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RANGER 800 Midsize

1. 87 INTRODUCTION The RANGER is an off road vehicle Familiarize vourself with all laws and regulations con cerning the operation of this vehicle in vour area The following signal words and svmbols appear throughout this manual and on vour vehicle Your safety is involved when these words and symbols used Become familiar with their meanings before reading the manual A The safetv alert svmbol indicates a potential personal injurv hazard DANGER A DANGER indicates a hazardous situation that if not avoided will result in death or serious injurv WARNING A WARNING indicates a hazardous situation that if not avoided could result in death or serious injurv CAUTION A CAUTION indicates a hazardous situation that if not avoided could result in minor or moderate injurv NOTICE A NOTICE indicates a situation that could result in propertv damage The Prohibition Safetv Sign indicates an action NOT to take in order to avoid a hazard O The Mandatorv Action Sign indicates an action that NEEDS to be taken to avoid a hazard INTRODUCTION Failure to follow the warnings contained in this manual can result in severe injurv or death A POLARIS RANGER is not a tov and can be hazardous to operate This vehicle handles differentiv than other vehicles such as motorcvcles and cars A collision or rollover can occur quickiv even during routine maneuvers like turning or driving on hills or over
2. 62 Torque Spark 50 Towing 39 Towing Speed sean ened 39 Trailer Hitch 20 48 Transmission Operation 53 54 Transmission System 54 Transmission 53 54 Transmission 54 Transporting the Vehicle 73 V Vehicle Identification Numbers 6 Vehicle 55 Vehicle 73 Warning 8 4 Warning Transmission Modification 53 54 Washing the 69 Wheel 62 Wheel Nut Torque 61 Wheel Removal gew sates gen inn ia 62 89
3. 50 Spark Plug Recommendations 50 Spark Plug Torque 0tactasceddadion weds 50 sleds 50 Spark Plugs Fouled 50 Specifications 74 75 Specifications 48 Speed TOWME EA 39 24 Starting the 31 Steering Wheel Inspection 60 Stopping the 31 KO 69 72 Storage ATC a aeni ae a 72 Storage TIPS 71 Storage Battery 67 Storage COVETS 72 Storage Removal 73 Switches AWD Switch 19 Differential Lock Switch 19 Ignition 19 Light 19 T TACHOMELET iiss i jn va wea ee mariah age 27 Throttle Freeplay Adjustment 58 Throttle Freeplay Inspection 58 Throttle 1 20 Throttle System 58 TEMPOS Sy shin 61 62 Nut 61 Tread 61 Wheel Installation 62 Wheel
4. of gt ONO 8 Radiator Front Bumper Brush Guard Muffler Spark Arrester Boot Rear Caliper FEATURES AND CONTROLS Console Auxiliary Outlet Instrument Storage The 12 receptacle has spade Cluster Button Compartment connections on the back that mav be used to power an auxiliarv light or other optional accessories or lights The connections are behind the con sole under the hood Mode Button The vellow button located in the instrument cluster is used to toggle through mode options available See pages 24 28 Gear Selector H High Gear Storag L Low G Gear Selector rav 12V Auxiliarv Up N Neutral Shifter Outlet Holder R Reverse P Park Low gear is the primary driving range for the RANGER High gear is intended for use on hard packed surfaces with light loads Whenever the vehicle is left unattended always place the transmission in PARK To change gears stop the vehicle and with the engine idling move the lever to the desired gear Do not attempt to shift gears with engine speed above idle or while the vehicle is mov ing Tip Maintaining shift linkage adjustment is important to assure proper transmission function See your dealer if you experience any shifting problems NOTICE Shifting gears with the engine speed above idle or while the vehicle is moving
5. 51 Cooling System 51 52 Corrosion Removal Chrome 70 Crankcase Emission Control System 42 Cylinder 222222 2 55 D Differential Lock Switch 19 Differential 40 Disengaging 41 Display Units Standard Metric 26 Drive Belt Weat 77 Drivetrain 29 Driving Downhill 35 Driving in 37 Driving 35 Driving on Slippery 34 Driving Over Obstacles 33 Driving 32 Driving Through Water 36 Driving Uphill 35 Driving with a Passenger 33 Driving After Driving in Water 54 Drying the 15510 54 Dumping the Cargo 39 E Emissions Limited Warrantv 83 84 Engaging AWD 41 Engine 8 2 222 22 222299 29 Engine 72 Engine Idle 58 Engine eee 46 47 Engine 31 Engine S
6. 66 8 2235994 den 67 Wain gS 65 Belt Burning sei rer sieb nee nade e 77 esi oe cic d 39 Belt 53 Belt Wear iu tc sma cued cea 77 018 22 ces ease b SE be od 9 Brake Fluid i ie 59 Brake 59 8222 l 64 Brake oi eae 20 Brakes ons i ri 59 31 2222 cay dense see s 29 Cab Frame sis 23 Cab NES a A 22 ea sep aie 38 Cargo Box Dumping 39 Chart Periodic Maintenance 43 45 Check Engine Indicator 28 Chrome Wheel 70 Cleaning and Storage 69 72 Cleaning the Exhaust System 57 Cleaning the Spark 57 Clothing asic cae eee knee 9 75 Component 17 0 18 Coolant Level Overflow Bottle 52 Coolant Level Radiator 52 Coolant Adding or Changing 51 Cooling
7. moisture and air dry the belt and clutches Do not hold the throttle wide open for more than 10 seconds 6 Allow the engine RPM to settle to idle speed Apply the brakes Shift the transmission to the lowest available range Test for belt slippage If the belt slips repeat the process 8 Take the vehicle to your dealer for service as soon as possible 54 MAINTENANCE Vehicle Immersion NOTICE If your vehicle becomes immersed major engine damage can result if the machine is not thoroughly inspected Take 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 Re ee 8 Move the vehicle to dry land or at the very least to water below the footrests Dry any water present in the air box Filter replacement is required if water is present Thoroughly dry the air pre cleaner located under the hood Remove the spark plugs Turn the engine over several times using the electric start Dry the spark plugs and reinstall or replace with new plugs Attempt to start the engine If necessary repeat the drying procedure Take the vehicle to your dealer for service as soon as possible whether you succeed in starting it or not If water has been ingested into the PVT follow the procedure on page 54 for drying Cylinder Head Cylinder Base Fastener Torque Have your dealer check the cylinder head and cylinder base
8. 7 Reinstall the seat Check Level on Top Side Dipstick 46 MAINTENANCE Engine Oil and Filter Change Alwavs change the oil and filter at the intervals outlined in the Periodic Maintenance Chart beginning on page 43 Alwavs change the oil filter whenever changing oil 1 gt Position vehicle a level surface Place the transmission in PARK Start the engine Allow it to idle for two to three minutes Stop the engine Clean the area around the drain plug Place a drain pan beneath the engine crankcase CAUTION Hot oil can cause burns to skin Do not allow hot oil to contact skin 6 Remove the drain plug Allow the oil to drain completely Install a new sealing washer on the drain plug The sealing surfaces on drain plug and crankcase should be clean and free of burrs nicks or scratches Reinstall the drain plug Torque to 20 ft 165 27 Nm Remove the seat Place shop towels beneath the oil filter Using an oil filter wrench turn the filter counter clockwise to remove it Using a clean dry cloth clean the filter sealing surface on the crankcase Lubricate the o ring on the new filter with a film of fresh engine oil Check to make sure the o ring is in good condition Install the new filter and turn by hand until the filter gasket contacts the sealing surface then turn and additional 1 2 turn Remove the dipstick and fill the sump with two quarts 1 9 1 o
9. 7175488 Age 16 Warning Operating this vehicle if you are under the age of 16 increases your chance of severe injury or death NEVER operate this vehicle if you are under age 16 and NEVER operate this vehicle without a valid driver s license 7175566 Shift Caution CAUTION To avoid transmission damage shift only when vehicle is stationary and at idle APPLY BRAKE TO START When this vehicle is not in operation or unattended place shift in the park position 7176170 SAFETV Safetv Labels and Locations Discretionarv Warning 800 Midsize WARNING Improper vehicle use can result in Severe Injurv or Death NEVER Operate At speeds too fast for your skills or the conditions After or while using Alcohol or Drugs On hills steeper than 15 degrees 15 On public roads a collision can occur with a another vehicle With more than one passenger or a passenger under age twelve or who cannot comfortably reach the floor and hand holds On paved surfaces pavement may seriously affect handling and control With non POLARIS approved accessories they may seriously affect stability ALWAYS Wear your seat belt Vehicle rollover could cause severe injury or death Wear a helmet and eye protection and keep hands and feet in vehicle at all times e Reduce speed and use extra caution when carrying passengers e Avoid sharp turns or turns while applying heavy throttle e Operate slowly in
10. 64 Turn the ignition switch to the ON position Depress the brake pedal The brake light should come on after about 10mm 0 4 in of pedal travel If the light doesn t come on check the bulb MAINTENANCE Batterv A WARNING Battery electrolyte is poisonous It contains sulfuric acid Serious burns can result from contact with skin eyes or clothing Antidote External Flush with water Internal Drink large quantities of water or milk Follow with milk of magnesia beaten egg or vegetable oil Call physician immediately Eyes Flush with water for 15 minutes and get prompt medical attention Batteries produce explosive gases Keep sparks flame cigarettes etc away Ventilate when charging or using in an enclosed space Always shield eyes when working near batteries KEEP OUT OF REACH OF CHILDREN Your vehicle may have either a sealed battery which requires little maintenance or a con ventional battery A sealed battery can be identified by its flat covers on the top of the bat tery A conventional battery has six filler caps on the top of the battery Always keep battery terminals and connections free of corrosion If cleaning is necessary remove the corrosion with a stiff wire brush Wash with a solution of one tablespoon baking soda and one cup water Rinse well with tap water and dry off with clean shop towels Coat the terminals with dielectric grease or petroleum jelly Be careful not to allow cleaning solu tion
11. OPERATION Driving Through Water Your POLARIS RANGER can operate through water up to 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 s impossible to bring the vehicle to your dealer before starting the engine perform the service outlined on page 55 and take the vehicle to your dealer at the first opportunity Follow these procedures when operating through water 1 Determine water depths and current before entering water 2 Choose a crossing where both banks have gradual inclines 3 Proceed slowly avoiding rocks and obsta cles 4 Avoid operating through deep or fast flowing water WARNING The large tires on your RANGER may cause the vehicle to float in deep or fast flowing ae water which could result loss of control and lead to serious injurv or death Never cross deep or fast Floorboard flowing water with vour RANGER as 5 After leaving water always dry the brakes by applying light pressure to the pedal repeatedly until braking action is normal NOTICE After running your vehicle in water it s critical that you perform the services outlined in the Periodic Maintenance Chart beginning on page 43 Give special attention to engine oil transmission oil front and rear ge
12. 1 Stop the vehicle 2 Operate in reverse for at least 10 feet 3 Stop completely 4 Shift into low gear and drive forward 41 EMISSION CONTROL SVSTEMS Noise Emission Control Svstem Do not modify the engine intake or exhaust components as doing so may affect compliance with U S A EPA noise control requirements 40 CFR 205 and local noise level require ments Operation on Public Lands in the U S A Your POLARIS vehicle has a spark arrester that was tested and qualified to be in accordance with the USFS standard 5100 1c Federal law requires that this spark arrester be installed and functional when the vehicle is operated on public lands Operation of off road vehicles on public lands in the U S A is regulated by 43 CFR 420 Violations are subject to monetary penalties Federal regulations can be viewed online at www gpoaccess gov ecfr Crankcase Emission Control System This engine is equipped with a closed crankcase system Blow by gases are forced back to the combustion chamber by the intake system All exhaust gases exit through the exhaust system Exhaust Emission Control System Exhaust emissions are controlled by engine design An electronic fuel injection EFI system controls fuel delivery The engine and EFI components are set at the factory for optimal per formance and are not adjustable The emissions label is located on the frame under the seat Electromagnetic Interference This spark ignition system comp
13. 7178725 SAFETV Safe Riding Gear Alwavs wear appropriate clothing when riding a POLARIS vehicle Wear protec L le tive clothing for comfort and to reduce ong ff Eye 22 Sleeves the chance of injurv Protection Helmet Long Wearing a helmet can prevent a severe Pants head injurv Whenever riding this POLARIS vehicle alwavs wear a helmet that meets or exceeds established safetv standards Gloves Approved helmets in the USA and Canada bear a U S Department of Over the Ankle Boots Helmet Transportation DOT label Approved helmets in Europe Asia and Oceania bear the ECE 22 05 label The ECE mark consists of a circle surrounding the letter E followed bv the distinguishing number of the countrv which has granted approval The approval number and serial number will also be displaved 051039 on the label 0006 31 Eve Protection Do not depend on eveglasses or sunglasses for eve protection Whenever ridinga POLARIS vehicle always wear shatterproof goggles or use a shatterproof helmet face shield POLARIS recommends wearing approved Personal Protective Equipment PPE bearing markings such as VESC 8 V 8 Z87 1 or CE Make sure protective eve wear is kept clean Gloves Wear gloves for comfort and for protection from sun cold weather and other elements Boots Wear sturdv over the ankle boots Do not ride a POLARIS vehicle with bare feet Clothing Wear long sleeves an
14. Remarks Page Brake svstem pedal travel Ensure proper operation Brake fluid Ensure proper level 59 Park gear Ensure vehicle does not roll when in PARK Ensure PARK light illuminates Front suspension Inspect lubricate if necessary 45 Rear suspension Inspect lubricate if necessary 45 Steering Ensure free operation 60 Tires Inspect condition and pressure Wheels fasteners Inspect ensure fastener tightness 61 Frame nuts bolts fasteners Inspect ensure tightness Fuel and oil Ensure proper levels ae Coolant level Ensure proper level 52 Coolant hoses Inspect for leaks Throttle Ensure proper operation 58 Indicator lights switches Ensure operation 19 Air filter pre filter Inspect clean 56 Air box sediment tube Drain deposits whenever visible 56 Headlamp Check operation apply POLARIS dielectric grease 63 when lamp is replace Brake light tail lamp Check operation apply POLARIS dielectric grease 64 when lamp is replace Seat Belts Check length of belt for damage check latches for 21 proper operation Cab Nets Check for wear or damage ensure proper installation 22 30 OPERATION Starting 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 3 Apply the brakes Place the transmission in PARK 4 Do not press the throttle pedal while starting the engine Turn the ignition key past the ON RUN position to START Engage the starter for a m
15. charging procedures Fluid Levels Inspect the fluid levels Add or change fluids as recommended in the Periodic Maintenance Chart beginning on page 43 e Front and rear gearcase fluid if equipped e Transmission fluid e Brake fluid change every two years and any time the fluid looks dark or contaminated e Coolant test strength fill Fog the Engine 1 Treat the fuel system with POLARIS Carbon Clean Follow the instructions on the con tainer Start the engine Allow it to idle for several minutes so the Carbon Clean reaches the injectors Stop the engine 2 Remove the spark plugs and add 2 3 tablespoons of engine oil To access the plug holes use a section of clear 1 4 hose and a small plastic squeeze bottle filled with the pre measured amount of oil Do this carefully If you miss the plug holes oil will drain from the spark plug cavities into the hole at the front of the cylinder head and appear to be an oil leak 3 Reinstall the spark plugs Torque to specification See page 50 Apply dielectric grease to the inside of each spark plug cap and reinstall the caps onto the plugs 5 Turn the engine over several times Oil will be forced in and around the piston rings and ring lands coating the cylinder with a protective film of fresh oil 6 If POLARIS fuel system additive is not used fuel tank fuel lines and injectors should be completely drained of gasoline Storage Area Covers Be sure the storage area is well venti
16. could cause transmission damage Always shift when the vehicle is stationary and the engine is at idle Using Low Range Always shift into low gear for any of the following conditions Operating in rough terrain or over obstacles e Loading the vehicle onto a trailer e Towing heavy loads 18 FEATURES AND CONTROLS Switches Tur kaw to 4 1 AWDIDifferential Ignition Switch Switch Light Switch Ignition Switch Light Switch The ignition switch is a four position kev operated switch The kev can be removed from the switch when it is in the OFF position OFF The engine is off electrical circuits are off including 12V LIGHTS ON Lights are on Electrical circuits are on Electrical equipment can be used LIGHTS OFF Lights are off Electrical circuits are on Electrical equipment can be used START Turn the kev to the START position to engage the electric starter Turn the kev to the LIGHTS ON position after starting the engine AWDIDifferential Lock Switch The AWD Differential Switch has three positions Wheel Drive AWD Differential Lock Two Wheel Drive 2WD and Off 1 WD Turf Mode Press the top of the rocker switch to engage All Wheel Drive AWD See page 41 for AWD operating instructions Move the rocker switch to the center position to lock the differential and operate in two wheel drive 2WD See page 40 for Differential Lock operating instructions Press the
17. main line of the display 2 Press and hold the MODE button to enter the diagnostics code menu 28 Suspect Parameter Number SPN Error Code Number 0 9 Failure Mode Indicator FMI Record the three numbers displaved in the gear position clock and odometer displavs Press the MODE button to advance to the next error code Press and hold the MODE button to exit the diagnostics code menu See an authorized POLARIS dealer for code details and diagnosis OPERATION Failure to operate the vehicle can result in collision loss of control accident or overturn which may result serious injury or death Read and understand all safety warnings outlined in the safety section of this owner s manual Break In Period The break in period for your new POLARIS RANGER is the first twenty hours of operation or the time it takes to use the first two tanks full of gasoline No single action on your part is as important as a proper break in period Careful treatment of a new engine will result in more efficient performance and longer life for the engine Perform the following procedures carefully NOTICE Excessive heat build up during the first three hours of operation will damage close fitted engine parts Do not operate at full throttle or high speeds for extended periods during the first three hours of use Engine and Drivetrain Break in 1 Fill the fuel tank with gasoline Review fuel warni
18. nec E essary E Throttle body air intake ducts 50 H 6M Inspect duct for proper sealing air leaks ange Drive belt 50 H 6M Inspect adjust replace as needed Cooling system if applicable 50 H 6M Inspect coolant strength seasonally pressure test system yearly Perform these procedures more often for vehicles subjected to severe use E Emission Related Service D Have an authorized POLARIS dealer perform these services 44 Periodic Maintenance Chart MAINTENANCE Item Maintenance Interval Remarks whichever comes first Hours Calendar Miles Km gt Engine oil change 100 H 6M Perform a break in oil change at one month Oil filter change 100 H 6M Replace with oil change gt Front Gearcase oil if equipped 100 H 6M Inspect level change yearly gt Middle Gearcase oil if equipped 100 H 6M Inspect level change yearly gt Rear gearcase oil if equipped 100 H 6M Inspect level change yearly gt Transmission oil 100 H 6M Inspect level change yearly D Fuel system 100 H 12M Check for leaks at tank cap lines fuel E valve pump throttle body replace lines every 2 years gt Radiator if applicable 100 H 12M Inspect clean external surfaces gt Cooling Hoses 100 H 12M Inspect for leaks gt Engine mounts 100 H 12M Inspect Exhaust muffler pipe 100 H 12M Inspect Spark plug 100 H 12
19. of the seat until the pins are fully seated into the grommets 20 FEATURES AND CONTROLS Seat Belts This POLARIS vehicle is equipped with three point lap and diagonal seat belts on all external seats Always make sure the seat belts are secured for all riders before operating WARNING Falling from a moving vehicle could result in serious Latch Plate injury or death Always fasten your seat belt securely before operating or riding in the RANGER To wear the seat belt properly follow this procedure 1 For 3 point belts pull the seat belt latch downward and across your chest toward the buckle at the inner edge of the seat The belt should fit snugly across your hips and diago nally across your chest Make sure the belt is not twisted 2 Push the latch plate into the buckle until it clicks 3 Release the strap it will self tighten Tip The center belt must be tightened manually by pulling on the strap 4 To release the seat belt press the square red button in the buckle s center Buckle Seat Belt Inspection Inspect all seat belts for proper operation before each use of the vehicle 1 Push the latch plate into the buckle until it clicks The latch plate must slide smoothly into the buckle A click indicates that it s securely latched Push the red release latch in the middle of the buckle to make sure it releases freely 3 Pull each seat belt completely out and inspect the full length for any damage i
20. or tap water into the battery Battery Fluid Conventional Battery Lower Upper A poorly maintained battery will deteriorate rapidly Check Mark Mak the battery fluid level often Maintain the fluid level between the upper and lower level marks Add only distilled water Tap water contains minerals that are harmful to a battery 65 MAINTENANCE Batterv Batterv Removal AWARNING Improperly connecting or disconnecting battery cables can result in an explosion and cause serious injury or death When removing the battery always disconnect the negative black cable first When reinstalling the battery always connect the negative black cable last 1 Remove the seat 2 conventional batteries remove the battery vent tube 3 Disconnect the black battery cable first Discon nect the red battery cable last 4 Remove the battery hold down strap 5 Lift the battery out of the vehicle Be careful not to tip a conventional battery sideways which could spill electrolyte NOTICE If electrolyte spills immediately wash it off with a solution of one tablespoon baking soda and one cup water to prevent damage to the vehicle 66 MAINTENANCE Batterv Batterv Installation Using a new batterv that has not been fullv charged can damage the batterv and result in a shorter life It can also hinder vehicle performance Follow the batterv charging instructions on page 68 before installing the batterv 1 E
21. or while the rear wheels are spinning Slow the vehicle to nearly stopped before engaging the differential 40 OPERATION Wheel Drive AWD The illuminated amber AWD switch indicates that the vehicle is AWD When the AWD switch is on the front gearcase will automatically engage any time the rear wheels lose traction When the rear wheels regain traction the front gearcase will automati cally disengage There is no limit to the length of time the vehicle may remain in AWD Initially the vehicle s electronic system will not enable the AWD until the engine RPM is below 3100 Once enabled the AWD remains enabled until the AWD switch is turned off If the switch is turned off while the front gearcase is moving it will not disengage until the rear wheels regain traction Engage the AWD before getting into conditions where front wheel drive may be needed If the rear wheels are spinning release the throttle before switching to AWD NOTICE Switching to AWD while the rear wheels are spinning may cause severe drive shaft and clutch damage Always switch to AWD while the rear wheels have traction or are at rest Disengaging AWD Under certain conditions it may be possible for the front gearcase to remain locked unneces sarily This condition causes increased steering effort and some vehicle speed restriction If the front gearcase remains locked after following these instructions return the vehicle to your dealer for service
22. 2 Remove the level Rear Fill check fill plug Plug Check the oil level 3 Remove the rear fill Fill plug and add the Level recommended oil as AS needed 2 25 4 Reinstall both fill plugs Torque to Level Check specification and Alternate Drain Plug Fill Plug Oil Change The drain plug is located near the bottom of the gearcase Remove the rear fill plug and the level check fill plug Place a drain pan under the gearcase Remove the drain plug Allow the oil to drain completely Clean and reinstall the drain plug Torque to specification Add the recommended oil Reinstall both fill plugs Torque to specification a ON OY Check for leaks Dispose of used oil properly 48 MAINTENANCE Gearcases Front Gearcase Alwavs check and change the front gearcase oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 43 Maintain the oil level even with the bottom thread of the fill plug hole Refer to the Gearcase Specifications Chart on page 48 for recommended lubricants capaci ties and torque specifications See page 76 for the part numbers of POLARIS products Check The front gearcase fill plug is located on the right side of the front gearcase 1 Position the vehicle on a level surface 2 Remove the fill plug Check the oil level 3 Add the recommended oil as needed 4 Reinstall the fill plug Torque to specification Oil Change 1 Support the
23. 2 4 2 2 bies 50 Polaris 76 Polishing the 70 Pre Ride 30 Break In 29 DANA sa 54 Syste cits deseo e a 54 System 53 Waring eee ees 53 54 PVT Cleaning 53 R Radiators 51 Radiator Coolant 52 Removing the Vehicle from Storage 73 Reverse 37 Rider Information Center 25 28 Riding Gear 9 Rollover Protective Structure 23 ROPS Cab Frame esis ae aa 23 5 Safety Labels 7 8 Safety Symbols 4 Safety 13 16 Seat Belt Inspection 21 Seat B lis ru 21 Seat Rettioval wade sem ade arja aa 20 Severe Use 43 Shifter 2 ai a dr 18 Shiftiti GOALS isa i ese ma teas 18 Shock Spring 60 Signal 5 2522 4 Spark Arrester Warning 57 Spark Arrestor Cleaning 57 Spark Plug Gap 50 Spark Plug
24. Front Rear Foot Activated 4 wheel hydraulic disc Hood Headlights 2 single beam 50W quartz halogen Taillights 10 L E D 28W Brake Light 10 L E D 3 1 Indicator Light 1 0 W Clutching See your POLARIS dealer for clutching specifications 75 POLARIS PRODUCTS Part Number Description Engine Lubricant 2870791 Fogging Oil 12 2 355 ml Aerosol 2876244 PS 4 PLUS Performance Synthetic 2W 50 4 Cvcle Oil qt 95 1 2876245 PS 4 PLUS Performance Svnthetic 2W 50 4 Cvcle Oil gal 3 8 1 Gearcase Transmission Lubricants 2878068 AGL PLUS Transmission Fluid qt 95 1 2878069 AGL PLUS Transmission Fluid gal 3 8 1 2877922 Demand Drive Plus Fluid qt 95 1 2877923 Demand Drive Plus Fluid gal 3 8 l 2871653 Premium ATV Angle Drive Fluid 8 2 237 ml 2872276 Premium ATV Angle Drive Fluid 2 5 gal 9 5 1 2870465 Pump for Gallon 3 8 I Jug Coolant 2871323 60 40 Coolant gal 2871534 60 40 Coolant qt Grease Specialized Lubricants 2871312 Grease Gun Kit Premium All Season 2871322 Premium All Season Grease 3 0z 89 ml cartridge 2871423 Premium All Season Grease 14 2 414 ml cartridge 2871460 Starter Drive Grease 2871515 Premium U Joint Lube 3 0z 89 ml cartridge 2871551 Premium U Joint Lube 14 0z 414 ml cartridge 2871329 Dielectric Grease Nyogel 2872073 Chain Lube Aerosol 6 25 oz 2872348 C
25. L IMPLIED WARRANTIES INCLUDING BUT NOT LIMITED TO ANY IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE ARE LIMITED IN DURATION TO THE WARRANTY PERIOD DESCRIBED HEREIN POLARIS DISCLAIMS ALL EXPRESS WARRANTIES NOT STATED IN THIS WARRANTY Some states do not allow limitations on how long an implied warranty lasts so the above limitation may not apply if it is inconsistent with the controlling state law This limited warranty excludes failures not caused by a defect in material or workmanship This limited warranty does not cover damage due to accidents abuse or improper handling maintenance or use This limited warranty also does not cover any engine that has been structurally altered or when the vehicle has been used in racing competition This limited warranty also does not cover physical damage corrosion or defects caused by fire explosions or other similar causes beyond the control of POLARIS Owners are responsible for performing the scheduled maintenance identified in the owner s manual POLARIS may deny warranty claims for failures that have been caused by the owner s or operator s improper maintenance or use by accidents for which POLARIS has no responsibility or by acts of God Any qualified repair shop or person may maintain replace or repair the emission control devices or systems on your vehicle POLARIS recommends that you contact an authorized POLARIS dealer to perform any service that may be necessary
26. M Inspect replace as needed D Ignition timing 100 H 12M Inspect Wiring 100 H 12M Inspect for wear routing security apply dielectric grease to connectors sub jected to water mud etc Clutches drive and driven 100 H 12M Inspect clean replace worn parts D wheel bearings 100 H 12M Inspect replace as needed D Brake fluid 200 H 24M Change every two years Spark arrester 300 H 36 Clean out Idle speed Adjust as needed D adjustment Inspect periodicallv adjust when parts are replaced brake equipped Inspect dailv adjust as needed Headlight aim Adjust as needed Lubrication Recommendations Check and lubricate all components at the intervals outlined in the Periodic Maintenance Chart beginning on page 43 or more often under severe use such as wet or dusty conditions Items not listed in the chart should be lubricated at the general lubrication interval Item Lube Method Engine Oil POLARIS PS 4 PLUS Performance See page 46 Synthetic 2W 50 4 cycle Oil Brake Fluid DOT 4 See page 59 Main Gearcase Oil Trans Premium AGL Synthetic Gearcase Lube See page 48 mission Front Gearcase Oil Demand Drive Plus Fluid See page 49 Front Prop Shaft Yoke POLARIS Premium U Joint Lube Locate fittings and grease 3 pumps maximum 45 MAINTENANCE Engine Oil Alwavs check and change the engine oil at the intervals outlined in t
27. RANTV U S A EPA Emissions Limited Warrantv This emissions limited warrantv is in addition to the POLARIS standard limited warrantv for vour 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 applicable U S Environmental Protection Agencv emission reg ulations POLARIS warrants that the vehicle is free from defects in materials and workmanship that would cause it to fail to meet these regulations The warrantv period for this emissions certified vehicle starts on the date the vehicle is first purchased and con tinues for a period of 500 hours of engine operation 5000 kilometers 3100 miles of vehicle travel or 30 calen dar months from the date of purchase whichever comes first This emissions limited warrantv covers components whose failure increases the vehicle s regulated emissions and it covers components of svstems whose onlv purpose is to control emissions Repairing or replacing other components not covered bv this warrantv is the responsibilitv of the vehicle owner This emissions limited war ranty does not cover components whose failure does not increase the vehicle s regulated emissions For exhaust emissions emission related components include any engine parts related to the following systems Air induction system Ignition system e Fuel system Exhaust gas recirculation systems The following parts ar
28. S Rollover Protective Structure ROPS The Rollover Protective Structure ROPS on this vehicle meets OSHA 1928 53 rollover performance requirements Always your authorized POLARIS dealer thoroughly inspect the ROPS if it ever becomes damaged in any way No device can assure occupant protection in the event of a rollover Always follow all safe operating practices outlined in this manual to avoid vehicle rollover WARNING Vehicle rollover could cause severe injury or death Always avoid operating in a manner that could result in vehicle rollover 23 FEATURES AND CONTROLS Instrument Cluster High water pressure mav damage components Wash the vehicle bv hand or witha garden hose using mild soap Do not use alcohol to clean instrument cluster Do not allow insect spravs to contact the lens Speedometer The speedometer displavs Vehicle speed in either miles per hour MPH or kilometers per hour km h See page 26 Center Indicator Lamps Speedometer Indicator Lamps Rider Information MODE Button Lamp Indicates Condition Vehicle Speed When standard mode is selected speed displavs in miles per hour When metric mode is selected speed displavs in kilometers per hour Over Temperature This lamp illuminates to indicate an overheated engine If the indicator flashes the overheating condition remains and the system will automatically reduce engine power
29. S Industries Dealers may not give authorization for export You should consult an authorized dealer to determine this vehicle s warranty or service bulletin coverage if you have any questions This policy does not apply to vehicles registered to government officials or military personnel on assignment out side the country of the selling dealer s authorized location This policy does not apply to Safety Bulletins How to Get Service In the Country where your vehicle was purchased Warranty or Service Bulletin repairs must be done by an authorized POLARIS dealer If you move or are travel ing within the country where your vehicle was purchased Warranty or Service Bulletin repairs may be requested from any authorized POLARIS dealer who sells the same line as your vehicle Outside the Country where your vehicle was purchased If you are traveling temporarily outside the country where your vehicle was purchased you should take your vehicle to an authorized POLARIS dealer You must show the dealer photo identification from the country of the selling dealer s authorized location as proof of residence Upon residence verification the servicing dealer will be authorized to perform the warranty repair If You Move If you move to another country be sure to contact POLARIS Customer Assistance and the customs department of the destination country before you move Vehicles importation rules vary considerably from country to country You may be req
30. 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 polarisindustries 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 Snowmobiles e All terrain vehicles ATVs e RANGER utility vehicles e Victory Motorcycles e Low Emission Vehicles LEVs We believe POLARIS sets a standard of excellence for all utility and recreational vehicles manufactured in the world today Many years of experience have gone into the engineering design and development of your POLARIS vehicle making it the finest machine we ve ever produced For safe and enjoyable operation of your vehicle be sure to follow the instructions and rec ommendations in this owner s manual Your manual contains instructions for minor mainte nance but information about major repairs is outlined in the POLARIS Service Manual and should be performed only by a factory certified Master Service Dealer MSD technician Your POLARIS dealer knows your vehicle best and is interested in your total satisfaction Be sure to return to your dealership for all of your service needs during and after the warranty period POLARIS POLARIS and RANGER are registered trademarks of POLARIS Industries Inc Copvright 2012 POLARIS Sales Inc information con
31. a trailer to any other loca tion or you may lose control of the vehicle 5 Never tow a trailer on a grade steeper than 15 Model Total Towed Total Towed Total Hitch Maximum Load Weight Load Weight Vertical Towin Level Ground 15 grade Weight Spee RANGER 800 1250 Ibs 567 kg 850 Ibs 386 kg 150 Ibs 68 1 kg 10 16 km h Midsize Belt Life To extend belt life use the lowest gear possible when hauling or towing heavy cargo Dumping the Cargo Box 1 2 3 4 2 WARNINGI If the weight distribution on the box is located toward the rear of the box when the release lever is pulled forward the box mav dump unexpectediv and cause serious injurv to the operator or Release Select a level site to dump the cargo box Do not attempt to dump or unload the vehicle while parked on an incline the brakes Place the transmission in PARK Dismount the vehicle Ensure that cargo is positioned evenly or toward the front of the cargo box Release the tailgate latches bystanders Never operate the dump lever without ensuring that the load is positioned evenly or at the front of the box 6 Us 8 Stand clear and pull up on the cargo box release lever Lift the front of the cargo box to dump the cargo Lower the cargo box and push down securely to latch Close the tailgate and secure both tailgate latches WARNING Operating the vehicle while the cargo box is raised could result in sever
32. al 33 3 1 Engine Oil Capacitv 2 qts 1 9 1 Coolant Capacitv 120 oz 3 5 1 Overall Length 108 in 274 3 cm Overall Width 56 5 in 143 5 cm Overall Height 73 in 185 cm Wheelbase 72 in 183 cm Cargo Box Dimensions Inside 32x42x11 5 in 81 107 29 cm Ground Clearance 10 in 25 4 cm Min Turning Radius 150 in 381 cm Towing Capacitv 1250 Ibs 567 kg Hitch Tongue Capacitv 150 Ibs 68 kg Max Cargo Box Load 500 Ibs 227 kg Engine 4 valve 4 stroke twin cylinder with counter balance Displacement 760 Bore x Stroke mm 80 x 76 5 Alternator Output 500 W 3000 RPM Compression Ratio 10 0 1 Starting Svstem Electric Fuel Svstem Electronic Fuel Injection Ignition Timing 302 5000 RPM Spark Plug Gap 035 in 0 9 mm Lubrication Svstem Drv Sump Cooling Liquid Front Suspension Dual A arm w 9 6 in 24 4 cm of travel Rear Suspension Independent w 9 in 23 cm of travel 74 SPECIFICATIONS RANGER 800 Midsize Driving Svstem Tvpe PVT Shift Tvpe Single Lever console Gear Reduction Low 7 70 1 Gear Reduction Reverse 7 00 1 Gear Reduction High 4 12 1 Drive Ratio Front 3 818 1 Tire Size Front 25x8 12 Tire Size Rear 25x 11 12 Tire Pressure Front 10 psi 68 9 kPa Tire Pressure Rear 12 psi 82 7 kPa Brakes
33. apply the brakes during a skid Sideways Turn in skid ii of D RA CIKLS lt S La O ODC 5 x c 34 OPERATION Driving Uphill Whenever traveling uphill follow these pre cautions 1 Always travel straight uphill 2 Avoid steep hills 15 maximum 3 Keep both feet on the floor 4 Always check the terrain carefully before ascending any hill 5 Never climb hills with excessively slip pery or loose surfaces 6 Proceed at a steady rate of speed and throt tle opening Never open the throttle sud denly 7 Never go over the crest of a hill at high speed An obstacle a sharp drop or another vehi cle or person could be on the other side of the hill Driving on a Sidehill Sidehilling Driving on a sidehill is not recommended Improper procedure could cause loss of control or overturn Avoid crossing the side of any hill unless absolutely necessary If crossing a sidehill is wnavoidable follow these precautions 1 Slow down 2 Exercise extreme caution 3 Avoid crossing the side of a steep hill 15 maximum Driving Downhill When driving downhill follow these precau tions 1 Avoid steep hills 15 maximum 2 Drive straight downhill Avoid descending a hill at an angle which would cause the vehicle to lean sharply to one side Travel straight downhill when possible 3 Slow down Apply the brakes slightly to aid in slowing 15 maximum 35
34. arcases if equipped and all grease fittings 36 OPERATION 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 Avoid turning at sharp angles 6 Never open the throttle suddenly Parking the Vehicle 1 Apply the brakes Stop the vehicle on a level surface 2 When parking inside a garage or other structure be sure that the structure is well venti lated and that the vehicle is not close to any source of flame or sparks including any appliance with pilot lights 3 Place the transmission in PARK 4 Turn the engine off 5 Remove the ignition switch key to prevent unauthorized use Parking on an Incline Avoid parking on an incline if possible If it s unavoidable follow these precautions mow DA Apply the brakes Place the transmission in PARK Turn the engine off Block the rear wheels on the downhill side 15 maximum 37 OPERATION Hauling Cargo A WARNING Hauling cargo improperlv can alter vehicle handling and mav cause loss of control or brake instabilitv which can result in serious injury or death Always follow these precautions when hauling cargo Never exceed the maximum weight capacity of the vehicle When determining the weight you are add
35. aximum of five seconds Release the key when the engine starts 5 Ifthe engine does not start within five seconds release the ignition switch and wait five seconds Repeat steps 4 and 5 until the engine starts 6 Vary the engine RPM slightly with the throttle to aid in warm up until the engine idles smoothly NOTICE Operating the vehicle immediately after starting could cause engine damage Allow the engine to warm up for several minutes before operating the vehicle Stopping the Engine 1 Release the throttle pedal completely and brake to a complete stop 2 Turn the engine off 3 Place the transmission in PARK WARNING A rolling vehicle can cause serious injury Always place the transmission in PARK when stopping the engine Braking 1 Release the throttle pedal completely 2 Press on the brake pedal evenly and firmly 3 Practice starting and stopping using the brakes until you re familiar with the controls Tip When the throttle pedal is released completely and the engine speed drops near an idle the vehi cle has no engine braking 31 OPERATION Driving Procedure 1 Wear a helmet eye protection gloves long sleeve shirt long pants and over the ankle boots 2 Sit in the driver s seat and fas ten the seat belt 3 Start the engine and allow it to warm up 4 Always use the cab nets while riding in this vehicle 5 Apply the service brakes and shift the transmission into gear 6 Check y
36. bottom of the switch to unlock the differential and allow the rear drive wheels to operate independently 1 WD This mode of operation is well suited to turf driving or when active traction is not needed FEATURES AND CONTROLS Trailer Hitch Bracket This vehicle is equipped with a receiver hitch bracket for a trailer hitch Trailer towing equip ment is not supplied with this vehicle To avoid injury and property damage always heed the warnings and towing capacities out lined on pages 38 39 Brake Pedal Depress the brake pedal to slow or stop the vehicle Apply the brakes while starting the engine Throttle Pedal Push the pedal down to increase engine speed Brake 5 Spring pressure returns the pedal to the rest position when released Alwavs check that the throttle pedal returns normallv before starting the engine Make sure there s adequate throttle pedal freeplav See page 58 for throttle pedal adjustment procedures Fuel Cap The fuel tank filler cap is located on the right hand side of the vehicle near the passenger seat When refueling alwavs use either leaded or unleaded gasoline with a minimum pump octane number of 87 R M 2 octane Do not use fuel with ethanol content greater than 10 percent such as E 85 fuel 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
37. d long pants to protect arms and legs SAFETV Operator Safetv A WARNING Serious injurv or death can result if vou do not follow these instructions and procedures which are outlined in further detail within your owner s manual e Read this manual and all labels carefully Follow the operating procedures described e Never allow anyone under age 16 to operate this vehicle and never allow anyone without a valid driver s license to operate this vehicle e Do not carry a passenger until you have at least two hours of driving experience with this vehicle e No person under the age of 12 may ride as a passenger in this vehicle Any passenger must be able to comfortably reach the floor and hand holds e TThe driver and all passengers must wear helmet eye protection gloves long sleeve shirt long pants over the ankle boots and seat belt at all times e Always use the cab nets while riding in this vehicle e Always keep hands and feet inside the vehicle at all times e Always keep both hands on the steering wheel and both feet on the floorboards of the vehicle during operation Never permit a guest to operate this vehicle unless the guest has read this manual and all product labels e To reduce tipover risk be especially careful when encountering obstacles and slopes and when braking on hills or during turns e This vehicle is for off road use only Never operate on public roads Always avoid paved surfaces Never consu
38. ditions 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 of vibration exposure measurement is dependent on many factors including e Instrument and calibration uncertainty e Variations in the machine such as wear of components e Variation of machine operators such as experience or physique e Ability of the worker to reproduce typical work during measurements e Environmental factors such as ambient noise or temperature SAFETV Safetv Labels and Locations Warning labels have been placed on the vehicle for vour 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 becomes illegible or comes off contact your POLARIS dealer to purchase a replacement Replacement safety labels are provided by POLARIS at no charge The part number is printed on the label Discretionary Warning Age 16 Warning Shift Caution Clutch Cover Warning Clutch Cover Warning WARNING Moving parts hazard under belt clutch guard To prevent serious injury do not operate vehicle with guard removed Do not modify engine or clutch Doing so can cause part failure possible imbalance and excessive engine RPM which can result in serious injury or death
39. e also considered emission related components for exhaust emissions Aftertreatment devices Sensors Crankcase ventilation valves e Electronic control units The following parts are considered emission related components for evaporative emissions Fuel Tank Vacuum Control Diaphragms Fuel Cap e Control Cables e Fuel Line e Control Linkages Fuel Line Fittings e Purge Valves Clamps Vapor Hoses e Pressure Relief Valves Liquid Vapor Separator e Control Valves e Carbon Canister Control Solenoids e Canister Mounting Brackets e Electronic Controls Carburetor Purge Port Connector As related to the evaporative emission control system 83 WARRANTV U S A EPA Emissions Limited Warrantv 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 FORTH IN THIS LIM ITED WARRANTY ARE THE ONLY REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF THIS WARRANTY POLARIS SHALL HAVE NO LIABILITY TO ANY PERSON FOR INCIDENTAL CONSE QUENTIAL OR SPECIAL DAMAGES OF ANY DESCRIPTION WHETHER ARISING OUT OF EXPRESS OR IMPLIED WARRANTY OR ANY OTHER CONTRACT NEGLIGENCE OR OTHER TORT OR OTHER WISE THIS EXCLUSION OF CONSEQUENTIAL INCIDENTAL AND SPECIAL DAMAGES IS INDE PENDENT FROM AND SHALL SURVIVE ANY FINDING THAT THE EXCLUSIVE REMEDY FAILED OF ITS ESSENTIAL PURPOSE AL
40. e event of an accident or sudden stop Riders must wear seat belts at all times Always make sure the seat belts are secured for both the operator and all passengers before riding a Protective Apparel Riding in this vehicle without wearing an approved helmet and protective evewear increases the risk of a serious injuries in the event of an accident Operator and all passengers must alwavs wear an approved helmet that fits properlv and eve protection goggles or face shield 13 SAFETV Operator Safetv Cab Nets Riding in this vehicle without using the cab nets increases the risk of serious injurv or death in the event of an accident or overturn Alwavs use the cab nets while riding in this vehicle Alwavs keep hands and feet inside the vehicle at all times Failure to Inspect Before Operating Failure to inspect and verifv that the vehicle is in safe operating condition before operating increases the risk of an accident Alwavs inspect vour RANGER before each use to make sure it s in safe operating condition Alwavs follow all inspection and maintenance procedures and schedules described in owner s manual Handling Gasoline Gasoline is highly flammable and explosive under certain conditions Always exercise extreme caution whenever handling gasoline Always stop the engine when refueling Remove flammable material containers from the box before filling them with fuel Always refuel outdoors o
41. e injury The box could close unexpectedly and cause injury to the driver or passenger The rear tires will also catch the rear of a raised box damaging the vehicle and creating hazardous driving conditions Never operate this vehicle with the cargo box in the raised position 39 OPERATION Differential Operation Modes The 4X4 rear axle is equipped with a lockable differential that allows the operator to choose between an open differential or a closed differential AWD Press the top of the rocker switch to engage All Wheel Drive AWD When in AWD the rear wheels rotate at the same speed The front wheels also rotate at the same speed See page 41 for AWD operating instructions 2WD Rear Differential Locked Move the rocker switch to the center position to lock the differen tial and operate in two wheel drive 2WD Locking the differen tial in slippery or low traction conditions helps improve traction When the rear differential is locked both rear wheels rotate at the same speed OFF Differential Unlocked 4 fi ti Press the bottom of the switch to unlock the differential and allow the rear drive wheels to operate independently LWD When rear differential is unlocked rear wheels rotate at different speeds Unlock the differential to make maneuvering easier and minimize damage to turf NOTICE Damage to the differential can occur if it is engaged while the vehicle is traveling at high speeds
42. educe speed and follow the instructions in this manual for hauling cargo or pulling a trailer Allow a greater distance for braking e Always place the transmission in PARK before getting out of the vehicle e Always stop the engine before refueling Remove flammable material containers from the box before filling them with fuel Make sure the refueling area is well ventilated and free of any source of flame or sparks Gasoline is extremely flammable See page 14 for fuel safety warnings e Always remove the ignition key when the vehicle is not in use to prevent unauthorized use or accidental starting FOR MORE INFORMATION ABOUT SAFETY call POLARIS at 1 800 342 3764 SAFETV Operator Safetv Equipment Modifications We strongly recommend that consumers do not install on POLARIS RANGER equip ment that may increase the speed or power of the vehicle or make any other modifications to the vehicle for these purposes Any modifications to the original equipment of the vehicle create a substantial safety hazard and increase the risk of bodily injury The warranty on your POLARIS RANGER is terminated if any equipment has been added to the vehicle or if any modifications have been made to the vehicle that increase its speed or power The addition of certain accessories including but not limited to mowers blades tires sprayers or large racks may change the handling characteristics of the vehicle Use only POLARIS approved accesso
43. ement safety labels are provided by POLARIS at no charge 69 MAINTENANCE Cleaning and Storage Polishing the Vehicle POLARIS recommends the use of common household aerosol furniture polish for polishing the finish on vour POLARIS vehicle Follow the instructions on the container e Avoid the use of automotive products some of which can scratch the finish of your vehi cle e Always use clean cloths and pads for cleaning and polishing Old or reused cloths and pads may contain dirt particles that will scratch the finish Chrome Wheel Care if equipped Proper maintenance will protect chrome wheels from corrosion preserve wheel life and ensure a like new appearance for many years Chrome wheels exposed to road salt or salt in the air in coastal areas are more susceptible to corrosion if not properly cleaned Clean chrome wheels more often if they re exposed to salt or other corrosive elements 1 Wash chrome wheels frequently Use a mild detergent Never use abrasive cleaners plated or painted surfaces 2 Rinse well with clear water Soap detergents salt dirt mud and other elements can cause corrosion 3 Polish the clean chrome wheels periodically Use an automotive grade chrome polish Routinely and liberally apply a weather resistant wax to each polished chrome wheel Choose a product suitable for chrome finishes Read and follow the product labels and instructions Removing Corrosion If light rust is f
44. enclosed area Exhaust contains poisonous carbon monoxide gas that can cause loss of consciousness or death in a very short time e Never go under the vehicle while it s inclined Use the following procedure to periodically purge accumulated carbon from the exhaust pipe 1 Remove the arrester clean out plug located on the bottom of the muffler Place the transmission in PARK 09 Start the engine Clean Out 74 Plug 2 Exhaust Outlet 4 Purge accumulated carbon from the system by momentarily revving the engine several times 5 Ifcarbon is expelled cover or plug the exhaust outlet and rap on the pipe around the clean out plug while revving the engine sev eral more times 6 If particles are still suspected to be in the muffler elevate the rear of the vehicle one foot higher than the front Block the wheels 7 Repeat steps 4 and 5 until no more particles are expelled when the engine is revved 8 Stop the engine Allow the arrester to cool 9 Reinstall the arrester plug and remove the outlet cover or plug 57 MAINTENANCE Throttle Svstem A WARNING Failure to check or maintain proper operation of the throttle svstem can result in an accident and lead to serious injurv or death if the throttle pedal sticks during operation Alwavs check the pedal for free movement and return before starting the engine and occasionallv during operation Never start or operate this vehicle if it has a sticking or imprope
45. ents of the POLARIS RANGER against defects in material or workmanship POLARIS also gives a one vear limited warrantv on the final drive chain for failure due to defects This warrantv covers the parts and labor charges for repair or replacement of defective parts which are covered this warrantv This warrantv begins on the date of purchase This warranty is transferable to another consumer during the warranty period through a POLARIS dealer REGISTRATION At the time of sale the Warranty Registration Form must be completed by your dealer and submitted to POLARIS within ten days Upon receipt of this registration POLARIS will record the registration for warranty No verification of registration will be sent to the purchaser as the copy of the Warranty Registration Form will be the warranty entitlement If you have not signed the original registration and received the customer copy please contact your dealer immediately NO WARRANTY COVERAGE WILL BE ALLOWED UNLESS YOUR VEHICLE IS REGISTERED WITH POLARIS Initial dealer preparation and set up of your vehicle is very important in ensuring trouble free operation Purchas ing a machine in the crate or without proper dealer set up will void your warranty coverage WARRANTY COVERAGE AND EXCLUSIONS LIMITATIONS OF WARRANTIES AND REMEDIES The POLARIS limited warranty excludes any failures that are not caused by a defect in material or workmanship This warranty does not cover accidental damage norma
46. f recommended oil Place the transmission in PARK Start the engine Allow it to idle for one to two minutes Stop the engine Inspect for leaks Check the oil level on the dipstick and add oil as necessary to bring the level to the upper mark on the dipstick Reinstall the seat Dispose of used filter and oil properly 47 MAINTENANCE Gearcases Gearcase Specification Chart Gearcase Lubricant Capacitv Fill Plug s Drain Plug Torque Torque Main Gearcase Premium AGL 34 oz 12 ft Ibs 12 ft Ibs Transmission Gearcase Lube 1000 ml 16 3 Nm 16 3 Nm Front Gearcase Demand Drive Plus Fluid 9 3 oz 8 10 ft Ibs 11 ft Ibs 275 ml 11 13 6 Nm 15 Nm Transmission Main Gearcase Always check and change the transmission oil at the intervals outlined in the Periodic Main tenance Chart beginning on page 43 Maintain the oil level even with the bottom of the fill plug hole threads Refer to the Gearcase Specifications Chart for recommended lubricants capacities and torque specifications See page 76 for the part numbers of POLARIS products Oil Check The fill plug is located on the rear of the gearcase A level check alternate fill plug is located on the side of the gearcase Maintain the oil level even with the bottom of the level check fill plug hole threads 1 Position the vehicle on a level surface PAEO 9 OL A 5 7
47. fasteners for proper torque at the first service or after 25 hours 55 MAINTENANCE Filter Svstems Air Filter Always change the air filter at the intervals outlined in the Periodic Maintenance Chart beginning on page 43 Service the air filter more frequently if the vehicle is operated in wet conditions or at high throttle openings for extended periods 1 Lift the cargo box to access the air box 2 Remove the air box cover and inspect the gasket It should 2 adhere tightly to the cover and Air Filter seal all the way around Tip Grasp the filter end to prevent damage to the filter paper 3 Remove the air filter 4 Do not attempt to clean the main element Install a new air filter Tip Apply a small amount of general purpose grease to the sealing edges of the filter before installing 5 Inspect the air box for oil or water deposits If present drain them into a suitable container 56 MAINTENANCE Spark Arrester A WARNING Failure to heed the following warnings while servicing the spark arrester could result in serious injurv or death Do not perform service on the spark arrester while the svstem is hot Exhaust svstem temperatures can reach 1000 Allow components to cool sufficiently before proceeding Remove any combustible materials from the area Wear eye protection and gloves Do not stand behind or in front of the vehicle while purging Never run the engine an
48. for your vehicle POLARIS also recommends that you use only Pure POLARIS parts It is a potential violation of the Clean Air Act if a part supplied by an aftermarket parts manufacturer reduces the effec tiveness of the vehicle s emission controls Tampering with emission controls is prohibited by federal law If you have any questions regarding your warranty rights and responsibilities please contact the POLARIS War ranty Department at 1 888 704 5290 84 MAINTENANCE LOG Use the following chart to record periodic maintenance DATE MILES TECHNICIAN SERVICE PERFORMED COMMENTS OR HOURS 85 MAINTENANCE LOG DATE MILES KM OR HOURS TECHNICIAN SERVICE PERFORMED COMMENTS 86 A Accessory Outlets fi so e 18 Adjustment Shock Spring 60 Throttle Freeplay 58 Air Filter eee ejt ed ound nes 56 All Wheel sia ila i 41 Wheel Drive 19 Auxiliary 18 Axle Nut 5 5 cea meneeds 61 B Battery 65 68 Charging Conventional 68 Charging Sealed 68 Fluid Conventional 65 67 1
49. hain Lube Aerosol 16 oz Additives Miscellaneous 2871326 Carbon Clean Plus 2872189 DOT 4 Brake Fluid 2871956 Loctite 565 Thread Sealant 2871076 POLARIS Battery Tender Charger 76 TROUBLESHOOTING Drive Belt Wear Burn Possible Cause Driving onto a pickup or tall trailer in high range Solution Use low range during loading Starting out going up a steep incline Use low range See warnings on page 35 Driving at low RPM or ground speed 3 7 MPH Drive higher speed or use low range more frequentiv See page 53 Insufficient warm up at low ambient temperatures Warm the engine at least 5 minutes With the transmission in neutral advance the throttle to about 1 8 throttle in short bursts 5 to 7 times The belt will become more flexible and prevent belt burning Slow easv clutch engagement Use the throttle quickly and effectively Towing pushing at low RPM low ground speed Use low range only Utility use plowing Use low range only Stuck in mud or snow Shift the transmission to low range and carefully use fast aggressive throt tle application to engage clutch WARNING Excessive throttle may cause loss of control and vehicle over turn Climbing over large objects from a stopped position Shift the transmission to low range and carefully use fast brief aggressive throttle application to engage clutch WARNING Excessive throttle may ca
50. hat will shorten the life of the lamp Headlight Lamp Replacement 1 Open hood CAUTIONI Hot components can cause burns to skin Allow lamps to cool before servicing 2 Unplug the headlamp from the wiring har ness Be sure to pull on the connector not on the wiring 3 Turn the lamp counter clockwise to remove it 4 Install the new lamp Tip Make sure the tab on the lamp locates properly in the housing 5 Reinstall the harness assembly into the head light assembly Wiring Harness kf 63 MAINTENANCE Lights Headlight Beam Adjustment 2 6 7 Place the vehicle a level surface with the headlight approximatelv 25 ft 7 6 m from a wall Measure the distance from the floor to the center of the headlight and make a mark on the wall at the same height the brakes Start the engine Turn on the headlights Observe the headlight aim The most intense part of the headlight beam should be aimed 8 20 cm below the mark placed on the wall Include the weight of a rider on the seat while performing this step Ifa headlight needs adjustment locate the adjustment screw at the back of the headlight Loosen the screw adjust the headlight and tighten the screw Repeat steps 4 6 until the lamp is properly adjusted Brake Lights When the brake pedal is depressed the console brake light comes on Check the brake light before each ride 1 2
51. he Periodic Maintenance Chart beginning on page 43 Alwavs change the oil filter whenever changing oil WARNINGI Vehicle operation with insufficient deteriorated or contaminated engine oil will cause accelerated wear and result in engine seizure accident and injurv Alwavs perform the maintenance procedures as outlined in the Periodic Maintenance Chart Oil Recommendations POLARIS recommends the use of POLARIS PS 4 PLUS Performance Synthetic 2W 50 4 cycle oil or a similar oil See page 76 for the part numbers of POLARIS products NOTICE Mixing brands or using a non recommended oil may cause serious engine damage Always use the recommended oil Never substitute or mix oil brands Oil Check The oil tank is located under the seat 1 Position the vehicle on a level surface Place the trans mission in PARK 2 Remove the seat See page 20 3 the lever lock to remove the dipstick Wipe it dry with a clean cloth 4 Reinstall the dipstick completely but do not lock it The dipstick must be screwed completely in to keep the angle and depth of the stick consistent 5 Remove the dipstick and check the oil level Maintain the oil level in the safe range Do not overfill Tip Due to the dipstick entry angle into the crankcase the oil level will read higher on the bottom side of the dipstick Always read the level on the upper surface of the dipstick 6 After reinstalling the dipstick be sure to seat the lever lock
52. ill automatically charge the bat tery if the voltage drops below a pre determined point See page 76 for the part numbers of POLARIS products 67 MAINTENANCE Batterv Batterv Charging Conventional Batterv 1 Remove the batterv from the vehicle to prevent damage from leaking or spilled electro Ivte during charging See page 66 2 Charge the battery with a charging output no larger than 1 10 of the battery s amp hr rat ing Charge as needed to raise the specific gravity to 1 270 or greater 3 Reinstall the battery See page 67 Make sure the positive terminal is toward the driver s side of the vehicle Battery Charging Sealed Battery The following battery charging instructions apply only to the installation of a sealed battery Read all instructions before proceeding with the installation of this battery The sealed battery is already filled with electrolyte and has been sealed and fully charged at the factory Never pry the sealing strip off or add any other fluid to this battery The single most important thing about maintaining a sealed battery is to keep it fully charged Since the battery is sealed and the sealing strip cannot be removed you must use a voltmeter or multimeter to measure DC voltage WARNING An overheated battery may explode causing severe injury or death Always watch charging times carefully Stop charging if the battery becomes very warm to the touch Allow it to cool before resuming charging F
53. in this manual Driving Over Obstacles Follow these precautions when operat ing over obstacles 1 2 Alwavs check for obstacles before operating in a new Look ahead and learn to read the terrain Be constantiv alert for haz ards such as logs rocks and low hanging branches Travel slowly and use extra caution when operating on unfamiliar ter rain Not all obstacles are immedi ately visible 33 OPERATION Driving On Slipperv Surfaces A WARNING Skidding or sliding can cause loss of control or overturn if tires regain traction unexpectediv When operating on slipperv surfaces such as ice or loose gravel reduce speed and use extra caution to reduce the chance of skidding or sliding out of control Do not operate on excessivelv slipperv surfaces Whenever riding on slipperv surfaces such as wet trails or loose gravel or during freezing weather follow these precautions 1 Donotoperate on excessivelv rough slipperv or loose terrain 2 Slow down before entering slippery areas 3 Maintain a high level of alertness reading the trail and avoiding quick sharp turns which can cause skids 4 Engage all wheel drive before wheels begin to lose traction NOTICE Severe damage to the drive train may occur if the AWD is engaged while the wheels are spinning Always allow the wheels to stop spinning before engaging AWD 5 Correct a skid by turning the steering wheel in the direction of the skid Never
54. including insect repellents and chemicals will damage plastic surfaces Do not allow these types of products to contact the vehicle The best and safest way to clean your POLARIS vehicle is with a garden hose and a pail of mild soap and water 1 Use a professional type washing cloth cleaning the upper body first and the lower parts last 2 Rinse with clean water frequently 3 Dry surfaces with a chamois to prevent water spots Washing Tips Avoid the use of harsh cleaners which can scratch the finish e Do not use a power washer to clean the vehicle e Do not use medium to heavy duty compounds on the finish e Always use clean cloths and pads for cleaning and polishing Old or reused cloths and pads may contain dirt particles that will scratch the finish Grease all zerk fittings immediately after washing Allow the engine to run for a while to evaporate any water that may have entered the engine or exhaust system Ifa high pressure water system is used for cleaning not recommended exercise extreme caution The water may damage components and could remove paint and labels Avoid directing the water stream at the following items e Wheel bearings Brakes Switches and controls e Radiator Cab body panels Electrical components and wiring e Transmission seals e Labels and decals If an informational or graphic label becomes illegible or comes off contact your POLARIS dealer to purchase a replacement Replac
55. ing items are excluded from warranty coverage in the event of a warranty claim Spark Plugs e Lubricants such as oil grease etc e Filters Batteries unless defective Fuel e Cosmetic damage repair Sealants e Coolants Hotel fees e Meals Towing charges Shipping handling fees e Mileage e Product pick up deliverv e Rentals Loss of product use e Loss of vacation personal time 80 WARRANTV LIMITATIONS OF WARRANTIES AND REMEDIES This warrantv also excludes failures resulting from improper lubrication improper engine timing improper fuel surface imperfections caused bv external stress heat cold or contamination operator error or abuse improper component alignment tension adjustment or altitude compensation failure due to snow water dirt or other for eign substance ingestion contamination improper maintenance modified components use of aftermarket com ponents resulting in failure unauthorized repairs repairs made after the warranty period expires or by an unauthorized repair center use of the product in competition or for commercial purposes Warranty will not apply to any product which has been damaged by abuse accident fire or any other casualty not determined a defect of materials or workmanship This warranty does not cover the use of unauthorized lubricants chemicals or fuels that are not compatible with the vehicle The exclusive remedy for breach of this warranty shall be at POLARIS exclusive
56. ing to the vehicle include the weight of the operator passenger accessories loads in the rack or box and the load on the trailer tongue The combined weight of these items must not exceed the maximum weight capacity REDUCE SPEED AND ALLOW GREATER DISTANCES FOR BRAKING WHEN HAULING CARGO Always load the cargo box with the load as far forward and as low as possible When operating over rough or hilly terrain reduce speed and cargo to maintain stable driving conditions Always operate the vehicle with extreme care when hauling or towing loads Slow down and drive in the lowest gear available SECURE ALL LOADS BEFORE OPERATING Unsecured loads can create unstable operating conditions which could result in loss of control of the vehicle OPERATE ONLY WITH STABLE AND SAFELY ARRANGED LOADS When handling off centered loads that cannot be centered securely fasten the load and operate with extra caution Always attach the tow load to the hitch point designated for your vehicle HEAVY LOADS CAN CAUSE BRAKING AND CONTROL PROBLEMS Use extreme caution when applying brakes with a loaded vehicle Avoid terrain or situations that may require backing downhill USE EXTREME CAUTION when operating with loads that extend over the rack sides Stability and maneuverability may be adversely affected causing the vehicle to overturn DO NOT TRAVEL FASTER THAN THE RECOMMENDED SPEEDS Vehicle should never exceed 10 MPH 16 km h while towing a load on a leve
57. jj EPS Warning This indicator illuminates briefly when the key is turned to the position If the light remains on the EPS system is inoperative See your authorized POLARIS dealer for service Neutral This lamp illuminates when the transmission is in neutral and the ignition key is in the ON position High Beam This lamp illuminates when the headlamp switch is set to high beam Helmet Seat Belt This lamp flashes for several seconds when the key is turned to the ON position The lamp is a reminder to the operator to ensure all riders are wearing helmets and seat belts before operating IN ED Check Engine 0 This indicator appears if an EFl related fault occurs Do operate the vehicle if this warning appears Serious engine damage could result See vour dealer 24 Instrument Cluster Rider Information Center The rider information center is located the instrument cluster segments will light up for one sec ond at start up If the instrument cluster fails to illuminate a batterv over voltage mav have occurred and the instrument cluster mav have shut off to protect the electronic speedometer If this occurs take the Vehicle to vour POLARIS dealer for proper diagnosis The information center is set to dis play standard units of measurement FEATURES AND CONTROLS FF TERE T PA Trip 1 NA i ne ROH NUN and a 12 hour clock at the factor
58. klist on page 30 Brake svstem Wheels fasteners Frame fasteners Engine oil level Nir filter pre filter Dailv Inspect clean often replace as needed box sediment tube Dailv Drain deposits when visible Coolant if applicable Dailv Check level dailv change coolant everv 2 vears Headlamp tail lamp Daily Check operation apply dielectric grease if replacing Air filter main element Inspect needed 4 Brake pad wear 10H Monthiv Inspect periodicallv Batterv 20H Monthiv Check terminals clean test gt Clutch Intake pre filter 25H Monthiv Inspect clean with compressed air replace if necessarv Engine breather filter if equipped 25 Monthly Inspect replace if necessary gt Front Gearcase oil if equipped 25H 1M Perform a break in oil level check Middle Gearcase oil if equipped 25H 1M Perform a break in oil level check Rear gearcase oil if equipped 25H 1M Perform a break in oil level check gt Transmission oil 25H 1M Perform a break in oil level check Engine oil change break in 25H 1M oe a break in oil change at one mon gt General lubrication 50 H Lubricate all fittings pivots cables etc Shift Linkage 50H 6M Inspect lubricate adjust D Steering 50H 6M Lubricate gt Front Suspension 50 H 6M Lubricate b Rear Suspension 50 H 6M Lubricate D Throttle cable 50 H 6M Inspect adjust lubricate replace if
59. l grass surface Vehicle speed should never exceed 5 MPH 8 km h when towing loads in rough terrain while cornering or while ascending or descending a hill The RANGER has been designed to carry or tow specific capacities Always read and under stand the load distribution warnings listed on the warning labels The total load operator passenger accessories cargo and weight on hitch must not exceed the maximum weight capacity of the vehicle Never exceed the following capacities Maximum Capacities Model Level Ground Cargo Box RANGER 800 Midsize 1000 Ibs 455 kg 500 Ibs 226 kg WARNING Driving with passengers in the cargo box can result in severe injury or death Never allow passengers to ride in the cargo box Passengers must always ride in the cab with seat belts fastened securely 38 OPERATION Towing Loads Towing improperly can alter vehicle handling and may cause loss of control or brake insta bility Always follow these precautions when towing 1 Never load more than 150 16 68 1 kg tongue weight on the towing bracket 2 Do not operate the vehicle faster than 10 MPH 16 km h when towing See page 38 Towing a trailer increases braking distance 3 Do not tow more than the recommended weight for the vehicle See the towing capacity chart below and the specifications charts beginning on page 74 4 Attach a trailer to the trailer hitch bracket only Do not attach
60. l wear and tear abuse or improper handling This war ranty also does not cover any vehicle that has been altered structurally modified neglected improperly main tained used for racing or used for purposes other than for which it was manufactured or for any damages which occur during trailer transit or as a result of unauthorized service or the use of unauthorized parts In addition this warranty does not cover physical damage to paint or finish stress cracks tearing or puncturing of upholstery material corrosion or defects in parts components or the vehicle due to fire explosions or any other cause beyond POLARIS control Warranty does not apply to parts exposed to friction surfaces stresses environmental conditions and or contami nation for which they were not designed or not intended including but not limited to the following items Wheels and tires e Finished and unfinished surfaces Suspension components Carburetor Throttle body components Brake components e Engine components Seat components e Drive belts Clutches and components Hydraulic components Steering components e Circuit breakers Fuses Batteries Electronic components Light bulbs Sealed beam lamps Warranty applies to the product only and does not allow for coverage of personal loss Some items are considered consumable meaning they are considered part of normal maintenance or part of completing an effective repair The follow
61. lant level through the opening 4 Use a funnel and slowly add coolant as needed Tip This procedure is required only if the cooling system has been drained for maintenance and or repair But if the overflow bottle has run dry the level in the radiator should also be inspected 5 Reinstall the pressure cap Use of a non standard pressure cap will not allow the recov ery system to function properly See your dealer for the correct replacement part 52 MAINTENANCE POLARIS Variable Transmission PVT Svstem A WARNING Failure to complv with the instructions in this warning can result in severe injurv or death Do not modifv anv component of the PVT svstem Doing so mav reduce its strength so that a failure mav occur at a high speed The PVT svstem has been precision balanced Anv modification will cause the svstem to be out of balance creating vibration and additional loads on components The PVT svstem rotates at high speeds creating large amounts of force on clutch components Extensive engineering and testing has been conducted to ensure the safetv of this product However as the owner vou have the following responsibilities to make sure this svstem remains safe Always follow all recommended maintenance procedures Always look for and remove debris inside and around the clutch and vent system when replacing the belt See your dealer as outlined in the owner s manual This PVT system is intended for use on POLARIS product
62. lated Cover the vehicle with a genuine POLARIS cover Do not use plastic or coated materials They do not allow enough ventilation to pre vent condensation and may promote corrosion and oxidation 12 MAINTENANCE Removal from Storage 1 Check the batterv electrolvte level and charge the batterv if necessarv Install it in the vehicle Make sure the batterv vent hose is routed properlv and that it s not pinched or restricted any way Make sure the spark plug is tight Fill the fuel tank with fuel Check all the points listed in the Daily Pre Ride Inspection section on page 30 Tightness of the bolts nuts and other fasteners should be checked by an authorized POLARIS dealer Lubricate at the intervals outlined in the Periodic Maintenance Chart beginning on page 43 Transporting the RANGER Follow these procedures when transporting the vehicle 1 the brakes Place the transmission in PARK Stop the engine Secure the fuel cap oil cap and seat Alwavs tie the frame of the RANGER to the transporting unit securelv with suitable straps or rope Do not attach tie straps to the front A arm bolt pockets Remove the to prevent loss during transporting 73 SPECIFICATIONS RANGER 800 Midsize Maximum Weight Capacity includes weight of operator passenger cargo accessories 1000 Ibs 454 kg Dry Weight 1055 Ibs 478 5 kg Fuel Capacity 8 8 g
63. le nuts that have a cotter pin installed See your POLARIS dealer 3 Attach the wheel nuts and washers and fin ger tighten 4 Carefully lower the vehicle to the ground 5 Torque the wheel nuts to specification See page 61 62 Fuses If the engine stops or will not start or if vou expe rience other electrical failures a fuse mav need replacement Locate and correct anv short circuits that mav have caused the blown fuse then replace the fuse Spare fuses are provided in the fuse box If vou suspect that a fuse or relav mav not be working properlv please see vour POLARIS dealer Fuse Feature Supported 20 Lights Headlights Taillights 10A Drive AWD 20 Accessory Winch Switch 12V Power Receptacle 10A Fuel Pump 20 Electronic Engine Control Starting Lights MAINTENANCE EFI RELAY FAN FUEL PUMP HEADLIGHT L iL CHASSIS RELAV 7177181 RELAV RELAV RELAV LIGHTS DRIVE JACCESSORV 20 10A 20A FUEL PUMP SPARE 20 30 Poor lighting can result in reduced visibilitv when driving Headlight and taillight lenses become dirtv during normal operation Clean lights frequentiv and replace burned out lamps promptiv Alwavs make sure lights are adjusted properlv for best visibilitv When servicing a halogen lamp don t touch the lamp with bare fingers Oil from vour skin leaves a residue causing a hot spot t
64. lies with Canadian ICES 002 This vehicle complies with the EMC requirements of European directives 97 24 EC and 2004 108 EC Non ionizing Radiation This vehicle emits some electromagnetic energy People with active or non active implantable medical devices such as heart monitoring or controlling devices should review the limitations of their device and the applicable electromagnetic standards and directives that apply to this vehicle 42 MAINTENANCE Periodic Maintenance Chart Careful periodic maintenance will help keep vour vehicle in the safest most reliable condi tion Inspection adjustment and lubrication of important components are explained in the periodic maintenance chart Inspect clean lubricate adjust and replace parts as necessary When inspection reveals the need for replacement parts use genuine POLARIS parts available from your POLARIS dealer Record maintenance and service in the Maintenance Log beginning on page 85 Tip Service and adjustments are important for proper vehicle operation If you re not familiar with safe service and adjustment procedures have a qualified dealer perform these operations Maintenance intervals in the following chart are based upon average riding conditions and an average vehicle speed of approximately 10 MPH 16 km h Vehicles subjected to severe use must be inspected and serviced more frequently Severe Use Definition e Frequent immersion in mud water or sand e Frequent o
65. ll and for braking on hills Check the terrain carefully before descending a hill Never travel downhill at high speed Avoid going downhill at an angle which would cause the vehicle to lean sharply to one side Travel straight down the hill where possible e Always check for obstacles before operating in a new area Never attempt to operate over large obstacles such as rocks or fallen trees Always follow the proper procedures outlined in this manual when operating over obstacles e Always be careful of skidding or sliding On slippery surfaces such as ice travel slowly and exercise caution to reduce the chance of skidding or sliding out of control e Never operate your vehicle in fast flowing water or in water deeper than that specified in this manual Wet brakes may have reduced stopping ability Test your brakes after leaving water If necessary apply them lightly several times to let friction dry out the pads e Always be sure there are no obstacles or people behind your vehicle when operating reverse When it s safe to proceed in reverse move slowly Avoid turning at sharp angles in reverse e Always use the proper size and type of tires specified in this manual Always maintain proper tire pressure as specified on safety labels e Never modify this vehicle through improper installation or use of accessories Never exceed the stated load capacity for this vehicle Cargo should be properly distrib uted and securely attached R
66. luding dirt and gravel roads In some areas it s unlawful to operate this vehicle on public streets roads and highways Turning Improperly Turning improperly could cause loss of traction loss of control accident or overturn Always follow proper procedures for turning Never turn abruptly or at sharp angles Never turn at high speeds Practice turning at slow speeds before attempting to turn at faster speeds Jumps and Stunts Attempting wheelies jumps and other stunts increases the risk of an accident or overturn Never attempt wheelies jumps or other stunts Avoid exhibition driving Operating in Unfamiliar Terrain Failure to use extra caution when operating on unfamiliar terrain could result in an accident or overturn Unfamiliar terrain may contain hidden rocks bumps or holes that could cause loss of control or overturn Travel slowly and use extra caution when operating on unfamiliar terrain Always be alert to changing terrain conditions 15 SAFETV Operator Safetv Improper Hill Climbing Climbing hills improperly can cause loss of control or vehicle overturn Always follow proper procedures for climbing hills as described in the owner s manual See page 35 Stalling While Climbing a Hill Stalling or rolling backwards while climbing a hill could cause an overturn Always maintain a steady speed when climbing a hill If all forward speed is lost Apply the brakes Place the transmission in reverse and sl
67. m ice conditions and thickness over your entire route Vehicle operators assume all risk associated with ice conditions on frozen bodies of water Unauthorized Use of the Vehicle Leaving the keys in the ignition can lead to unauthorized use of the vehicle which could result in an accident or overturn Always remove the ignition key when the vehicle is not in use Hot Exhaust Systems Exhaust system components are very hot during and after use of the vehicle Hot components can cause burns and fire Do not touch hot exhaust system components Always keep combustible materials away from the exhaust system Use caution when traveling through tall grass especially dry grass 16 FEATURES AND CONTROLS Component Locations Your vehicle is equipped with cab nets on both sides of vehicle Cab nets must be used by both operator and passengers at all times The vehicle illustrated below is shown without cab nets only to allow component identification Always use the cab nets Not all models come with all features Refer to the specifications section beginning on page 74 ROPS Cab 4 Hip Bar Cargo Box Console Tailgate H Latch H Releases Headlights 1 Tailgate B PELARIS
68. me alcohol or drugs before or while operating this vehicle e Never operate at excessive speeds Always travel at a speed proper for the terrain visibility and operating conditions and your experience Never attempt jumps or other stunts e Always inspect your vehicle each time you use it to make sure it s in safe operating condition Always follow the inspection and maintenance procedures and schedules described in this manual e Always travel slowly and use extra caution when operating on unfamiliar terrain Be alert to changing terrain e Never operate on excessively rough slippery or loose terrain e Always follow proper procedures for turning Practice turning at slow speeds before attempting to turn at faster speeds Never turn at excessive speeds 10 SAFETV Operator Safetv e Always have this vehicle checked by an authorized POLARIS dealer if it has been involved in an accident e Never operate this vehicle on hills too steep for the vehicle or for your abilities Practice on smaller hills before attempting larger hills e Always follow proper procedures for climbing hills as described in this manual Check the terrain carefully before attempting to climb a hill Never climb hills with excessively slip pery or loose surfaces Never open the throttle suddenly or make sudden gear changes Never go over the top of a hill at high speed e Always follow the proper procedures outlined in this manual for traveling downhi
69. mediately see your POLARIS dealer Low battery voltage Recharge the battery to 12 8 VDC Mechanical failure See your dealer Engine Backfires Possible Cause Weak spark from spark plug Solution Inspect clean and or replace spark plugs Incorrect spark plug gap or heat range Set gap to specs or replace plugs Old or non recommended fuel Replace with fresh recommended fuel Incorrectiv installed spark plug wires See dealer Incorrect ignition timing See vour dealer Mechanical failure See vour dealer Loose ignition connections Check all connections and tighten Water present in fuel Replace with fresh recommended fuel Engine Pings or Knocks Possible Cause TROUBLESHOOTING Solution Poor qualitv or low octane fuel Replace with recommended fuel Incorrect ignition timing See vour dealer Incorrect spark plug gap or heat range Set gap to specs or replace plugs Engine Runs Irregularly Stalls Misfires Possible Cause Solution Fouled or defective spark plugs Inspect clean and or replace spark plugs Worn or defective spark plug wires See vour dealer Incorrect spark plug gap or heat range Set gap to specs or replace plugs Loose ignition connections Check all connections and tighten Water present in fuel Replace with new fuel Low batterv voltage Recharge batte
70. ncluding cuts wear fraying or stiffness If any damage is found or if the seat belt does not oper ate properly have the seat belt system checked and or replaced by an authorized POLARIS dealer 4 clean dirt or debris from the seat belts sponge the straps with mild soap and water Do not use bleach dye or household detergents 21 FEATURES AND CONTROLS Cab Nets Riding in this vehicle without using the cab nets increases the risk of serious injurv or death in the event accident or overturn Cab nets must be used both operator and passen gers at all times Make sure all latches are secure before operating the vehicle Alwavs inspect cab nets for tightness wear and damage before each use of the vehicle Use the strap adjusters to tighten anv loose straps Promptiv replace worn or damaged cab nets with new cab nets available from vour authorized Polaris dealer Securing a Net 1 After entering the vehicle insert the lower net rod into the net mount on the floor Make sure the ball at the end of the rod is properlv secured in the slot at the base of the mount 2 Connect the latch at the top edge of the net to receiver latch mounted on the front frame Openinga Net 1 exit the vehicle release the top front latch 2 Rotate the net rearward and slide the lower net rod out of mount to remove it 3 Allow the net to hang freely outside the vehicle while dismounting 22 FEATURES AND CONTROL
71. ngs on page 14 2 Check the oil level See page 46 Add the recommended oil as needed to maintain the oil level in the normal safe operating range 3 Drive slowly at first Select an open area that allows room to familiarize yourself with vehicle operation and handling Vary throttle positions Do not operate at sustained idle 5 Perform regular checks on fluid levels controls and areas outlined on the daily pre ride inspection checklist See page 30 6 Pull only light loads 7 Check fluid levels of transmission and all gearcases after the first 25 hours of operation and every 100 hours thereafter 8 During the break in period change both the oil and the filter at 25 hours PVT Break in Clutches Belt A proper break in of the clutches and drive belt will ensure a longer life and better perfor mance Break in the clutches and belt by operating at slower speeds during the break in period as recommended Pull only light loads Avoid aggressive acceleration and high speed operation during the break in period Ifa belt fails always clean any debris from the duct and from the engine compartment 29 OPERATION Pre Ride Inspection Failure to inspect and verifv that the vehicle is in safe operating condition before operating increases the risk of an accident Alwavs inspect the vehicle before each use to make sure it s in safe operating condition Item
72. ns 7 4 4 8 Turf Mode Indicator This indicator illuminates when the operator unlocks the differ ential See page 40 25 FEATURES AND CONTROLS Instrument Cluster Rider Information Center Use the MODE button to toggle through the information area options Displav Units Standard Metric The displav can be changed to displav either standard or metric units of measurement To exit the set up mode at any time 10 seconds The display automatically exits and returns to the odometer display Standard Display Metric Display Distance Miles Kilometers Fuel U S Gallons Liters Imperial Gallons Temperature Fahrenheit Celsius Time 12 Hour Clock 24 Hour Clock 1 Turn the key to the OFF position Press and hold the MODE button while turning the key to the ON position 3 When the display flashes the distance setting tap the MODE button to advance to the desired setting 4 Press and hold the MODE button to save the setting and advance to the next display option 5 Repeat the procedure to change remaining display settings Clock Mode Tip The clock must be reset any time the battery has been disconnected or discharged 1 Turn the key to the ON position Use the MODE button to toggle to the odometer dis play Press and hold the MODE button until the hour segment flashes Release the button With the segment flashing tap the MODE button to advance to the desired setting Pres
73. nsure that battery is fully charged 2 Place the fully charged battery in the battery holder 3 With conventional batteries install the battery vent tube sealed batteries do not have a vent tube The vent tube must be free of obstructions and securelv installed Route the tube awav from the frame and vehicle bodv to prevent contact with electrolvte WARNINGI Batterv gases could accumulate in an improperiv installed vent tube and cause an explosion resulting in serious injurv or death Alwavs ensure that the vent tube is free of obstructions and is securelv installed as recommended 4 Coat terminals with dielectric grease or petroleum jelly 5 Connect and tighten the red cable first Connect and tighten the black cable last 6 Verify that cables are properly routed Cables should be safely tucked away at the front and rear of the battery 7 Install the battery hold down strap Battery Storage Whenever the vehicle is not used for a period of three months or more remove the battery from the vehicle ensure that it s fully charged and store it out of the sun in cool dry place Check battery voltage each month during storage and recharge as needed to maintain a full charge See page 68 POLARIS recommends maintaining battery charge by using a POLARIS Battery Tender charger or by charging about once a month to make up for normal self discharge Battery Tender can be left connected during the storage period and w
74. nter clockwise 3 Reverse the procedure for spark plug installation Torque to specification Normal Plug The normal insulator tip is gray tan or light brown There will be few combustion deposits The electrodes are not burned or eroded This indicates the proper type and heat range for the engine and the service The tip should not be white A white insulator tip indicates overheating caused by use of an improper spark plug or incorrect throttle body adjustments Wet Fouled Plug The wet fouled insulator tip is black A damp oil film covers the firing end There may be a carbon layer over the entire nose Generally the electrodes are not worn General causes of fouling are excessive oil use of non recommended injection oil or incorrect throttle body adjustments 50 MAINTENANCE Cooling Svstem The engine coolant level is controlled or maintained the recoverv svstem The svstem 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 pressure cap and into the overflow bottle As engine coolant tem perature decreases the contracting cooled coolant is drawn back up from the tank past the pressure cap and into the radiator Some coolant level drop on new vehicles is normal as the svstem is purging itself of trapped air Observe coolant level
75. obstacles if vou fail to take proper precautions e Read this owner s manual Understand all safety warnings precautions and operating procedures before operating the vehicle Keep this manual with the vehicle e This vehicle is an ADULT VEHICLE ONLY You MUST be at least age 16 and have valid driver s license to operate this vehicle person under the age of 12 may ride as a passenger in this vehicle Any passenger must be able to comfortably reach the floor and hand holds e Never permit a guest to operate this vehicle unless the guest has read this manual and all product labels Always use the cab nets while riding in this vehicle Always wear a helmet eye protection gloves long sleeve shirt long pants and over the ankle boots Always keep hands and feet inside the vehicle at all times INTRODUCTION Vehicle Identification Numbers Record vour vehicle s identification numbers and kev number in the spaces provided Remove the spare key and store it in a safe place An ignition key can be duplicated only ordering a POLARIS key blank using your key number and mating it with one of your existing keys The ignition switch must be replaced if all keys are lost Vehicle Model Number Frame VIN Engine Serial Number Key Number European Vibration and Noise The driver perceived noise and hand arm and whole body vibration levels of this machinery is measured per prEN 15997 The operating con
76. of the rubber boot and slide it over the Lock Nut cable adjuster to its original position djuster 58 Brakes The front and rear brakes are hvdraulic disc tvpe brakes Press down on the brake pedal to engage the brakes See page 20 Brake Fluid Inspect the brake svstem routinelv Inspect the level of the brake fluid before each operation WARNINGI After opening a bottle of brake fluid alwavs discard anv unused portion Never store or use partial bottle Brake fluid is hvgroscopic meaning it absorbs moisture from the air The moisture causes the boiling temperature of the brake fluid to drop which can lead to brake fade and the possibilitv of accident or severe injurv Change the brake fluid everv two vears and anv time the fluid becomes contaminated the fluid level 15 below the minimum or if the tvpe and brand of the fluid in the reservoir are unknown See page 45 for fluid recommendations 1 2 Position the vehicle on a level surface View the brake fluid level at the reservoir in the driver s side wheel well The level should be between the upper MAX and lower MIN level lines If the fluid level is lower than the upper level line add brake fluid to the upper MAX line Apply the brake forcefully for a few seconds and check for fluid leakage around the fittings Brake Inspection 1 2 Check the brake system for fluid leaks Check the brake pedal for excessive travel or a
77. on Recommendations 45 88 M Main 48 Maintenance 85 Maintenance 43 45 Metric 26 Mode Button 18 12 Noise Emission Control System 42 Obstacles ecs ecs ee eee es 33 Engines 46 47 Oil Change 4 559 ene en 47 Front Gearcase 49 Main Gearcase 48 48 Oil Level 46 Front Gearcase 49 Main Gearcase 48 48 Oil Recommendation Engine 46 48 Operation on Public Lands 42 Operator 10 16 Outlets Auxiliary 18 P Parking an 37 Parking the 37 Periodic Maintenance Chart 43 45 osc eens ko evens 50 Plug Torque rei 50 Plug ACCESSO 5 18 Plugs 5 2 2 2
78. onous and can cause loss of consciousness or death in a short time Never start the engine or let it run in an enclosed area The engine exhaust from this product contains chemicals known to cause cancer birth defects or other reproductive harm Operate this vehicle outdoors or in well ventilated areas Operating a Damaged Vehicle Operating a damaged vehicle can result in an accident After anv overturn or accident have a qualified service dealer inspect the entire machine for possible damage including but not limited to brakes throttle and steering svstems Operating at Excessive Speeds Operating this vehicle at excessive speeds increases the operator s risk of losing control Alwavs operate at a speed that s appropriate for the terrain the visibilitv and operating conditions and vour experience Operating on Pavement This vehicle s tires are designed for off road use not for use on pavement Operating this vehicle on paved surfaces including sidewalks paths parking lots and drivewavs mav adverselv affect the handling of the vehicle and could result in loss of control and accident or overturn Avoid operating the vehicle on pavement If it s unavoidable travel slowly and avoid sudden turns or stops Operating on Public Roads Operating this vehicle on public streets roads or highways could result in a collision with another vehicle Never operate this vehicle on any public street road or highway inc
79. option repair or replacement of any defective materials or components or products THE REMEDIES SET FORTH IN THIS WARRANTY ARE THE ONLY REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF THIS WAR RANTY POLARIS SHALL HAVE NO LIABILITY TO ANY PERSON FOR INCIDENTAL CONSEQUEN TIAL OR SPECIAL DAMAGES OF ANY DESCRIPTION WHETHER ARISING OUT OF EXPRESS OR IMPLIED WARRANTY OR ANY OTHER CONTRACT NEGLIGENCE OR OTHER TORT OR OTHER WISE THIS EXCLUSION OF CONSEQUENTIAL INCIDENTAL AND SPECIAL DAMAGES IS INDE PENDENT FROM AND SHALL SURVIVE ANY FINDING THAT THE EXCLUSIVE REMEDY FAILED OF ITS ESSENTIAL PURPOSE Some states do not permit the exclusion or limitation of incidental or consequential damages or implied warranties so the above limitations or exclusions may not apply to you if inconsistent with controlling state law ALL IMPLIED WARRANTIES INCLUDING BUT NOT LIMITED TO THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE ARE LIMITED IN DURATION TO THE ABOVE SIX MONTH WARRANTY PERIOD POLARIS FURTHER DISCLAIMS ALL EXPRESS WARRANTIES NOT STATED IN THIS WARRANTY Some states do not allow limitations on how long an implied warranty lasts so the above limitation may not apply to you if inconsistent with controlling state law HOW TO OBTAIN WARRANTY SERVICE If your vehicle requires warranty service you must take it to POLARIS Servicing Dealer When requesting war ranty service you must present your copy of the Warranty Regi
80. or refresh charge follow all instructions carefully 1 Check the battery voltage with a voltmeter or multimeter A fully charged battery will register 12 8 V or higher If the voltage is less than 12 8 volts recharge the battery at 1 2 amps or less until battery voltage is 12 8 or greater 2 When using an automatic charger refer to the charger manufacturer s instructions for recharging When using a constant current charger use the guidelines below for recharg ing Always verify battery condition before and l 2 hours after the end of charging State of Charge Time Voltage Action Using constant current Charge charger standard amps specified on top of battery 100 12 8 13 0 volts None check at 3 mos from date of None required manufacture 75 100 12 5 12 8 volts May need slight charge if no charge 3 6 hours given check in 3 months 50 75 12 0 12 5 volts Needs charge 5 11 hours 25 50 11 5 12 0 volts Needs charge At least 13 hours verify state of charge 0 25 11 5 volts or less Needs charge with desulfating charger At least 20 hours 68 MAINTENANCE Cleaning and Storage Washing the Vehicle 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 damage components POLARIS recommends washing the vehicle by hand or with a garden hose using mild soap NOTICE Certain products
81. ound on the chrome finish use steel wool 0000 grade to remove it Gently rub the affected areas with the steel wool until the corrosion has been removed Clean and polish the wheel as outlined above 70 MAINTENANCE Cleaning and Storage Storage Tips NOTICE Starting the engine during the storage period will disturb the protective film created 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 69 Stabilize the Fuel 1 Fill the fuel tank 2 Add POLARIS Carbon Clean Fuel Treatment or POLARIS Fuel Stabilizer Follow the instructions on the container for the recommended amount Carbon Clean removes water from fuel systems stabilizes fuel and removes carbon deposits from pistons rings valves and exhaust systems 3 Allow the engine to run for 15 20 minutes to allow the stabilizer to disperse through the entire fuel delivery system Oil and Filter Change the oil and filter See page 47 Air Filter Air Box 1 Inspect and clean or replace the pre cleaner and air filter See page 56 2 Clean the air box 3 Drain the sediment tube 71 MAINTENANCE Cleaning and Storage Storage Tips Inspect and Lubricate Inspect all cables and lubricate all areas of the vehicle as recommended in the Periodic Main tenance Chart beginning on page 43 Batterv Maintenance See pages 67 68 for storage and
82. our surroundings and determine your path of travel 7 Keeping both hands on the steering wheel slowly release the brakes and depress the throttle with your right foot to begin driving 8 Drive slowly Practice maneuvering and using the throttle and brakes on level surfaces Do not carry a passenger until you have at least two hours of driving experience with this vehicle 32 OPERATION Driving with a Passenger 1 2 9 Perform the pre ride inspection See page 30 Make sure all passengers are at least 12 vears of age and tall enough to comfortablv and safelv sit in a passenger seat with the seat belt secured put both feet on the floor and grasp the hand hold Make sure all passengers are wearing helmet eve protection gloves long sleeve shirt long pants and over the ankle boots Make sure all passengers secure their seat belt Make sure all cab nets are properlv secured Do not carry more than recommended number of passengers for your vehicle See page 8 Allow a passenger to ride only in a passenger seat Slow down Always travel at a speed appropriate for your skills your passengers skills and operating conditions Avoid unexpected or aggressive maneuvers that could cause discomfort or injury to a passenger Vehicle handling may change with a passenger and or cargo on board Allow more time and distance for braking 10 Always follow all operating guidelines as outlined on safety labels and
83. owly allow the vehicle to roll straight downhill while applying light brake pressure to control speed If you begin rolling downhill Never apply engine power Apply the brakes gradually until the vehicle is fully stopped Place the transmission in reverse and slowly allow the vehicle to roll straight downhill while applying light brake pressure to control speed Improper Tire Maintenance Operating this vehicle with improper tires or with improper or uneven tire pressure could cause loss of control or accident Always use the size and type of tires specified for your vehicle Always maintain proper tire pressure as described in the owner s manual and on safety labels Operating on Slippery Terrain Failure to use extra caution when operating on excessively rough slippery or loose terrain could cause loss of traction loss of control accident or overturn Do not operate on excessively slippery surfaces Always reduce speed and use additional caution when operating on slippery surfaces Operating on Frozen Bodies of Water Severe injury or death can result if the vehicle and or the operator fall through the ice Never operate the vehicle on a frozen body of water unless you have first verified that the ice is sufficiently thick to support the weight and moving force of the vehicle you and your passengers and your cargo together with any other vehicles in your party Always check with local authorities and residents to confir
84. r in a well ventilated area Do not smoke or allow open flames or sparks or near the area where refueling is performed or where gasoline is stored Do not overfill the tank Do not fill the tank neck If gasoline spills on your skin or clothing immediately wash it off with soap and water and change clothing Operating With a Load on the Vehicle The weight of both cargo and passengers impacts vehicle operation For your safety and the safety of others carefully consider how your vehicle is loaded and how to safely operate the vehicle Follow the instructions in this manual for loading tire pressure gear selection and speed Do not exceed vehicle weight capacities The vehicle s maximum weight capacity is listed in the specifications section of this manual and on a label on the vehicle When more passenger weight is added cargo weight may need to be reduced accordingly recommended tire pressures are listed in the specifications section of this manual and on a label on the vehicle Always follow these guidelines Under ANY of these conditions Do ALL of these steps Passenger and or cargo exceeds half the maximum weight capacity 1 Slow down Operating in rough terrain 2 Verify tire pressure 3 Use extra caution when Operating over obstacles operating Climbing an incline Towing 14 SAFETV Operator Safetv Exposure to Exhaust Engine exhaust fumes are pois
85. r prolonged operation in dusty environments e Racing or race style high RPM use e Prolonged low speed heavy load operation e Extended idle e Short trip cold weather operation Pay special attention to the oil level A rise in oil level during cold weather can indicate con taminants collecting in the oil sump or crankcase Change oil immediately if the oil level begins to rise Monitor the oil level and if it continues to rise discontinue use and determine the cause or see your dealer Maintenance Chart Key gt Perform these operations more often for vehicles subjected to severe use Enmission related service Failure to conduct this maintenance will not void the emis sions warranty but may affect emissions D Have an authorized POLARIS dealer perform these services WARNING Improperly performing the procedures marked with a D could result in component failure and lead to serious injury or death Have an authorized POLARIS dealer perform these services 43 MAINTENANCE Periodic Maintenance Chart Perform all services at whichever maintenance interval is reached first Item Maintenance Interval Remarks whichever comes first Hours Calendar Miles Km Steering Front suspension Rear suspension Tires Brake fluld level Pre Ride Make adjustments as need ed See Brake pedal travel Pre Ride Chec
86. rerne soe 49 Fuel e ret es 20 Fuel Safety sce oc sess iri cae cas eee 14 Fuel Stabilizer L 71 Fuel Tank 20 FUSES 63 G Gap Spark Plug L 50 Gasoline 14 Gear Selectors xa mina b 18 Gearcase Specification Chart 48 Geat ase sies ales hb nega de o o 49 Gearcase Main 48 secu dentine nee ee neal 48 49 Gears SHTUNE f A ak wea 18 GOV ES adits 9 H Hauling 38 Headlight Beam Adjustment 64 Headlight Lamp Replacement 63 ead inc sacar ew i l a 9 Hitch 20 Hitch Weight cscs 39 l Idle Speed bis its sp ter ta EEEN 58 Ignition Switch LL 19 Immersion of Vehicle 55 Indicator 24 Instrument 24 28 K Key Periodic Maintenance Chart 43 L Light 295 19 6 6 5 2254554554 00 63 64 Brake 4 8 64 Headlight Beam Adjustment 64 Headlight Lamp Replacement 63 Lubricants 48 Lubricati
87. reverse avoid sharp turns or sudden braking Make sure passenger reads and understands all safety labels e Watch for branches or other hazards that could enter vehicle LOCATE AND READ OWNER S MANUAL FOLLOW ALL INSTRUCTIONS AND WARNINGS 7176169 Passenger Tire Pressure Warning WARNING Passengers can be thrown off This can cause serious injury or death e Never carry passengers in cargo box WARNING IMPROPER TIRE PRESSURE OR OVERLOADING CAN CAUSE LOSS OF CONTROL RESULTING IN SERIOUS INJURY OR DEATH Reduce speed and allow greater distance for braking when carrying cargo Overloading or carrying tall off center or unsecured loads will increase your risk of losing control Loads should be centered and carried as low as possible in box For stability on rough or hilly terrain reduce speed and cargo Be careful if load extends over the side of the box RANGER MID SIZE 400 500 800 Crew LSV EV MAXIMUM CARGO BOX LOAD 500 Ibs 500 Ibs 500 Ibs 500 Ibs 226 kg 226 kg 226 kg 226 kg TIRE PRESSURE IN PSI KPa FRONT 10 69 FRONT 10 69 FRONT 14 97 FRONT 20 138 REAR 12 83 REAR 16 110 REAR 16 110 REAR 20 138 kiel bida 1000 Ibs 1000 Ibs 1250 165 1000 Ibs OPERATOR PASSENGER CARGO 454 ko Arka odka AND ACCESSORIES Read Operation and Maintenance Manual for more detailed loading information
88. ries and familiarize yourself with their function and effect on the vehicle 12 SAFETV Operator Safetv AWARNING Failure to operate the RANGER properly can result in a collision loss of control accident or overturn which may result in serious injury or death Heed all safety warnings outlined in this section of the owner s manual See the OPERATION section of the owner s manual for proper operating procedures Age Restrictions This vehicle is an ADULT VEHICLE ONLY NEVER operate this vehicle if you are under age 16 and NEVER operate without a valid driver s license No person under the age of 12 may ride as a passenger in this vehicle Any passenger must be able to comfortably reach the floor and hand holds Operating Without Instruction Operating this vehicle without proper instruction increases the risk of an accident The operator must understand how to operate the vehicle properly in different situations and on different types of terrain All operators must read and understand the Owner s Manual and all warning and instruction labels before operating the vehicle Using Alcohol or Drugs Operating the vehicle after consuming alcohol or drugs could adversely affect operator judgment reaction time balance and perception Never drink alcohol or use drugs or medications before or while operating this vehicle Seat Belts Riding in this vehicle without wearing the seat belt increases the risk of serious injury in th
89. rly operating throttle pedal Immediately contact your dealer for service if throttle problems arise Throttle Freeplay Inspection If the throttle pedal has excessive play due to cable stretch or misadjustment it will cause a delay in throttle response especially at low engine speed The throttle may also not open fully If the throttle pedal has no freeplay the throttle may be hard to control and the idle speed may be erratic Check the throttle pedal freeplay at the intervals outlined in the Periodic Maintenance Chart beginning on page 43 Adjust the freeplay if necessary 1 Place the transmission in PARK 2 Start the engine Allow it to warm up thoroughly 3 Measure the distance the throttle pedal moves before the engine begins to pick up speed Freeplay should be 1 16 to 1 8 inches 1 6 3 2 mm Throttle Body Idle RPM Idle RPM is preset by the manufacturer If the engine idle speed is not satisfactory please see your POLARIS dealer for adjustment Throttle Freeplay Adjustment 1 Remove the seat 2 Locate the throttle cable adjuster 3 Squeeze the end of the rubber boot and slide it far enough to expose the end of the inline cable adjuster 4 Loosen the adjuster lock nut 5 Rotate the boot to turn the adjuster until 1 16 to 1 8 1 5 3 Boot mm of freeplay is achieved at the throttle pedal Tip While adjusting lightly flip the throttle pedal up and down 6 Tighten the lock nut 7 Squeeze the end
90. rv to 12 8 VDC Kinked or plugged fuel tank vent line Inspect and replace Incorrect fuel Replace with recommended fuel Clogged air filter Inspect and clean or replace Other mechanical failure Possible Lean Fuel Cause Low or contaminated fuel See vour dealer Solution Add or change fuel clean the fuel svstem Low octane fuel Possible Rich Fuel Cause Fuel is verv high octane Replace with recommended fuel Solution Replace with lower octane fuel Engine Stops or Loses Power Possible Cause Solution Out of fuel Refuel Kinked or plugged fuel vent line Inspect and replace Water is present in fuel Replace with new fuel Fouled or defective spark plugs Inspect clean and or replace spark plug Worn or defective spark plug wires See vour dealer Incorrect spark plug gap or heat range Set gap to specs or replace plug Loose ignition connections Check all connections and tighten Low batterv voltage Recharge the batterv to 12 8 VDC Incorrect fuel Replace with fresh recommended fuel Clogged air filter Inspect and clean or replace Other mechanical failure See vour dealer Overheated engine Clean radiator screen and core clean engine exterior see your dealer 79 WARRANTV LIMITED WARRANTV POLARIS Sales Inc 2100 Highwav 55 Medina MN 55340 givesa SIX MONTH LIMITED WARRANTV on all compon
91. rval 1 Press the MODE button until remaining service hours displav 2 Press and hold the MODE button 3 When the service hours flash press and release the MODE button to advance the hours to the desired setting including OFF Press and hold the MODE button to set the new service hour interval Diagnostic Display Mode The EFI diagnostic display mode is for informational purposes only Please see your POLARIS dealer for all major repairs The diagnostic mode is accessible only when the check engine warning indicator activates after the key has been turned on Leave the key on if you want to view the active code fail ure code The diagnostic mode becomes inaccessible if the key is turned off and on and the warning indicator is no longer active This allows the determination of persistent as well as intermit tent faults Inactive codes are stored in the history of the unit 27 FEATURES 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 restarting the engine If the CHECK ENGINE light illuminates retrieve the error codes from the display 1 Ifthe error codes are not displayed use the MODE button to toggle until ENG displays on the
92. s and hold the MODE button until the next segment flashes Release the button Repeat steps 3 4 twice to set the 10 minute and l minute segments After completing the l minute segment step 4 will save the new settings and exit the clock mode 6 Turn the key to the OFF position 26 FEATURES AND CONTROLS Instrument Cluster Rider Information Center Odometer Mode The odometer records and displavs the distance traveled bv the vehicle Trip Meter Mode The trip meter records the distance traveled bv the vehicle if reset before each trip To reset select the trip meter mode Press and hold the MODE button until the meter resets to zero In the Rider Information Center the trip meter displav contains a decimal point but the odome ter displavs without a decimal point Hour Meter Mode This mode logs the total hours the engine has been in operation Tachometer Mode The engine RPM is displaved digitallv Tip Small fluctuations in the RPM from dav to dav mav be normal because of changes in humiditv temperature and elevation Programmable Service Interval When the hours of engine operation equal the programmed service interval setting the wrench icon will flash for 5 seconds each time the engine is started When this feature is enabled it provides a convenient reminder to perform routine maintenance The service interval is programmed at 50 hours at the factorv Use the following procedure to change the service inte
93. s and maintain as recommended bv adding coolant to the overflow bottle Adding or Changing Coolant To ensure that the coolant maintains its abilitv to protect the engine we recommend that the svstem be completelv drained everv two vears and a fresh mixture of antifreeze and water added POLARIS recommends the use of POLARIS Premium 60 40 anti freeze coolant 50 50 mixture of high qualitv aluminum compatible anti freeze coolant and distilled water POLARIS Premium 60 40 is already premixed and ready to use Do not dilute with water See page 76 for the part numbers of POLARIS products Always follow the manufacturer s mixing recommendations for the freeze protection required in your area Any time the cooling system has been drained for maintenance or repair replace the coolant If the recovery bottle has run dry the level in the radiator should be inspected Add coolant as needed Radiator and Cooling Fan Always check and clean the screen and radiator fins at the intervals outlined in the Periodic Maintenance Chart beginning on page 43 Do not obstruct or deflect air flow through the radiator by installing unauthorized accessories in front of the radiator or behind the cooling fan Interference with the radiator air flow can lead to overheating and consequent engine damage NOTICE Washing the vehicle with a high pressure hose could damage the radiator fins and impair the radiator s effectiveness Using a high pressure system is no
94. s only Do not install it in any other product e Always make sure the PVT housing is securely in place during operation Belt Replacement Debris Removal If a belt fails always clean any debris from the duct and from the clutch and engine compart ments when replacing the belt WARNING Failure to remove ALL debris when replacing the belt could result in vehicle damage and severe injury or death 1 Remove the seat 2 Remove the clutch cover screws and open the clutch cover Remove all debris wrapped in and around the PVT system 3 Remove all debris from the entire clutch air duct passage 4 Check for signs of damage to seals on the transmission and engine See your dealer promptly for service if any seals appear to be damaged Tip Belt slip is responsible for creating excessive heat that destroys belts wears clutch components and causes outer clutch covers to fail Switch to low range while operating at slower speeds to extend the life of the PVT components belt cover etc 53 MAINTENANCE POLARIS Variable Transmission PVT Svstem PVT Drving There mav be some instances when water is ingested into the PVT svstem Use the following instructions to drv it out before operating 1 Position the vehicle on a level surface Remove the drain plug Allow the water to drain completely Reinstall the drain plug Place the transmission in PARK Start the engine Apply varying throttle for 10 15 seconds to expel
95. spongy feel Check the friction pads for wear damage and looseness Check brake discs for signs of cracks excessive corrosion warping or other damage Clean any grease using an approved brake cleaner or alcohol NOTICE Do not apply WD 40 or any petroleum product to 5 brake discs Inspect the brake disc spline and pad wear surface excessive wear Change pads when worn to 3 64 1 mm MAINTENANCE Maximum Minimum 59 MAINTENANCE Steering Wheel Inspection Check the steering wheel for specified freeplav and smooth operation at the intervals out lined in the Periodic Maintenance Chart beginning on page 43 1 Position the vehicle on a level surface 2 Lightly turn the steering wheel left and right 3 There should be 0 8 1 0 20 25 mm of freeplay 4 If there is excessive freeplay or strange noises or the steering feels rough or catchy have the steering system inspected by an authorized POLARIS dealer Spring Adjustment Adjust the front and rear shock absorber springs by rotating the adjustment cam either clockwise or counter clockwise to increase or decrease spring tension 60 MAINTENANCE Tires A WARNING Operating vour vehicle with worn tires improperlv inflated tires non standard tires or improperlv installed tires will affect vehicle handling and could cause an accident resulting in serious injurv or death Alwavs follow all tire maintenance procedures as outlined in this man
96. stration form to the dealer THE COST OF TRANSPORTATION TO AND FROM THE DEALER IS YOUR RESPONSIBILITY POLARIS suggests that you use your original selling dealer however you may use any POLARIS Servicing Dealer to perform warranty service Please work with your dealer to resolve any warranty issues Should your dealer require any additional assistance they will contact the appropriate person at POLARIS This warranty gives you specific legal rights and you may also have other rights which vary from state to state If any of the above terms are void because of state or federal law all other warranty terms will remain in effect Lubricants 1 Mixing oil brands or using non recommended oil may cause engine damage We recommend the use of POLARIS engine oil 2 Damage resulting from the use of non recommended lubricants may not be covered by warranty SPARK ARRESTER POLARIS warrants that the spark arrester in this vehicle will meet the efficiency requirements of USFS standard 5100 1c for at least 1000 hours when subjected to normal use and when maintenance and installation are in accor dance with POLARIS recommendations 81 WARRANTV Exported Vehicles EXCEPT WHERE SPECIFICALLY REQUIRED BY LAW THERE IS NO WARRANTY OR SERVICE BUL LETIN COVERAGE ON THIS VEHICLE IF IT IS SOLD OUTSIDE THE COUNTRY OF THE SELLING DEALER S AUTHORIZED LOCATION This policy does not apply to vehicles that have received authorization for export from POLARI
97. t recommended 51 MAINTENANCE Cooling Svstem Overflow Bottle Coolant Level Alwavs check and change the coolant at the intervals outlined in the Periodic Maintenance Chart beginning on page 43 Maintain the coolant level between the min imum and maximum marks on the bottle when the fluid is cool 1 Position the vehicle on a level surface 2 Liftthe hood View the coolant level in the over flow bottle 3 Ifthe coolant level is below the safe operating range lift the hood and locate the overflow bottle lid Remove the cap and use a funnel to add coolant through the filler opening Reinstall the cap Tip If coolant must be added often or if the overflow bottle runs completely dry there may be a leak in the system Have the cooling system inspected by your POLARIS dealer Radiator Coolant Level Always check and clean the screen and radiator fins at the intervals outlined in the Periodic Maintenance Chart beginning on page 43 Do not obstruct or deflect air flow through the radiator by installing unauthorized accesso ries in front of the radiator or behind the cooling fan Interference with the radiator air flow can lead to over heating and consequentially engine damage 1 Lift the hood CAUTION Escaping steam can cause burns Never remove the pressure cap while the engine is warm or hot Always allow the engine to cool before removing the pressure cap 2 Slowly remove the radiator cap 3 View the coo
98. tained within this publication is based on the latest product information at the time of publication Due to constant improvements in the design and qualitv of produc tion components some minor discrepancies mav result between the actual vehicle and the information presented in this publication Depictions and or procedures in this publication are intended for reference use only No liabil itv can be accepted for omissions or inaccuracies Anv reprinting or reuse of the depictions and or procedures contained within whether whole or in part is expressly prohibited The original instructions for this vehicle are in English Other languages are provided as translations of the origi nal instructions Printed in U S A 2013 RANGER 800 Midsize Owner s Manual P N 9923960 TABLE OF CONTENTS ii ia i a 4 DOIG bad Da 8 7 Features and 17 Operation a 29 Emission Control Systems 42 Maintenance 275 i tone ee pe ake ep cas 43 ceeds E 74 POLARIS lt 76 77 Warranty 80 Maintenance Log 85 IE anew mace
99. topping 31 Equipment 12 Error Codes 28 Exhaust Cleaning os suisse eva say 57 Exhaust Emission Control System 42 Exhaust System Warning 57 Eve Protection 2 5425525 555 9 F Fastener Torque Cvlinder Head Base 55 Filtet Systems sensei gna vie 56 Filter s s eck coke au ded de 56 Fluid Battery 2 65 Fluid Change ENBINE sage ea wis 47 Front 49 Main 48 Transmission 48 Fluid Level Coolant Overflow Bottle 52 Coolant Radiator 52 En ine 46 Front 49 Main 48 Transmission 48 Fluid Levels During Storage 72 87 INDEX F Fluid Recommendation Coolant i 51 Engine 46 GEATCASES 48 Fluid Brakes save haves 59 Fogging 72 Fouled Plugs 50 Freeplay Adjustment Throttle 58 Front sereis ce
100. ual and on the labels on the vehicle Alwavs use original equipment size and tvpe when replacing tires Tire Tread Depth Always replace tires when tread depth is 1 8 3 mm worn to 1 8 3 mm or less Axle and Wheel Nut Torque 2 NS Specifications Inspect the following items occasionally for tightness and if they ve been loosened for main tenance service Do not lubricate the stud or the lug nut Nut Type Location Nut Torque Lug Nut Front and Rear 30 ft Ibs 41 Nm PLUS 1 4 TURN Aluminum Wheels Nut and Washer gt Front and Rear 35 ft Ibs 47 Nm Steel Wheels O Nut Front 70 ft Ibs 95 Nm Hub Retaining Nuts Center and Rear 110 ft Ibs 150 Nm 61 MAINTENANCE Tires Wheel Removal 1 Apply the brakes 2 Place the transmission in PARK 3 Stop the engine 4 Loosen the wheel nuts slightly 5 Elevate the side of the vehicle by placing a suitable stand under the frame 6 Remove the wheel nuts and washers Remove the wheel Wheel Installation 1 Place the transmission in PARK 2 Place the wheel in the correct position on the wheel hub Be sure the valve stem is toward the outside and rotation arrows on the tire point toward forward rotation WARNING Improperly installed wheels can adversely affect tire wear and vehicle handling which can result in serious injury or death Always ensure that all nuts are torqued to specification Do not service ax
101. uired to present documentation of your move to POLARIS Industries in order to continue your warranty coverage You may also be required to obtain documentation from POLARIS Industries in order to reg ister your vehicle in your new country You should warranty register your vehicle at a local POLARIS dealer in your new country immediately after you move to continue your warranty coverage and to ensure that you receive safety information and notices regarding your vehicle If Purchased From A Private Party If you purchase a POLARIS product from a private citizen to be kept and used outside of the country in which the vehicle was originally purchased all warranty coverage will be denied You must nonetheless warranty regis ter your vehicle under your name and address with a local POLARIS dealer in your country to ensure that you receive safety information and notices regarding your vehicle Notice If your vehicle is registered outside of the country where it was purchased and you have not followed the proce dure set out above your vehicle will no longer be eligible for warranty or service bulletin coverage of any kind other than safety bulletins Vehicles registered to Government officials or military personnel on assignment out side of the country where the vehicle was purchased will continue to be covered by the basic warranty For questions call POLARIS Customer Assistance United States 1 888 704 5290 Canada 1 204 925 7100 82 WAR
102. use loss of control and vehicle over turn Belt slippage from water or snow ingestion into the PVT system Dry out the PVT See page 54 Inspect clutch seals for damage if repeated leaking occurs Clutch malfunction See your POLARIS dealer Poor engine performance Check for fouled plugs or foreign material in fuel tank or fuel lines See your dealer Slippage from failure to warm up belt Always warm up the belt by operating below 30 MPH for one mile 5 miles or more when temperature is below freezing Wrong or missing belt Install the recommended belt Improper break in Always break in a new belt and or clutch See pages 29 and 53 77 TROUBLESHOOTING Engine Doesn t Turn Over Possible Cause Low battery voltage Solution Recharge the battery to 12 8 VDC Loose battery connections Check all connections and tighten Loose solenoid connections Check all connections and tighten Loose electronic control box connections Inspect clean reinstall connectors Engine Turns Over Fails to Start Possible Cause Out of fuel Solution Refuel Water is present in fuel Drain the fuel svstem and refuel Old or non recommended fuel Replace with fresh recommended fuel Fouled or defective spark plugs Inspect plugs and replace if necessary No spark to spark plug Inspect plugs and replace if necessary Water or fuel in crankcase Im
103. vehicle securelv with jackstand Fill Plug 2 Remove the front tire on the driver s side 3 Remove the fill plug 4 Place a drain pan under the drain plug on the bottom right hand side Drain Plug 5 Remove the drain plug Drain the oil 6 Clean the drain plug Reinstall the drain plug Torque to specification 7 Add the recommended oil 8 Reinstall the fill plug Torque to specification 9 Check for leaks 10 Discard used oil properly 49 MAINTENANCE Spark Plugs Spark Plug Recommendations Refer to the specifications section beginning on page 74 for the recommended spark plug tvpe for vour vehicle Alwavs torque spark plugs to specification NOTICE Using non recommended spark plugs can result in serious engine damage Alwavs use POLARI S recommended spark plugs Spark Plug Gap Torque Electrode Gap New Plug Torque Used Plug Torque 035 9 mm 18 ft Ibs 24 Nm 18 ft Ibs 24 Nm Spark Plug Inspection Spark plug condition is indicative of engine operation The spark plug firing end condition should be read after the engine is warmed up and the vehicle is driven at higher speeds Immediatelv check the spark plug for correct color CAUTIONI A hot exhaust svstem and engine can cause burns Wear protective gloves when removing a spark plug for inspection 1 Remove the seat 2 Remove the spark plug cap Using the spark plug wrench provided in the tool kit remove the plug rotating it cou
104. y To change to metric and or a 24 hour clock see page 26 1 Gear Indicator This indicator displays gear shifter position H High Gear L Low Gear N Neutral R Reverse Gear Gear Signal Error or shifter between gears When the last segment clears a low fuel warning is activated All segments including If the fuel icon fails to display an open or short circuit has occurred in the fuel sensor circuit See Information Display Area This area displays odometer trip meter engine hour meter Under Over Voltage This warning usually indicates that the vehicle is operating at an RPM too low to keep the battery charged It may also occur when the engine is at idle Clock The clock displays time in a 12 hour or 24 hour format See page 26 for reset Service Indicator A flashing wrench symbol alerts the operator that the preset service interval has been reached The vehicle should be brought to your dealer for scheduled 4X4 Indicator This indicator illuminates when the 4X4 system is engaged switch is 2 Fuel Gauge The segments of the fuel gauge show the level of fuel in the fuel tank the fuel icon will flash Refuel immediately Tip your dealer 3 and programmable service hour interval 4 and high electrical load lights cooling fan accessories is applied Drive ata higher RPM or recharge the batterv to clear the warning 5 ting instructions 6 maintenance See page 26 for resetting instructio

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