Any illustrations without cab nets are only to allow component identification. Always use the cab nets (or doors). Not all models come with al[...]

22 FEA TURES AND CONTROLS Console Auxiliary Outlet s The 12-volt receptacles have spade connections on the back that may be used to power an auxiliary light or other optional accessories or lights. The connections are behind the console, under the dash. On CREW models, an additional receptacle is located on the rear of the driver ’ s seat. Gear S[...]

23 FEA TURES AND CONTROLS Switches Ignition Switch The ignition switch is a three-position, key-operated switch. The key can be removed from the switch when it is in the OFF position. Mode Button The MODE button is located on the instrument cluster . Use the MODE button to toggle through mode options available in the instrument cluster . See pages [...]

24 FEA TURES AND CONTROLS T railer Hitch Bracket This vehicle is equipped with a receiver hitch bracket for a trailer hitch. T o avoid injury and property damage, always heed the warnings and towing capacities outlined on pages 44-45. Brake Pedal Depress the brake pedal to slow or stop the vehicle. Apply the brakes while starting the engine. Thrott[...]

25 FEA TURES AND CONTROLS Park Brake Lever T o help prevent the vehicle from rolling, engage the park brake when parking the vehicle. When the p ark brake is fully engaged, “BRAKE” appears in the rider information display . Engine speed is limited to 1300 RPM in all gears, except neutral. If throttle is applied, this limiting feature prevents o[...]

26 FEA TURES AND CONTROLS Cab Net s Riding in this vehicle without using the cab n ets (or doors, if equipped) increases the risk of serious injury or death in the event of an accident or rollover . Cab nets (or doors) must be used by both operator and passengers at all times . Make sure all latche s are secure before operating the vehicle. Always [...]

27 FEA TURES AND CONTROLS Seat Removal Pull up on the front of the seat and slide it toward the front of the vehicle. Install the seat by sliding the tabs into the rear of the seat base. Push down firmly on the front of the seat until the pins are fully seated into the grommets. Seat Belt s This POLARIS vehicle is equipped with three-point lap and [...]

28 FEA TURES AND CONTROLS Rollover Protective St ructure (ROPS) The Rollover Protective Structure (ROPS) on this vehicle meets OSHA 1928.53 rollover performance requirements. Always have your authorized POLARIS dealer thoroughly inspect the ROPS if it ever becomes damaged in any way . No device can assur e occupant pr otection in the event of a r o[...]

29 FEA TURES AND CONTROLS Instrument Cluster High water pressure may damage components. W ash the vehicle by hand or with a garden hose using mild soap. Do not use alcohol to clean the instrument cluster . Do not allow insect sprays to contact the lens. Speedometer The speedomete r displays vehicle speed in either miles per hour (MPH) or kilometers[...]

30 FEA TURES AND CONTROLS Instrument Cluster Rider Information Center The rider information center is located in the instrument cluster . All segments will light up for one second at start-up. If the instrument cluster fails to illuminate, a battery over-vol tage may have occurred and the instrument cluster may have shut off to protect the electron[...]

31 FEA TURES AND CONTROLS Instrument Cluster Rider Information Center Use the MODE button to toggle through the information area options. Display Units (S tandard/Metric) The display can be changed to display either st andard or metric uni ts of measurement. Tip : T o exit the set-up mode at any time, wait 10 seconds.The display automatically exits[...]

32 FEA TURES AND CONTROLS Instrument Cluster Rider Information Center Odometer Mode The odometer records and displays th e distance traveled by the vehicle. T rip Meter Mode The trip meter records the distance traveled by the vehicle if reset before each trip. T o reset, select the trip meter mode. Press and hold the MODE button until the meter res[...]

33 FEA TURES AND CONTROLS Instrument Cluster Rider Information Center Engine Error Codes The error screen displays only when the CHECK ENGINE light is on or when it goes on and off during one ignition cycle. Error codes are not stored. When the key is turned OFF , the code and message is lost, but will reappear if the fault reoccurs after restartin[...]

34 OPERA TION Failure to operate the vehicle properly can result in a collision, loss of contro l, accident or ro llover , which may result in serious injury or death. Read and un derstand all safety warni ngs outlined in the safety section of this owner ’s manual. Break-In Period The break-in period for your new RANGER is the first twenty hours [...]

35 OPERA TION Pre-Ride Inspection Failure to inspect and verify that the vehicle is in safe operating condition before operating increases the risk of an accident. Alwa ys inspect the vehicle be fore each use to make sure it's in safe operating condition. Item Remarks Page Brake system/pedal travel Ensure proper operation 24 79 Brake fluid Ens[...]

36 OPERA TION S tarting the Engine 1. Always start the engine outdoors or in a well-ventilated area. 2. Sit in the driver's seat and fasten the seat belt. Secure the cab nets (or doors). 3. Apply the brakes. Engage the park brake. 4. Shift the transmission to neutral. 5. Do not press the throttle pedal while starting the engine. T urn the igni[...]

37 OPERA TION Driving Procedure 1. W ear a helmet, eye protection, gloves, long-sleeve shirt, long pants and over -the-ankle boots. 2. Perform the pre-ride inspection. See page 35. 3. Sit in the driver's seat and fasten the seat belt. 4. Always use the cab nets (or doors) while riding in this vehicle. 5. Star t the engine and allow it to warm [...]

38 OPERA TION Driving with a Passenger 1. Perform the pre-ride inspection. See page 35. 2. Make sure all passengers are at least 12 y ears of a ge and tall enough to comfortably and safely sit in a passenger seat with the seat belt secured, put both feet on the floor and grasp the hand hold. 3. Make sure all passengers are wearing h elmet, eye prot[...]

39 OPERA TION Driving on Slippery Surfaces Skidding or sliding can cause loss of control or rollover (if tires regain traction unexpe cted ly). When operating on slippery surfaces such as ice or loos e gravel, reduce speed and use extra caution to reduce the chance of ski dding or sliding o ut of control. Do not operate on excessively slippery surf[...]

40 OPERA TION Driving Over Obst acles Follow these precautions when operating over obstacles: 1. Always check for obstacles before operating in a new area. 2. Look ahead and learn to read the terrain. Be constantly alert for hazards such as logs, rocks and low hanging branches. 3. T ravel slowly and use extra caution when operating on unfamiliar te[...]

41 OPERA TION Driving Uphill Whenever traveling uphill, follow these precautions: 1. Always travel straight uphill. 2. A void excessively steep hills. 3. Keep both feet on the floor . 4. Always check the terrain carefully before ascending any hill. 5. Never climb hills with excessively slippery or loose surfaces. 6. Proceed at a steady rate of spee[...]

42 OPERA TION Driving Through W a ter Y our POLARIS RANGER can operate through water up to a maximum recommended depth equal to the floorboards. NOTICE: Immersion can result in major damage if the vehicle isn't serviced correctly and promptly . After immersion, always take the vehicle to your dealer service. Do not start the engine! If it&apos[...]

43 OPERA TION Driving in Reverse Follow these precautions when operating in reverse: 1. Always check for obstacles or people behind the vehicle. Always inspect left and right fields of vision before backing. 2. Always avoid backing downhill. 3. Back slowly . 4. Apply the brakes lightly for stopping. 5. A void turning at sharp angles. 6. Never open [...]

44 OPERA TION Hauling Cargo Hauling cargo imprope rly can alter vehicle handl ing and may cau se loss of control or brake instability , which can result in se rious injury or death. Always follow these precautions when hauling cargo: Never exceed the maximum weight cap acit y of the vehicle. Wh en determining th e weight you are adding to the vehic[...]

45 OPERA TION T owing Loads T owing improperly can alter vehicle handli ng and may cause loss of control or brake instability . Always follow these precautions when towing: 1. Never load more than 150 lbs. (68.1 kg) tongue weig ht on the towing bracket. 2. Always shift to low gear for towing. 3. When towing a disabled RANGER vehicle, place the disa[...]

46 OPERA TION Dumping the Cargo Box 1. Select a level site to dump the cargo box. Do not attempt to dump or unload the vehicle while parked on an incline. 2. Apply the brakes. Place the transmission in gear . Engage the park brake. 3. Dismount the vehicle. 4. Ensure that the cargo is positioned evenly or toward the front of the cargo box. 5. Releas[...]

47 OPERA TION All Wheel Drive (A WD) Engaging A WD Press the top of the switch to engage All Wheel Drive (A WD). The 4X4 indi cator illuminates in the rider information center to indicate that t h e vehicle is in A WD. See page 30. When the A WD switch is on, the front wheels will automatically engage any time the rear wheels lose traction. When th[...]

48 OPERA TION All Wheel Drive (A WD) Locking the Differential NOTICE: Damage to the differential can occur if it is engaged while the vehicle is traveling at high speeds or while the rear wheels are spinning. Slow the vehicle to nearly stoppe d before engaging the differential. Locking the differential in slippery or low traction conditions helps i[...]

49 WINCH GUIDE These safety warnings and instructions apply if your vehicle came equipped with a winch or if you choose to add an a ccessory winch to your vehicle. Improper winch use can result in SEVERE INJURY or DEA TH. Always foll ow all winch instructi ons and warnings in this manual. Your winch may have a cable made of either wire rope or spec[...]

50 WINCH GUIDE Winch Safety Precautions 13. Never winch up or down at sharp angles. This can destabilize the winching vehicle and possibly cause it to move without warning. 14. Never attempt to winch loads that weigh more than the wi nch’ s rated capacity . 15. The winch motor may become hot during winch use. If you winch for more than 45 seconds[...]

51 WINCH GUIDE Winch Operation Read the W inch Safety Pr ecautions in the preceding pages before using your winch. Tip : Consider practicing the operation and use of your winch be fore you actually need to us e it in the field. Improper winch use can result in SEVERE INJURY or DEA TH. Always foll ow all winch instructi ons and warnings in this manu[...]

52 WINCH GUIDE Winch Operation 4. Always use the hook strap when handling the hook. W ARNING! Never put your fingers into the hook. This could lead to SEVERE INJURY . A. Attach the hook itself onto the load or use a tow strap or chain to secure the lo ad to the winch cabl e. Tip : A “tow strap” is NOT in tended to stretch. A “reco very strap?[...]

53 WINCH GUIDE Winch Operation 8. Read and adhere to the following inform ation for winch damping to ensure safe winch use. A. In order to absorb energy that could be released by a winch cab le fa ilure, always place a “damper” on the wi nch cable. A damper can be a heavy jacket, tarp, or other soft, dense object. A damper can absorb much of th[...]

54 WINCH GUIDE Winch Operation 13. Extensive winching will run down the battery on the winching vehicle. Let the winching vehicle’ s engine run while operating the winch to prevent the battery from running low if winching for long periods. 14. The winch motor may become hot during winch use. If you winch for more than 45 seconds, or if the winch [...]

55 WINCH GUIDE Winch Cable Care For your safety , always replace POLARIS winch parts (including the cable) with genuine POLARIS replacement parts available at your authorized POLARIS dealer . W ARNING! Use of worn or damaged cable could lead to sudden failure and SEVERE INJUR Y . 1. Always inspect your winch before each use. Inspect for worn or loo[...]

56 WINCH GUIDE Shock Loading W ARNING! Y our winch cable is very strong but it is NOT designed for dynamic, or “shock” loading. Shock loading may tension a win ch cable beyond its strength and ca use the cable to break. The end of a broken winch cable under such high loadi ng can cause SEVERE INJURY or DEA TH to you and other bystanders. W inch[...]

57 WINCH GUIDE Winch Maintenance and Service Safety W ARNING! Improper or lack of winch maintenance and service could lead to SEVERE INJURY or DEA TH. Always follow all winch instructio ns and warnings in this manual. 1. Always inspect your winch before each use. Inspect for worn or kinked winch cable. Also inspect for worn or loose parts includi n[...]

58 EMISSION CONTROL SYSTEMS Noise Emission Control System Do not modify the engine, in take or exhaust components, as doing so may affect compliance with U.S.A. EP A noise control requirements (40 CFR 205) and local noise level requirements. Operation on Public Lands in the U.S.A. Y our POLARIS vehicle has a spark arrester that was tested and quali[...]

59 MAINTENANCE Periodic Maintenance Chart Careful periodic maintenance will help keep yo ur vehicle in the safest, most reliable condition. Inspection, adjustment and lubrication of important components are explained in the periodic maintenance chart. Inspect, clean, lubricate, adjust and replace part s as necessary . When inspection reveals the ne[...]

60 MAINTENANCE Periodic Maintenance Chart Perform all services at whichever maintenance interval is reached first. Ź Perform these procedures more often for vehicles subjected to severe use. E Emission-Related Service D Have an authorized POLARIS dealer perform these services. Item Maintenance Interval (whichever comes first) Remarks Hours Calenda[...]

61 MAINTENANCE Periodic Maintenance Chart Ź Perform these procedures more often for vehicles subjected to severe use. E Emission-Related Service D Have an authorized POLARIS dealer perform these services. Item Maintenance Interval (whichever comes first) Remarks Hours Calendar Miles (Km) D E Throttle cable/throttle pedal 50 H 6 M - Inspect; adjust[...]

62 MAINTENANCE Lubrication Recommendations Check and lubricate all components at the intervals outlined in the Periodic Maintenance Chart beginning on page 59, or more often under severe use, such as wet or dusty conditions. Items not listed in the chart sh ould be lubricated at the general lubrication interval. Item Lube Method Engine Oil PS-4 5W-[...]

63 MAINTENANCE Engine Int ake Restrictor Plate Some RANGER 800 models are equipped with an in take restrictor plate in order to meet vehicle class regulations. This plate MUST NOT be removed for any reason. Removal of the intake r estrictor plate will void the warranty on the vehicle. Engine Oil Always check and change the engine oil at the interva[...]

64 MAINTENANCE Engine Oil Oil and Filter Change Always change the oil and filter at the intervals outlined in the Periodic Maintenance Chart beginning on page 59. Always change the oil filter whenever changing oil. 1. Position the vehicle on a level surface. 2. Run the engine for two to three minutes until warm. Stop the engine. 3. Clean the area a[...]

65 MAINTENANCE Gearcases Gearcase Specification Chart RANGER 4X4 Gearcase Specifications Gearcase Lubricant Cap acity Fill Plug(s) To r q u e Drain Plug T o rque Main Gearcase (T ransmission) AGL Gearcase Lubricant & T ransmission Fluid 34 oz. (1000 ml) 12 ft. lbs. (16.3 Nm) 12 ft. lbs. (16.3 Nm) Front Gearcase Demand Drive Fluid 9.3 oz. (275 m[...]

66 MAINTENANCE Gearcases T ransmission (Main Gearcase) (4X4/CREW) Always check and change the transmission oil at the intervals outlined i n the Periodic Maintenance Chart beginning on page 59. Refer to the Gearcase Specifications Chart on page 65 for recommended lubricants, capacities and torque specifications. See page 100 for the part numbers of[...]

67 MAINTENANCE Gearcases T ransmission (Mai n Gearcase) (6X6) Always check and change the transmission oil at the intervals outlined i n the Periodic Maintenance Chart beginning on page 59. Mainta in the oil level even with the bottom of the fill plug hole. Refer to the Gearcase Specifications Chart on page 65 for recommended lubricants, capacities[...]

68 MAINTENANCE Gearcases Front Gearcase Always check and change the front gearcase oil at the intervals outlined in the Periodic Maintenance Chart beginning on pa ge 59. Maintain the oil level even with the bottom thread of the fill plug hole. Refer to the Gearcase Specifications Chart on page 65 for recommended lubricants, capacities and torque sp[...]

69 MAINTENANCE Gearcases Middle Gearcase (6X6) Always check and change the mi ddle gearcase oil at the inte rvals outlined in the Periodic Maintenance Chart beginning on pa ge 59. Maintain the oil level even with the bottom thread of the fill plug hole. Refer to the Gearcase Specifications Chart on page 65 for recommended lubricants, capacities and[...]

70 MAINTENANCE Gearcases Rear Gearcase (6X6) Always check and change the rear gearcase oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 59. Refer to the Gearcase Specifications Chart on page 65 for recommended lubricants, capacities and torque specifications. See page 100 for the part numbers of POLARIS products. Th[...]

71 MAINTENANCE Spar k P l u g s Sp ark Plug Recommendations Refer to the specifications section beginning on page 94 for the recommended spark plug type for your vehicle. Always torque spark plugs to specification. NOTICE: Using non-recommended spark plugs can result in serious engine damage. Always use POLARIS-recommended spark plugs. Sp ark Plug [...]

72 MAINTENANCE Cooling System The engine coolant level is controlled or maintained by the recovery system. The recovery system components are the overflow bottle, radiator filler neck, radiator pressure cap and connecting hose. As coolant operating temperature increases, the expanding (heated) excess coolant is forced out of the radiator , past the[...]

73 MAINTENANCE Cooling System Overflow Bottle Coolant Level Always check and change the coolant at the intervals outlined in the Periodic Maintenance Chart beginning on page 59. Maintain the coolant level between the minimum and maximum marks on the bottle (when the fluid is cool). The overflow bottle is located in front of the right front wheel. 1[...]

74 MAINTENANCE POLARIS V ariable T ransmission (PVT) System Failure to comply with the instructions in this warning can result in severe injury or death. Do not modify any component of the PVT system. Doing so may reduce its strength so that a failure may occur at a high speed. The PVT system has been precision b alanced. Any modification will caus[...]

75 MAINTENANCE POLARIS V ariable T ransmission (PVT) System Belt Replacement/Debris Removal If a belt fails, always clean any debris from the duct and from the clutch and engine compartments when replacing the belt. W ARNING! Failure to remove ALL debris when replacing the belt could result in vehicl e damage, loss of control and severe injury or d[...]

76 MAINTENANCE V ehicle Immersion NOTICE: If your vehicle becomes immersed, major engine damage can result if the machine is not thoroughly inspected. T ake the vehicle to your dealer before starting the engine. If it's impossible to take your RANGER to a dealer before starting it, follow the steps outlined below . 1. Move the vehicle to dry l[...]

77 MAINTENANCE S p ark Arrester Failure to heed the following warnings while servicing the spark arrester coul d result in serious inj ury or death. • Do not perform service on the s park arrester whil e the system is hot. Exhaust system temperatures can reach 1000° F . Allow components to cool sufficiently before proceeding. • Remove any comb[...]

78 MAINTENANCE Throttle System Failure to check or maintain proper operation of the throttle system can result in an accident and lead to serious injury or death if the th rottle pedal sticks during operation. Always check the pedal for free movement and return be fo re starting the engine and occasionally during operation. Never start or operate t[...]

79 MAINTENANCE Brakes The front and rear brakes are hydraulic disc ty pe brakes activated by th e brake pedal. See page 24. Brake Fluid Inspect the brake system routinely . Inspect the level of the brake fluid before each operation. W ARNING! After opening a bottle of brake fluid, always discard any unused portion. N ever store or use a partial bot[...]

80 MAINTENANCE Brakes Park Brake Adjustment Inspect and adjust park brake cable tension after the first 25 hours of operation and every 100 hours thereafter to ensure pro per cable tension. Loss of tension in the park brake cable may cause “BRAKE” to display in the rider information center , along with activation of the limiting feature. If thi[...]

81 MAINTENANCE Ti re s Operating your vehicle with worn tires, improperl y inflated tires, non-standard tires or improperly installed tires will affect vehicle handling and could cause an accident resulting in serious injury or death. Always follow all tire maintenance proced ures as outlined in this manual and on the labels on the vehicle. Always [...]

82 MAINTENANCE Ti re s Wheel Removal 1. Apply the brakes. Engage the park brake. 2. Stop the engine. Place the transmission in gear . 3. Loosen the wheel nuts slightly . 4. Elevate the side of the vehicle by placing a suitable stand under the frame. 5. Remove the wheel nuts and washers. Remove the wheel. Wheel Inst allation 1. Apply the brakes. 2. [...]

83 MAINTENANCE Light s Poor lighting can result in reduced visibility when driving. Headlight and taillight lenses become dirty during normal operation. Clean lights frequently and replace burned out lamps promptly . Do not operate this vehicle at night or in low light conditions until the headl ight is replaced. Always make sure lights are adjuste[...]

84 MAINTENANCE Light s Headlight Beam Adjustment 1. Place the vehicle on a level surface with th e headlight approximately 25 ft. (7.6 m) from a wall. 2. Place the transmission in gear . Engage the park brake. 3. Measure the distance from the floor to the center of the headlight and make a mark on the wall at the same height. 4. Apply the brakes. S[...]

85 MAINTENANCE Fuses If the engine stops or will not start, or if you experience other electrical failures, a fuse may need replacement. Locate and correct any short circuits that may have caused the blown fuse, then replace the fuse. Spare fuses are provided in the fuse box. The power steering fuse (if equipped) is located on the power steering wi[...]

86 MAINTENANCE Battery Battery electrolyte is poisonous. It contains sulfu ric acid. Serious burns can result from contact with skin, eyes or clothing. Antidote: External : Flush with water . Internal : Drink la rge quantities of water or milk. Follo w with milk of magnesia, beaten egg , or vegetable oil. Call physicia n immediately . Eyes : Flush [...]

87 MAINTENANCE Battery Battery Removal Improperly connecting or disconnecting battery cabl es can result in an explosion and cause serious injury or death. When removing the battery , alwa ys di sconnect the negative (b lack) cable first. When reinstalling the battery , always connect the neg ative (black) cable last. 1. Remove the seat. Remove the[...]

88 MAINTENANCE Battery Battery Inst allatio n Using a new battery that has not been fully char ged can damage the battery and result in a shorter life. It can also hinder vehicle performance. Follow the battery char ging instructions on page 89 before installing the battery . 1. Ensure that the battery is fully charged. 2. Place the fully char ged [...]

89 MAINTENANCE Battery Battery Charging (Conventional Battery) 1. Remove the battery from the vehicle to prevent damage from leaking or spilled electrolyte during char ging. See page 87. 2. Char ge the battery with a char ging output no larger than 1/10 of the battery’ s amp/hr rating. Charge as needed to raise the specific gravity to 1.270 or gr[...]

90 MAINTENANCE Cleaning and St orage W ashing the V ehicle Keeping your POLARIS vehicle clean will not only improve its appearance but it can also extend the life of various components. NOTICE: High water pressure may damag e components. POLARIS recommends washing the vehicle by hand or with a garden hose, using mild soap. NOTICE: Certain products,[...]

91 MAINTENANCE Cleaning and St orage Sto ra g e Ti ps NOTICE: S tarting the engine during the storage period will disturb the protective film cre ated by fogging and damage could occur . Never start the engine during the storage period. Clean the Exterior Make any necessary repairs and clean the vehicle as recommended. See page 90. St abilize the F[...]

92 MAINTENANCE Cleaning and St orage Sto ra g e Ti ps Inspect and Lubricate Inspect all cables and lubricat e all areas of the vehicle as recommended in the Periodic Maintenance Chart beginning on page 59. Battery Maintenance See page 88 for storage and char ging procedures. Fluid Levels Inspect the fluid levels. Add or change fluids as recommended[...]

93 MAINTENANCE Removal from S t orage 1. Check the battery electrolyte level and charge the battery if necessary . Install it in the vehicle. Make sure the battery vent hose is routed properly and that it's not pinched or restricted in any way . 2. Make sure the spark plug is tight. 3. Fill the fuel tank with fuel. 4. Check all the points list[...]

94 SPECIFICA TIONS RANGER 800 EFI/EPS Maximum W eight Capacity 1500 lbs. (681 kg) (including operator , passenger, car go, accessories) 1 100 lbs. (499 kg) (Models sold in California) Dry W eight 1237 lbs. (561 kg) T est GVW - Rollover Protection System (ROPS) 2940 lbs. (1333.5 kg) per OSHA 29 CFR 1928.53 Fuel Capacity 8.8 gal. (33.3 l) Engine Oil [...]

95 SPECIFICA TIONS Clutching See your POLARIS dealer for clutching specifications. RANGER 800 EFI/EPS Driving System T ype PVT , 4-wheel independent shaft, lockable differential Shift T ype Single Lever (H/L/N/R) Gear Reduction - Low 7.70:1 Gear Reduction - Reverse 7 .00:1 Gear Reduction - High 3.6:1 Drive Ratio - Front: 3.818:1 Drive Ratio - Rear [...]

96 SPECIFICA TIONS RANGER 6X6 Maximum W eight Capacity 2000 lbs. (907 kg) (includes weight of operator, passenger , cargo, accesso- ries) Dry W eight 1551 lbs. (703.5 kg) T est GVW - Rollover Protection System (ROPS) 3660 lbs. (1660 kg) per OSHA 29 CFR 1928.53 Fuel Capacity 8.8 gal. (33.3 l) Engine Oil Capacity 2 qts. (1.9 l) Coolant Capacity 3.25 [...]

97 SPECIFICA TIONS Clutching See your POLARIS dealer for clutching specifications. RANGER 6X6 Driving System T ype PVT Shift T ype Single Lever , Console (H/L/N/R) Gear Reduction - Low 8.71:1 Gear Reduction - Reverse 7 .91:1 Gear Reduction - High 3.85:1 Drive Ratio - Front: 3.818:1 Drive Ratio - Final 3.70:1 T ire Size - Front 25 x 10 - 12 T ire Si[...]

98 SPECIFICA TIONS RANGER CREW 800 Maximum W eight Capacity 1750 lbs. (795 kg) (includes weight of operator, passengers, car go, acces- sories) Dry W eight 1495 lbs. (678 kg) T est GVW - Rollover Protection System (ROPS) 3360 lbs. (1524 kg) per OSHA 29 CFR 1928.53 Fuel Capacity 8.8 gal. (33.3 l) Engine Oil Capacity 2 qts. (1.9 l) Coolant Capacity 1[...]

99 SPECIFICA TIONS Clutching See your POLARIS dealer for clutching specifications. RANGER CREW 800 Driving System T ype PVT , 4-wheel independent shaft, lockable differential Shift T ype Single Lever (H/L/N/R) Gear Reduction - Low 7.70:1 Gear Reduction - Reverse 7 .0:1 Gear Reduction - High 4.63:1 Drive Ratio - Front: 3.818:1 Drive Ratio - Final 3.[...]

100 POLARIS PRODUCTS Part Number Description Engine Lub ricant 2870791 Fogging Oil (12 oz./355 ml Aerosol) 2876244 PS-4 Full Synthetic 5W -50 4-Cycle Oil (qt./.95 l) 2876245 PS-4 Full Synthetic 5W -50 4-Cycle Oil (gal./3.8 l) Gearcase / T ransmission Lubricants 2878068 AGL Full Synthetic Gearcase Lubricant & Transmission Fluid (qt./.95 l) 28780[...]

101 TROUBLESHOOTING Drive Belt Wear/Burn Possible Cause Solution Driving onto a pickup or tall trailer in high range Use low range during loading. Starting out going up a steep incline Use low range. See warnings on p a ge 41. Driving at low RPM or ground speed (3-7 MPH) Drive at a higher speed or use low range more frequently . Insufficient warm-u[...]

102 TROUBLESHOOTING Park Brake Engine Limiting Feature Fails to Disengage Engine Doesn't T urn Over Engine T urns Over , Fails to S t art Engine Backfires Engine Pings or Knocks Possible Cau se Solution Park brake is not completely disengaged Ensure lever is in forward-most position Park brake connector malfunction or switch move- ment or fail[...]

103 TROUBLESHOOTING Engine Runs Irregularly , S talls or Misfires Engine Stop s or Loses Power Possible Cau se Solution Fouled or defective spark plugs I n spec t, clean and/or replace spark plugs W orn or defective spark plug wires See your dealer Incorrect spark plug gap or heat range Set gap to specs or replace plugs Loose ignition connections C[...]

104 W ARRANTY LIMITED W ARRANTY POLARIS Sales Inc., 2100 Highway 55, Medina, MN 55340 (POLARIS) gives a SIX MONTH LIMITED W ARRANTY on all components of your POLARIS vehicle against defects in material or workmanship. POLARIS further warrants that the spark arrestor in this product will meet the efficiency requirements of USFS standard 5100-1C for [...]

105 W ARRANTY LIMIT A T IONS OF W ARRANTIES AND REMEDIES This warranty excludes damages or failures caused by abuse, accident, fire, or any other ca use o ther than a defect in materials or workmanship and provides no coverage for consumable components, general wear items, or any parts exposed to friction surfaces, stresses, environmental condition[...]

106 W ARRANTY HOW TO OBT AIN W A RRANTY SERVICE If your vehicle requires warr anty service, you must take it to a POLARIS Servicing Dealer . When requesting warranty service you must present your copy of the W arranty Registration From to the dealer . (THE COST OF TRANSPOR T A TION T O AND FROM THE DEALER IS YOUR RESPONSIBILITY). POLARIS suggests t[...]

107 W ARRANTY U.S.A. EP A Emissions Limited W arranty This emissions limited warranty is in addition to the POLARIS standard limi ted warranty for your vehicle. POLARIS Industries Inc. warrants that at the time it is first purchased, this emissions-certified vehicle is designed, built and equipped so it conforms with applic able U.S. Environmental [...]

108 W ARRANTY U.S.A. EP A Emissions Limited W arranty The exclusive remedy for breach of this limited warranty shall be, at the exclusive option of POLARIS, repair or replacement of any defective materials, components or products. THE REMEDIES SET FOR TH IN THIS LIMITED W ARRANTY ARE THE ONL Y REMEDIES A V AILABLE TO ANY PERSON FOR BREACH O F THIS [...]

109 MAINTENANCE LOG Use the following chart to record periodic maintenance. DA TE MILES (KM) OR HOURS TECHNICIAN SERVICE PERFORMED / COMMENTS[...]

11 0 INDEX A Accessory O u tl ets . . . . . . . . . . . . . . . . . . . . . . . . 22 Air Filte r . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76 Air Filte r Cleaning . . . . . . . . . . . . . . . . . . . . . . . . 76 All Wheel Drive . . . . . . . . . . . . . . . . . . . . . . . 47-48 Disengaging AWD . . . . . . . . . . . . . . . 47[...]

111 INDEX F Fan, Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72 Filter Cleaning, Air . . . . . . . . . . . . . . . . . . . . . . . . 76 Filter Sys tems . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76 Filter, Air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76 Fluid, Battery . . . . . . . . . . . . .[...]

11 2 INDEX O Oil Recommendation , Engine . . . . . . . . . . . . . . . 63 Operation on Public Lands . . . . . . . . . . . . . . . . . 58 Operator Safety . . . . . . . . . . . . . . . . . . . . . . . . 13-20 Outlets, Auxil iary . . . . . . . . . . . . . . . . . . . . . . . . 22 P Park Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .[...]

11 3 INDEX T Tachometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Throttle Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78 Throttle Free pla y Adj ustment . . . . . . . . . . . . . . . . 78 Throttle Free pla y Inspection . . . . . . . . . . . . . . . . . 78 Throttle Pedal . . . . . . . . . . . . . . . . . . . . [...]

PMS 419 W ARNING Improper vehicle use can result in SEVERE INJURY or DEATH NEVER Operate: • Without first viewing safety video and taking a ROHVA training course at www.rohva.org. • If you are under age 16 and without a valid driver’s license. • On excessively steep hills. • On public roads (unless designated for off-road use). • With a[...]