Polaris Ranger 800 Midsize User Manual

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RANGER

Midsize

Owner's Manual

for Maintenance and Safety

800

WARNING

Read, understand, and follow all of the instructions and safety precautions in this manual and on all product labels.

Failure to follow the safety precautions could result in serious injury or death.

WARNING

The engine exhaust from this product contains chemicals known to the State

of California to cause cancer, birth defects or other reproductive harm.

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

• All-terrain vehicles (ATVs)

• RANGER® utility vehicles

• Victory Motorcycles®

• 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 recommendations in this owner’s manual. Your manual contains instructions for minor maintenance, 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.

product information at the time of publication. Due to constant improvements in the design and quality of production components, some minor discrepancies may 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 liability can be accepted for omissions or inaccuracies. Any 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 original instructions.

Printed in U.S.A. 2013 RANGER 800 Midsize Owner’s Manual P/N 9923960

TABLE OF CONTENTS

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Features and Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Emission Control Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

POLARIS Products. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

Maintenance Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87

INTRODUCTION

The RANGER is an off-road vehicle. Familiarize yourself with all laws and regulations con- cerning the operation of this vehicle in your area.

The following signal words and symbols appear throughout this manual and on your vehicle. Your safety is involved when these words and symbols are used. Become familiar with their meanings before reading the manual.

The safety alert symbol indicates a potential personal injury hazard.

DANGER

A DANGER indicates a hazardous situation that, if not avoided, will result in death or serious injury.

WARNING

A WARNING indicates a hazardous situation that, if not avoided, could result in death or serious injury.

CAUTION

A CAUTION indicates a hazardous situation that, if not avoided, could result in minor or moderate injury.

NOTICE

A NOTICE indicates a situation that could result in property damage.

The Prohibition Safety Sign indicates an action NOT to take in order to avoid a hazard.

The Mandatory Action Sign indicates an action that NEEDS to be taken to avoid a hazard.

INTRODUCTION

WARNING

Failure to follow the warnings contained in this manual can result in severe injury or death. A POLARIS RANGER is not a toy and can be hazardous to operate. This vehicle handles differently

than other vehicles, such as motorcycles and cars. A collision or rollover can occur quickly, even during routine maneuvers like turning, or driving on hills or over obstacles, if you fail to take proper precautions.

• Read this owner’s manual. Understand all safety warnings, precautions and operating procedures before operating the vehicle. Keep this manual with the vehicle.

• This vehicle is an ADULT VEHICLE ONLY. You MUST be at least age 16 and have a valid driver’s license to operate this vehicle.

• 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.

• 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 your vehicle's identification numbers and key number in the spaces provided. Remove the spare key and store it in a safe place. An ignition key can be duplicated only by ordering a POLARIS key blank (using your key number) and mating it with one of your existing keys. The ignition switch must be replaced if all keys are lost.

####

VIN

Vehicle Model Number: ________________________________________________________________________

Frame VIN: _________________________________________________________________________________

Engine Serial Number: ________________________________________________________________________

Key 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 conditions of the machinery during testing:

The vehicles were in like-new condition. The environment was controlled as indicated by the test procedure(s).

The uncertainty of vibration exposure measurement is dependent on many factors, including:

• Instrument and calibration uncertainty

• Variations in the machine such as wear of components

• Variation of machine operators such as experience or physique

• Ability of the worker to reproduce typical work during measurements

• Environmental factors such as ambient noise or temperature

SAFETY

Safety Labels and Locations

Warning labels have been placed on the vehicle for your protection. Read and follow the instructions of the labels on the vehicle carefully. If any of the labels depicted in this manual differ from the labels on your vehicle, always read and follow the instructions of the labels on the vehicle.

If any label 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.

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

SAFETY

Safety Labels and Locations

Discretionary Warning (800 Midsize)

WARNING Improper vehicle use can result in Severe Injury 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.

• Reduce speed and use extra caution when carrying passengers.

• Avoid sharp turns or turns while applying heavy throttle.

• Operate slowly in reverse - avoid sharp turns or sudden braking.

• Make sure passenger reads and understands all safety labels.

• 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.

• 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

TIRE PRESSURE IN PSI (KPa)

MAXIMUM WEIGHT CAPACITY

INCLUDES WEIGHT OF OPERATOR, PASSENGER, CARGO

500 lbs.

(226 kg)

FRONT 10 (69)

REAR 12 (83)

1000 lbs.

(454 kg)

AND ACCESSORIES

Read Operation and Maintenance Manual for more detailed loading information.

500 lbs. (226 kg)

FRONT 10 (69) REAR 16 (110)

1000 lbs.

(454 kg)

500 lbs. (226 kg)

FRONT 14 (97) REAR 16 (110)

1250 lbs.

(547 kg)

500 lbs. (226 kg)

FRONT 20 (138)

REAR 20 (138)

1000 lbs.

(454 kg)

7178725

SAFETY

Helmet

Eye

Protection

Gloves

Over-the-Ankle Boots

Long

Pants

Long

Sleeves

Safe Riding Gear

Always wear appropriate clothing when riding a POLARIS vehicle. Wear protective clothing for comfort and to reduce the chance of injury.

Helmet

Wearing a helmet can prevent a severe head injury. Whenever riding this POLARIS vehicle, always wear a helmet that meets or exceeds established safety standards.

Approved helmets in the USA and Canada bear a U.S. Department of 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 by the distinguishing number of the country which has granted approval. The approval number and serial number will also be displayed on the label.

Eye Protection

Do not depend on eyeglasses or sunglasses for eye protection. Whenever riding a 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 eye wear is kept clean.

051039

0006.31

Gloves

Wear gloves for comfort and for protection from sun, cold weather and other elements.

Boots

Wear sturdy over-the-ankle boots. Do not ride a POLARIS vehicle with bare feet.

Clothing

Wear long sleeves and long pants to protect arms and legs.

SAFETY

WARNING

Operator Safety

Serious injury or death can result if you do not follow these instructions and procedures, which are outlined in further detail within your owner's manual.

• Read this manual and all labels carefully. Follow the operating procedures described.

• Never allow anyone under age 16 to operate this vehicle and never allow anyone without a valid driver's license to operate this vehicle.

• Do not carry a passenger until you have at least two hours of driving experience with this vehicle.

• 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.

• 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.

• Always use the cab nets while riding in this vehicle.

• Always keep hands and feet inside the vehicle at all times.

• 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.

• To reduce tipover risk, be especially careful when encountering obstacles and slopes and when braking on hills or during turns.

• This vehicle is for off road use only. Never operate on public roads. Always avoid paved surfaces.

• Never consume alcohol or drugs before or while operating this vehicle.

• 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.

• 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.

• Always travel slowly and use extra caution when operating on unfamiliar terrain. Be alert to changing terrain.

• Never operate on excessively rough, slippery or loose terrain.

• Always follow proper procedures for turning. Practice turning at slow speeds before attempting to turn at faster speeds. Never turn at excessive speeds.

SAFETY

Operator Safety

• Always have this vehicle checked by an authorized POLARIS dealer if it has been

involved in an accident.

• Never operate this vehicle on hills too steep for the vehicle or for your abilities. Practice

on smaller hills before attempting larger hills.

• 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 slippery or loose surfaces. Never open the throttle suddenly or make sudden gear changes. Never go over the top of a hill at high speed.

• Always follow the proper procedures outlined in this manual for traveling downhill 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.

• 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.

• 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.

• 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.

• Always be sure there are no obstacles or people behind your vehicle when operating in

reverse. When it's safe to proceed in reverse, move slowly. Avoid turning at sharp angles in reverse.

• Always use the proper size and type of tires specified in this manual. Always maintain

proper tire pressure as specified on safety labels.

• Never modify this vehicle through improper installation or use of accessories.

• Never exceed the stated load capacity for this vehicle. Cargo should be properly distrib-

uted and securely attached. Reduce speed and follow the instructions in this manual for hauling cargo or pulling a trailer. Allow a greater distance for braking.

• Always place the transmission in PARK before getting out of the vehicle.

• 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.

• 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.

SAFETY

Operator Safety

Equipment Modifications

We strongly recommend that consumers do not install on a POLARIS RANGER any equipment 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 accessories, and familiarize yourself with their function and effect on the vehicle.

SAFETY

WARNING

Operator Safety

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 the 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.

Protective Apparel

Riding in this vehicle without wearing an approved helmet and protective eyewear increases the risk of a serious injuries in the event of an accident.

Operator and all passengers must always wear an approved helmet that fits properly and eye protection (goggles or face shield).

SAFETY

Operator Safety

Cab Nets

Riding in this vehicle without using the cab nets increases the risk of serious injury or death in the event of an accident or overturn. Always use the cab nets while riding in this vehicle.

Always keep hands and feet inside the vehicle at all times.

Failure to Inspect Before Operating

Failure to inspect and verify that the vehicle is in safe operating condition before operating increases the risk of an accident.

Always inspect your RANGER before each use to make sure it's in safe operating condition. Always follow all inspection and maintenance procedures and schedules described in the 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 or in a well ventilated area.

• Do not smoke or allow open flames or sparks in 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.

• The 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

Operating over obstacles

Climbing an incline

Towing

2. Verify tire pressure.

3. Use extra caution when operating.

SAFETY

Operator Safety

Exposure to Exhaust

Engine exhaust fumes are poisonous 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 only outdoors or in well-ventilated areas.

Operating a Damaged Vehicle

Operating a damaged vehicle can result in an accident. After any overturn or accident, have a qualified service dealer inspect the entire machine for possible damage, including (but not limited to) brakes, throttle and steering systems.

Operating at Excessive Speeds

Operating this vehicle at excessive speeds increases the operator's risk of losing control. Always operate at a speed that's appropriate for the terrain, the visibility and operating conditions, and your experience.

Operating on Pavement

This vehicle's tires are designed for off-road use only, not for use on pavement. Operating this vehicle on paved surfaces (including sidewalks, paths, parking lots and driveways) may adversely 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, including 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.

SAFETY

Operator Safety

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 slowly 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 confirm 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.

FEATURES AND CONTROLS

Tailgate

Latch

Releases

Receiver

Hitch

CV Boot/Rear Caliper

Muffler

(Spark Arrester)

Tailgate

Component Locations

Your vehicle is equipped with cab nets on both sides of the 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

Frame

Cargo Box

Hip Bar

Fuel Tank Cap

Headlights

Console

Cab Net

Radiator

Front Bumper/Brush Guard

FEATURES AND CONTROLS

Cup

Holder

12V Auxiliary

Outlet

Mode

Button

Storage

Tray

Instrument

Cluster

Gear Selector

(Shifter)

Storage

Compartment

Console

Auxiliary Outlet

The 12-volt receptacle has spade connections on the back that may be used to power an auxiliary light or other optional accessories or lights. The connections are behind the console, under the hood.

Mode Button

The yellow button located in the instrument cluster is used to toggle through mode options available. See pages 24-28.

Gear Selector

H: High Gear L: Low Gear N: Neutral 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 moving.

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 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

• Loading the vehicle onto a trailer

• Towing heavy loads

FEATURES AND CONTROLS

Ignition Switch

Light Switch

AWD/Differential

Switch

Switches

Ignition Switch/Light Switch

The ignition switch is a four-position, key-operated switch. The key can be removed from the switch when it is in the OFF position.

OFF The engine is off. All 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 key to the START position to engage the electric starter. Turn the key

to the LIGHTS ON position after starting the engine.

AWD/Differential Lock Switch

The AWD/Differential Switch has three positions: All Wheel Drive (AWD), Differential Lock/Two Wheel Drive (2WD) and Off (1WD/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 bottom of the switch to unlock the differential and allow the rear drive wheels to operate independently (1WD). This mode of operation is well suited to turf driving or when active traction is not needed.

FEATURES AND CONTROLS

Throttle

Pedal

Brake Pedal

Trailer Hitch Bracket

This vehicle is equipped with a receiver hitch bracket for a trailer hitch. Trailer towing equipment is not supplied with this vehicle.

To avoid injury and property damage, always heed the warnings and towing capacities outlined 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. Spring pressure returns the pedal to the rest position when released. Always check that the throttle pedal returns normally before starting the engine. Make sure there's adequate throttle pedal freeplay. See page 58 for throttle pedal adjustment procedures.

Fuel Cap

The fuel tank filler cap is located on the righthand side of the vehicle near the passenger seat. When refueling, always 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 of the seat until the pins are fully seated into the grommets.

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 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 diagonally 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.

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.

2. 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, including

cuts, wear, fraying or stiffness. If any damage is found, or if the seat belt does not operate properly, have the seat belt system checked and/or replaced by an authorized POLARIS dealer.

4. To clean dirt or debris from the seat belts, sponge the straps with mild soap and water.

Do not use bleach, dye or household detergents.

Latch Plate

Buckle

FEATURES AND CONTROLS

Cab Nets

Riding in this vehicle without using the cab nets increases the risk of serious injury or death in the event of an accident or overturn. Cab nets must be used by both operator and passengers at all times. Make sure all latches are secure before operating the vehicle.

Always inspect cab nets for tightness, wear and damage before each use of the vehicle. Use the strap adjusters to tighten any loose straps. Promptly replace worn or damaged cab nets with new cab nets, available from your 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 properly secured in the slot at the base of the mount.

2. Connect the latch at the top edge of the net to the receiver latch mounted on the front

frame.

Opening a Net

1. To exit the vehicle, release the top front latch.

2. Rotate the net rearward and slide the lower net rod out of the mount to remove it.

3. Allow the net to hang freely outside the vehicle while dismounting.

To p

Latch

Rod Mount

Net Rod

FEATURES AND CONTROLS

Rollover Protective Structure (ROPS)

The Rollover Protective Structure (ROPS) on this vehicle meets OSHA 1928.53 rollover performance requirements. Always have your authorized POLARIS dealer thoroughly inspect the ROPS if it ever becomes damaged in any way.

No device can 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.

FEATURES AND CONTROLS

Rider

Information

Center

Speedometer

Indicator

Lamps

MODE Button

Instrument Cluster

High water pressure may damage components. Wash the vehicle by hand or with a garden hose using mild soap. Do not use alcohol to clean the instrument cluster. Do not allow insect sprays to contact the lens.

Speedometer

The speedometer displays vehicle speed in either miles per hour (MPH) or kilometers per hour (km/h). See page 26.

Indicator Lamps

Lamp Indicates Condition

Vehicle Speed

When standard mode is selected, speed displays in miles per hour.

When metric mode is selected, speed displays in kilometers per hour.

Over Temperature This lamp illuminates to indicate an overheated engine. If the

EPS Warning This indicator illuminates briefly when the key is turned to the ON

Neutral This lamp illuminates when the transmission is in neutral and the

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

Check Engine This indicator appears if an EFI-related fault occurs. Do not operate

indicator flashes, the overheating condition remains, and the system will automatically reduce engine power.

position. If the light remains on, the EPS system is inoperative. See your authorized POLARIS dealer for service.

ignition key is in the ON position.

ON position. The lamp is a reminder to the operator to ensure all riders are wearing helmets and seat belts before operating.

the vehicle if this warning appears. Serious engine damage could result. See your dealer.

FEATURES AND CONTROLS

Instrument Cluster

Rider Information Center

The rider information center is located in the instrument cluster. All segments will light up for one second at start-up. If the instrument cluster fails to illuminate, a battery over-voltage may have occurred and the instrument cluster may have shut off to protect the electronic speedometer. If this occurs, take the vehicle to your POLARIS dealer for proper diagnosis.

The information center is set to display standard units of measurement and a 12-hour clock at the factory. To change to metric and/or a 24hour 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)

2. Fuel Gauge - The segments of the fuel gauge show the level of fuel in the fuel tank.

When the last segment clears, a low fuel warning is activated. All segments including the fuel icon will flash. Refuel immediately.

Tip: If the fuel icon fails to display, an open or short circuit has occurred in the fuel sensor circuit. See

your dealer.

3. Information Display Area - This area displays odometer, trip meter, engine hour meter

and programmable service hour interval.

4. 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 and high electrical load (lights, cooling fan, accessories) is applied. Drive at a higher RPM or recharge the battery to clear the warning.

5. Clock - The clock displays time in a 12-hour or 24-hour format. See page 26 for reset-

ting instructions.

6. 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 maintenance. See page 26 for resetting instructions.

7. 4X4 Indicator - This indicator illuminates when the 4X4 system is engaged (switch is

on 4X4).

8. Turf Mode Indicator - This indicator illuminates when the operator unlocks the differ-

ential. See page 40.

Trip 1

RPM

FEATURES AND CONTROLS

Instrument Cluster

Rider Information Center

Use the MODE button to toggle through the information area options.

Display Units (Standard/Metric)

The display can be changed to display either standard or metric units of measurement.

Tip: To exit the set-up mode at any time, wait 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 Tem per ature Fahrenheit Celsius Time 12-Hour Clock 24-Hour Clock

1. Turn the key to the OFF position.

2. 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.

2. Press and hold the MODE button until the hour segment flashes. Release the button.

3. With the segment flashing, tap the MODE button to advance to the desired setting.

4. Press and hold the MODE button until the next segment flashes. Release the button.

5. Repeat steps 3-4 twice to set the 10-minute and 1-minute segments. After completing the

1-minute segment, step 4 will save the new settings and exit the clock mode.

6. Turn the key to the OFF position.

FEATURES AND CONTROLS

Instrument Cluster

Rider Information Center

Odometer Mode

The odometer records and displays the distance traveled by the vehicle.

Trip Meter Mode

The trip meter records the distance traveled by 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 display contains a decimal point, but the odometer displays 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 displayed digitally.

Tip: Small fluctuations in the RPM from day to day may be normal because of changes in humidity,

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 factory. Use the following procedure to change the service interval.

1. Press the MODE button until remaining service hours display.

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 (failure 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 intermittent faults.

Inactive codes are stored in the history of the unit.

FEATURES AND CONTROLS

Suspect Parameter

Number (SPN)

Error Code

Number (0-9)

Failure Mode Indicator (FMI)

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. If the error codes are not displayed, use the MODE button to toggle until “Ck ENG” displays on the main line of the display.

2. Press and hold the MODE button to enter the diagnostics code menu.

3. Record the three numbers displayed in the gear position, clock and odometer displays.

4. Press the MODE button to advance to the next error code.

5. Press and hold the MODE button to exit the diagnostics code menu.

6. See an authorized POLARIS dealer for code details and diagnosis.

OPERATION

WARNING

Failure to operate the vehicle properly can result in a collision, loss of control, accident or overturn, which may result in 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 and Drivetrain Break-in

1. Fill the fuel tank with gasoline. Review the fuel warnings on page 14.

2. Check the oil level. See page 46. Add the recommended oil as needed to maintain the oil

3. Drive slowly at first. Select an open area that allows room to familiarize yourself with

4. 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

6. Pull only light loads.

7. Check fluid levels of transmission and all gearcases after the first 25 hours of operation

8. During the break-in period, change both the oil and the filter at 25 hours.

engine parts. Do not operate at full throttle or high speeds for extended periods during the first three hours of use.

level in the normal (safe) operating range.

vehicle operation and handling.

inspection checklist. See page 30.

and every 100 hours thereafter.

PVT Break-in (Clutches/Belt)

A proper break-in of the clutches and drive belt will ensure a longer life and better performance. 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.

If a belt fails, always clean any debris from the duct and from the engine compartment.

OPERATION

Pre-Ride Inspection

Failure to inspect and verify that the vehicle is in safe operating condition before operating increases the risk of an accident. Always inspect the vehicle before each use to make sure it's in safe operating condition.

Item Remarks Page

Brake system/pedal travel Ensure proper operation 20

Brake fluid Ensure proper level 59

Park gear Ensure vehicle does not roll when in PARK. Ensure

Front suspension Inspect, lubricate if necessary 45

Rear suspension Inspect, lubricate if necessary 45

Steering Ensure free operation 60

Tires Inspect condition and pressure 8

Wheels/fasteners Inspect, ensure fastener tightness 61

Frame nuts, bolts, fasteners Inspect, ensure tightness -

Fuel and oil Ensure proper levels 20

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

Brake light/tail lamp Check operation, apply POLARIS dielectric grease

Seat Belts Check length of belt for damage, check latches for

Cab Nets Check for wear or damage, ensure proper installation 22

PARK light illuminates.

when lamp is replaced

proper operation

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 maximum of five seconds. Release the key when the engine starts.

5. If the 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

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-

engine to warm up for several minutes before operating the vehicle.

cle has no engine braking.

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 your 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.

9. Do not carry a passenger until you have at least two hours of driving experience with this

vehicle.

OPERATION

Driving with a Passenger

1. Perform the pre-ride inspection. See page 30.

2. Make sure all passengers are at least 12 years of age and tall enough to comfortably and safely sit in a passenger seat with the seat belt secured, put both feet on the floor and grasp the hand hold.

3. Make sure all passengers are wearing helmet, eye protection, gloves, long-sleeve shirt, long pants and over-the-ankle boots.

4. Make sure all passengers secure their seat belt.

5. Make sure all cab nets are properly secured.

6. Do not carry more than the recommended number of passengers for your vehicle. See page 8.

7. Allow a passenger to ride only in a passenger seat.

8. 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.

9. 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 in this manual.

Driving Over Obstacles

Follow these precautions when operating over obstacles:

1. Always check for obstacles before operating in a new area.

2. Look ahead and learn to read the terrain. Be constantly alert for hazards such as logs, rocks and low hanging branches.

3. Travel slowly and use extra caution when operating on unfamiliar terrain. Not all obstacles are immediately visible.

OPERATION

WARNING

Driving On Slippery Surfaces

Skidding or sliding can cause loss of control or overturn (if tires regain traction unexpectedly). When operating on slippery 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 excessively slippery surfaces.

Whenever riding on slippery surfaces such as wet trails or loose gravel, or during freezing weather, follow these precautions:

1. Do not operate on excessively rough, slippery 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

5. Correct a skid by turning the steering wheel in the direction of the skid. Never apply the

spinning. Always allow the wheels to stop spinning before engaging AWD.

brakes during a skid.

Sideways

skid

Turn in

direction of

skid

OPERATION

Driving Uphill

Whenever traveling uphill, follow these precautions:

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 slippery or loose surfaces.

6. Proceed at a steady rate of speed and throttle opening. Never open the throttle suddenly.

7. Never go over the crest of a hill at high speed. An obstacle, a sharp drop, or another vehicle 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 unavoidable, follow these precautions:

1. Slow down.

2. Exercise extreme caution.

3. Avoid crossing the side of a steep hill (15° maximum).

15° maximum

Driving Downhill

When driving downhill, follow these precautions:

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.

4. Apply the brakes slightly to aid in slowing.

15° maximum

OPERATION

Driving Through Water

Your POLARIS RANGER can operate through water up to a maximum recommended depth equal to the floorboards.

NOTICE: Immersion can result in major damage if the vehicle isn't serviced correctly and promptly.

Follow these procedures when operating through water:

1. Determine water depths and current before

2. Choose a crossing where both banks have

3. Proceed slowly, avoiding rocks and obsta-

4. Avoid operating through deep or fast-

WARNING! The large tires on your RANGER may cause the vehicle to float in deep or fast-flowing water, which could result in loss of control and lead to serious injury or death. Never cross deep or fastflowing water with your RANGER.

5. After leaving water, always dry the brakes

NOTICE: After running your vehicle in water, it's critical that you perform the services outlined in the

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.

entering water.

gradual inclines.

cles.

flowing water.

Floorboard

by applying light pressure to the pedal repeatedly until braking action is normal.

Periodic Maintenance Chart beginning on page 43. Give special attention to engine oil, transmission oil, front and rear gearcases (if equipped), and all grease fittings.

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 ventilated 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:

1. Apply the brakes.

2. Place the transmission in PARK.

3. Turn the engine off.

4. Block the rear wheels on the downhill side.

15° maximum

OPERATION

WARNING

Hauling Cargo

Hauling cargo improperly can alter vehicle handling and may cause loss of control or brake instability, 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 adding 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 level 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 understand 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.

Model

RANGER 800 Midsize 1000 lbs. (455 kg) 500 lbs. (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.

Maximum Capacities

(Level Ground)

Cargo Box

OPERATION

Release

Lever

Towing Loads

Towing improperly can alter vehicle handling and may cause loss of control or brake instability. Always follow these precautions when towing:

1. Never load more than 150 lbs. (68.1 kg) tongue 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 a trailer to any other location or you may lose control of the vehicle.

5. Never tow a trailer on a grade steeper than 15°.

Model Total Towed

RANGER 800

Midsize

Load Weight

(Level Ground)

1250 lbs. (567 kg) 850 lbs. (386 kg) 150 lbs. (68.1 kg) 10 MPH (16 km/h)

Total Towed

Load Weight

(15° grade)

Total Hitc h

Vertical

Weight

Maximum

Towing

Speed

Belt Life

To extend belt life, use the lowest gear possible when hauling or towing heavy cargo.

Dumping the Cargo Box

1. Select a level site to dump the cargo box. Do not attempt to dump or unload the vehicle while parked on an incline.

2. Apply the brakes.

3. Place the transmission in PARK. Dismount the vehicle.

4. Ensure that the cargo is positioned evenly or toward the front of the cargo box.

5. Release the tailgate latches.

WARNING! If the weight distribution on the box is located toward the rear of the box when the release lever is pulled forward, the box may dump unexpectedly and cause serious injury to the operator or bystanders. Never operate the dump lever without ensuring that the load is positioned evenly or at the front of the box.

6. Stand clear and pull up on the cargo box release lever. Lift the front of the cargo box to dump the cargo.

7. Lower the cargo box and push down securely to latch.

8. Close the tailgate and secure both tailgate latches.

WARNING! Operating the vehicle while the cargo box is raised could result in severe 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.

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 differential and operate in two wheel drive (2WD). Locking the differential 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

Press the bottom of the switch to unlock the differential and allow the rear drive wheels to operate independently (1WD). When the rear differential is unlocked, the rear wheels can 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 or while the rear wheels are spinning. Slow the vehicle to nearly stopped before engaging the differential.

OPERATION

All Wheel Drive (AWD)

The illuminated amber AWD switch indicates that the vehicle is in 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 automatically 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

Disengaging AWD

Under certain conditions, it may be possible for the front gearcase to remain locked unnecessarily. 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.

1. Stop the vehicle.

2. Operate in reverse for at least 10 feet.

3. Stop completely.

4. Shift into low gear and drive forward.

clutch damage. Always switch to AWD while the rear wheels have traction or are at rest.

EMISSION CONTROL SYSTEMS

Noise Emission Control System

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 requirements.

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 performance and are not adjustable.

The emissions label is located on the frame under the seat.

Electromagnetic Interference

This spark ignition system complies 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.

MAINTENANCE

Periodic Maintenance Chart

Careful periodic maintenance will help keep your vehicle in the safest, most reliable condition. Inspection, adjustment and lubrication of important components are explained in the periodic maintenance chart.

Inspect, clean, lubricate, adjust and replace 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

• Frequent immersion in mud, water or sand

• Frequent or prolonged operation in dusty environments

• Racing or race-style high RPM use

• Prolonged low speed, heavy load operation

• Extended idle

• Short trip cold weather operation

Pay special attention to the oil level. A rise in oil level during cold weather can indicate contaminants 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

 Perform these operations more often for vehicles subjected to severe use.

E Emission-related service (Failure to conduct this maintenance will not void the emissions 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.

MAINTENANCE

Periodic Maintenance Chart

Perform all services at whichever maintenance interval is reached first.

Item Maintenance Interval

Steering Front suspension Rear suspension Tires Brake fluid level Brake pedal travel Brake system Wheels/fasteners Frame fasteners Engine oil level

►EAir filter, pre-filter - Daily - Inspect; clean often; replace as needed

►EAir box sediment tube - Daily - Drain deposits when visible

Coolant (if applicable) - Daily - Check level daily, change coolant every

Headlamp/tail lamp - Daily - Check operation; apply dielectric

►EAir filter, main element - Weekly - Inspect; replace as needed

►DBrake pad wear 10 H Monthly - Inspect periodically

Battery 20 H Monthly - Check terminals; clean; test

► Clutch Intake, pre-filter 25 H Monthly - Inspect; clean with compressed air;

►EEngine breather filter (if equipped) 25 H Monthly - Inspect; replace if necessary

(whichever comes first)

Hours Calendar Miles (Km)

Pre-Ride Make adjustments as need ed. See

Pre-Ride Checklist on page 30.

2 years

grease if replacing

replace if necessary

Remarks

► Front Gearcase oil (if equipped) 25 H 1 M - Perform a break-in oil level check ► Middle Gearcase oil (if equipped) 25 H 1 M - Perform a break-in oil level check ► Rear gearcase oil (if equipped) 25 H 1 M - Perform a break-in oil level check ► Transmission oil 25 H 1 M - Perform a break-in oil level check ► Engine oil change (break-in) 25 H 1 M - Perform a break-in oil change at one

► General lubrication 50 H 3 M - Lubricate all fittings, pivots, cables, etc.

Shift Linkage 50 H 6 M - Inspect, lubricate, adjust

D Steering 50 H 6 M - Lubricate

► Front Suspension 50 H 6 M - Lubricate ► Rear Suspension 50 H 6 M - Lubricate

DEThrottle cable 50 H 6 M - Inspect; adjust; lubricate; replace if nec-

E Throttle body air intake ducts/

flange Drive belt 50 H 6 M - Inspect; adjust; replace as needed Cooling system (if applicable) 50 H 6 M - Inspect coolant strength seasonally;

► Perform these procedures more often for vehicles subjected to severe use.

E Emission-Related Service. D Have an authorized POLARIS dealer perform these services.

50 H 6 M - Inspect duct for proper sealing/air leaks

month

essary

pressure test system yearly

Periodic Maintenance Chart

MAINTENANCE

Item Maintenance Interval

 Engine oil change 100 H 6 M - Perform a break-in oil change at one

 Oil filter change 100 H 6 M - Replace with oil change

 Front Gearcase oil (if equipped) 100 H 6 M - Inspect level; change yearly

 Middle Gearcase oil (if equipped) 100 H 6 M - Inspect level; change yearly

 Rear gearcase oil (if equipped) 100 H 6 M - Inspect level; change yearly

 Transmission oil 100 H 6 M - Inspect level; change yearly

DEFuel system 100 H 12 M - Check for leaks at tank cap, lines, fuel

 Radiator (if applicable) 100 H 12 M - Inspect; clean external surfaces

 Cooling Hoses 100 H 12 M - Inspect for leaks

 Engine mounts 100 H 12 M - Inspect

Exhaust muffler/pipe 100 H 12 M - Inspect

ESpark plug 100 H 12 M - Inspect; replace as needed

D Ignition timing 100 H 12 M - Inspect

 Wiring 100 H 12 M - Inspect for wear, routing, security; apply

DClutches (drive and driven) 100 H 12 M - Inspect; clean; replace worn parts

D Front wheel bearings 100 H 12 M - Inspect; replace as needed

D Brake fluid 200 H 24 M - Change every two years

Spark arrester 300 H 36 M - Clean out

Idle speed - Adjust as needed

D Toe adjustment - Inspect periodically; adjust when parts

DAuxiliary brake (if equipped) - Inspect daily; adjust as needed

(whichever comes first)

Hours Calendar Miles (Km)

month

valve, pump, throttle body; replace lines every 2 years

dielectric grease to connectors subjected to water, mud, etc.

are replaced

Remarks

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

Brake Fluid DOT 4 See page 59.

Main Gearcase Oil (Transmission)

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

Synthetic 2W-50 4-cycle Oil

Premium AGL Synthetic Gearcase Lube See page 48.

See page 46.

maximum).

MAINTENANCE

Safe

{

Safe

Range

Check Level

on Top Side

Dipstick

Add

Engine Oil

Always check and change the engine oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 43. Always change the oil filter whenever changing oil.

WARNING! Vehicle operation with insufficient, deteriorated, or contaminated engine oil will cause accelerated wear and may result in engine seizure, accident, and injury. Always 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 4cycle 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

Oil Check

The oil tank is located under the seat.

1. Position the vehicle on a level surface. Place the trans-

2. Remove the seat. See page 20.

3. Lift the lever lock to remove the dipstick. Wipe it dry

4. Reinstall the dipstick completely, but do not lock it. The

5. Remove the dipstick and check the oil level. Maintain

Tip: Due to the dipstick entry angle into the crankcase, the oil level

6. After reinstalling the dipstick, be sure to seat the lever

7. Reinstall the seat.

use the recommended oil. Never substitute or mix oil brands.

mission in PARK.

with a clean cloth.

dipstick must be screwed completely in to keep the angle and depth of the stick consistent.

the oil level in the safe range. Do not overfill.

will read higher on the bottom side of the dipstick. Always read the level on the upper surface of the dipstick.

lock.

MAINTENANCE

Engine Oil

Oil and Filter Change

Always change the oil and filter at the intervals outlined in the Periodic Maintenance Chart beginning on page 43. Always change the oil filter whenever changing oil.

1. Position the vehicle on a level surface.

2. Place the transmission in PARK.

3. Start the engine. Allow it to idle for two to three minutes. Stop the engine.

4. Clean the area around the drain plug.

5. 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.

7. 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.

8. Reinstall the drain plug. Torque to 20 ft. lbs. (27 Nm).

9. Remove the seat.

10. Place shop towels beneath the oil filter. Using an oil filter wrench, turn the filter counterclockwise to remove it.

11. Using a clean dry cloth, clean the filter sealing surface on the crankcase.

12. 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.

13. Install the new filter and turn by hand until the filter gasket contacts the sealing surface, then turn and additional 1/2 turn.

14. Remove the dipstick and fill the sump with two quarts (1.9 l) of recommended oil.

15. Place the transmission in PARK.

16. Start the engine. Allow it to idle for one to two minutes.

17. Stop the engine. Inspect for leaks.

18. Check the oil level on the dipstick and add oil as necessary to bring the level to the upper mark on the dipstick.

19. Reinstall the seat.

20. Dispose of used filter and oil properly.

MAINTENANCE

Drain Plug

Level Check

and Alternate

Fill Plug

Rear Fill

Plug

Fill

Level

Gearcases

Gearcase Specification Chart

Gearcase Lubricant Capacity Fill Plug(s)

Main Gearcase (Transmission)

Front Gearcase Demand Drive Plus Fluid 9.3 oz.

Premium AGL Synthetic

Gearcase Lube

34 oz.

(1000 ml)

(275 ml)

Torq ue

12 ft. lbs.

(16.3 Nm)

8-10 ft. lbs.

(11-13.6 Nm

Drain Plug Torque

12 ft. lbs.

(16.3 Nm)

11 ft. lbs.

(15 Nm)

Transmission (Main Gearcase)

Always check and change the transmission oil at the intervals outlined in the Periodic Maintenance 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.

2. Remove the level

check/fill plug. Check the oil level.

3. Remove the rear fill

plug and add the recommended oil as needed.

4. Reinstall both fill

plugs. Torque to specification.

Oil Change

The drain plug is located near the bottom of the gearcase.

1. Remove the rear fill plug and the level check/fill plug.

2. Place a drain pan under the gearcase.

3. Remove the drain plug. Allow the oil to drain completely.

4. Clean and reinstall the drain plug. Torque to specification.

5. Add the recommended oil.

6. Reinstall both fill plugs. Torque to specification.

7. Check for leaks. Dispose of used oil properly.

MAINTENANCE

Drain Plug

Fill Plug

Gearcases

Front Gearcase

Always 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, capacities and torque specifications. See page 76 for the part numbers of POLARIS products.

Oil 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 vehicle securely with a jackstand.

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.

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.

MAINTENANCE

Spark Plugs

Spark Plug Recommendations

Refer to the specifications section beginning on page 74 for the recommended spark plug type for your vehicle. Always torque spark plugs to specification.

NOTICE: Using non-recommended spark plugs can result in serious engine damage. Always use

Spark Plug Gap/Torque

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. Immediately check the spark plug for correct color.

CAUTION! A hot exhaust system 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,

3. Reverse the procedure for spark plug installation. Torque to specification.

POLARIS-recommended spark plugs.

Electrode Gap New Plug Torque Used Plug Torque

.035" (.9 mm) 18 ft. lbs. (24 Nm) 18 ft. lbs. (24 Nm)

remove the plug by rotating it counter-clockwise.

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.

MAINTENANCE

Cooling System

The engine coolant level is controlled or maintained by the recovery system. The recovery system components are the overflow bottle, radiator filler neck, radiator pressure cap and connecting hose.

As coolant operating temperature increases, the expanding (heated) excess coolant is forced out of the radiator, past the pressure cap, and into the overflow bottle. As engine coolant temperature 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 system is purging itself of trapped air. Observe coolant levels and maintain as recommended by adding coolant to the overflow bottle.

Adding or Changing Coolant

To ensure that the coolant maintains its ability to protect the engine, we recommend that the system be completely drained every two years and a fresh mixture of antifreeze and water added. POLARIS recommends the use of POLARIS Premium 60/40 anti-freeze/coolant or a 50/50 mixture of high quality 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 not recommended.

MAINTENANCE

Cooling System

Overflow Bottle Coolant Level

Always check and change the coolant at the intervals outlined in the Periodic Maintenance Chart beginning on page 43. Maintain the coolant level between the minimum and maximum marks on the bottle (when the fluid is cool).

1. Position the vehicle on a level surface.

2. Lift the hood. View the coolant level in the overflow bottle.

3. If the 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

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 coolant 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 recovery system to function properly. See your dealer for the correct replacement part.

MAINTENANCE

WARNING

POLARIS Variable Transmission (PVT) System

Failure to comply with the instructions in this warning can result in severe injury or death.

Do not modify any component of the PVT system. Doing so may reduce its strength so that a failure may occur at a high speed. The PVT system has been precision balanced. Any modification will cause the system to be out of balance, creating vibration and additional loads on components.

The PVT system rotates at high speeds, creating large amounts of force on clutch components. Extensive engineering and testing has been conducted to ensure the safety of this product. However, as the owner, you have the following responsibilities to make sure this system 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 products only. Do not install it in any other product.

• 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 compartments 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.).

MAINTENANCE

POLARIS Variable Transmission (PVT) System

PVT Drying

There may be some instances when water is ingested into the PVT system. Use the following instructions to dry it out before operating.

1. Position the vehicle on a level surface.

2. Remove the drain plug. Allow the water to drain completely. Reinstall the drain plug.

3. Place the transmission in PARK.

4. Start the engine.

5. Apply varying throttle for 10-15 seconds to expel the 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.

7. Test for belt slippage. If the belt slips, repeat the process.

8. Take the vehicle to your dealer for service as soon as possible.

MAINTENANCE

Vehicle Immersion

NOTICE: If your vehicle becomes immersed, major engine damage can result if the machine is not

If it's impossible to take your RANGER to a dealer before starting it, follow the steps outlined below.

1. Move the vehicle to dry land or at the very least, to water below the footrests.

2. Dry any water present in the air box. Filter replacement is required if water is present.

3. Thoroughly dry the air pre-cleaner located under the hood.

4. Remove the spark plugs. Turn the engine over several times using the electric start.

5. Dry the spark plugs and reinstall, or replace with new plugs.

6. Attempt to start the engine. If necessary, repeat the drying procedure.

7. Take the vehicle to your dealer for service as soon as possible, whether you succeed in

8. 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 fasteners for proper torque at the first service or after 25 hours.

thoroughly inspected. Take the vehicle to your dealer before starting the engine.

starting it or not.

MAINTENANCE

Filter Systems

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 adhere tightly to the cover and 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.

Air Filter

MAINTENANCE

WARNING

Clean-Out

Plug

Exhaust Outlet

Spark Arrester

Failure to heed the following warnings while servicing the spark arrester could result in serious injury or death.

• Do not perform service on the spark arrester while the system is hot. Exhaust system temperatures can reach 1000° F. 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 in an enclosed area. Exhaust contains poisonous carbon monoxide gas that can cause loss of consciousness or death in a very short time.

• 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.

2. Place the transmission in PARK.

3. Start the engine.

4. Purge accumulated carbon from the system

by momentarily revving the engine several times.

5. If carbon is expelled, cover or plug the

exhaust outlet and rap on the pipe around the clean-out plug while revving the engine several 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.

MAINTENANCE

WARNING

Boot

Adjuster

Lock Nut

Throttle System

Failure to check or maintain proper operation of the throttle system can result in an accident and lead to serious injury or death if the throttle pedal sticks during operation.

Always check the pedal for free movement and return before starting the engine and occasionally during operation. Never start or operate this vehicle if it has a sticking or improperly 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

Pedal

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 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 of the rubber boot and slide it over the cable adjuster to its original position.

MAINTENANCE

Maximum

Minimum

Brakes

The front and rear brakes are hydraulic disc type brakes. Press down on the brake pedal to engage the brakes. See page 20.

Brake Fluid

Inspect the brake system routinely. Inspect the level of the brake fluid before each operation.

WARNING! After opening a bottle of brake fluid, always discard any unused portion. Never store or use a partial bottle. Brake fluid is hygroscopic, meaning it rapidly absorbs moisture from the air. The moisture causes the boiling temperature of the brake fluid to drop, which can lead to early brake fade and the possibility of accident or severe injury.

Change the brake fluid every two years and any time the fluid becomes contaminated, the fluid level is below the minimum, or if the type and brand of the fluid in the reservoir are unknown. See page 45 for fluid recommendations.

1. Position the vehicle on a level surface.

2. 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.

3. If the fluid level is lower than the upper level line, add brake fluid to the upper (MAX) line.

4. Apply the brake forcefully for a few seconds and check for fluid leakage around the fittings.

Brake Inspection

1. Check the brake system for fluid leaks.

2. Check the brake pedal for excessive travel or a spongy feel.

3. Check the friction pads for wear, damage and looseness.

4. 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. Inspect the brake disc spline and pad wear surface

brake discs.

for excessive wear. Change pads when worn to 3/64" (1 mm).

3/64" (1mm)

MAINTENANCE

Cam

Steering Wheel Inspection

Check the steering wheel for specified freeplay and smooth operation at the intervals outlined 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.

MAINTENANCE

WARNING

Tires

Operating your vehicle with worn tires, improperly inflated tires, non-standard tires or improperly installed tires will affect vehicle handling and could cause an accident resulting in serious injury or death. Always follow all tire maintenance procedures as outlined in this manual and on the labels on the vehicle. Always use original equipment size and type when replacing tires.

Tire Tread Depth

Always replace tires when tread depth is worn to 1/8" (3 mm) or less.

Axle and Wheel Nut Torque Specifications

Inspect the following items occasionally for tightness, and if they've been loosened for maintenance service.

Do not lubricate the stud or the lug nut.

Nut Type Location Nut Torque

1/8" (3 mm)

Lug Nut (Aluminum Wheels)

Nut and Washer (Steel Wheels)

Spindle Nut Front 70 ft. lbs. (95 Nm)

Hub Retaining Nuts Center and Rear 110 ft. lbs. (150 Nm)

Front and Rear 30 ft. lbs. (41 Nm) PLUS 1/4 TURN

Front and Rear 35 ft. lbs. (47 Nm)

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 axle nuts that have a cotter pin installed. See your POLARIS dealer.

3. Attach the wheel nuts and washers and finger tighten.

4. Carefully lower the vehicle to the ground.

5. Torque the wheel nuts to specification. See page 61.

MAINTENANCE

Fuses

If the engine stops or will not start, or if you experience other electrical failures, a fuse may need replacement. Locate and correct any short circuits that may have caused the blown fuse, then replace the fuse. Spare fuses are provided in the fuse box.

If you suspect that a fuse or relay may not be working properly, please see your POLARIS dealer.

Fuse Feature Supported

20A Lights: Headlights, Taillights 10A Drive: AWD 20A Accessory: Winch Switch, 12V Power

Receptacle 10A Fuel Pump 20A Electronic Engine Control, Starting

Lights

Poor lighting can result in reduced visibility when driving. Headlight and taillight lenses become dirty during normal operation. Clean lights frequently and replace burned out lamps promptly. Always make sure lights are adjusted properly for best visibility.

When servicing a halogen lamp, don't touch the lamp with bare fingers. Oil from your skin leaves a residue, causing a hot spot that will shorten the life of the lamp.

Headlight Lamp Replacement

1. Open the hood.

CAUTION! Hot components can cause burns to skin. Allow lamps to cool before servicing.

2. Unplug the headlamp from the wiring harness. 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 headlight assembly.

Wiring Harness

MAINTENANCE

25 ft.

(7.6 m)

8" (20 cm)

Lights

Headlight Beam Adjustment

1. Place the vehicle on a level surface with the headlight approximately 25 ft. (7.6 m) from a wall.

2. Measure the distance from the floor to the center of the headlight and make a mark on

the wall at the same height.

3. Apply the brakes. Start the engine. Turn on the headlights.

4. 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.

5. If a headlight needs adjustment, locate the adjustment screw at the back of the headlight.

6. Loosen the screw, adjust the headlight, and tighten the screw.

7. 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. Turn the ignition switch to the ON position.

2. 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

WARNING

Lower

Mark

Upper

Mark

Battery

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 conventional battery. A sealed battery can be identified by its flat covers on the top of the battery. 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 solution or tap water into the battery.

Battery Fluid (Conventional Battery)

A poorly maintained battery will deteriorate rapidly. Check 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.

MAINTENANCE

WARNING

Battery

Battery Removal

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. On 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.

MAINTENANCE

Battery

Battery Installation

Using a new battery that has not been fully charged can damage the battery and result in a shorter life. It can also hinder vehicle performance. Follow the battery charging instructions on page 68 before installing the battery.

1. Ensure that the 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 securely installed. Route the tube away from the frame and vehicle body to prevent contact with electrolyte.

WARNING! Battery gases could accumulate in an improperly installed vent tube and cause an explosion, resulting in serious injury or death. Always ensure that the vent tube is free of obstructions and is securely installed as recommended.

4. Coat the 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 a 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 will automatically charge the battery if the voltage drops below a pre-determined point. See page 76 for the part numbers of POLARIS products.

MAINTENANCE

Battery

Battery Charging (Conventional Battery)

1. Remove the battery from the vehicle to prevent damage from leaking or spilled electrolyte 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.

For a 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 recharging.

Always verify battery condition before and 1-2 hours after the end of charging.

State of

Charge

100% 12.8-13.0 volts None, check at 3 mos. from date of

75%-100% 12.5-12.8 volts May need slight charge, if no charge

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,

0%-25% 11.5 volts or less Needs charge with desulfating charger At least 20 hours

Voltage Action

manufacture

given, check in 3 months

Charge Time

(Using constant current charger @ standard amps specified on top of battery)

None required

3-6 hours

verify state of charge

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

NOTICE: Certain products, including insect repellents and chemicals, will damage plastic surfaces.

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

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.

• Do not use a power washer to clean the vehicle.

• Do not use medium to heavy duty compounds on the finish.

• 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.

If a 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:

• Wheel bearings • Brakes • Switches and controls

• Radiator • Cab and body panels • Electrical components and wiring

• Transmission seals • Labels and decals

by hand or with a garden hose, using mild soap.

Do not allow these types of products to contact the vehicle.

last.

If an informational or graphic label becomes illegible or comes off, contact your POLARIS dealer to purchase a replacement. Replacement safety labels are provided by POLARIS at no charge.

MAINTENANCE

Cleaning and Storage

Polishing the Vehicle

POLARIS recommends the use of common household aerosol furniture polish for polishing the finish on your POLARIS vehicle. Follow the instructions on the container.

• Avoid the use of automotive products, some of which can scratch the finish of your vehicle.

• 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 on

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.

4. 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 found on the chrome finish, use steel wool (#0000-OTT 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.

MAINTENANCE

Cleaning and Storage

Storage Tips

NOTICE: Starting the engine during the storage period will disturb the protective film created by

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

3. Allow the engine to run for 15-20 minutes to allow the stabilizer to disperse through the

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.

fogging and damage could occur. Never start the engine during the storage period.

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.

entire fuel delivery system.

MAINTENANCE

Cleaning and Storage

Storage Tips

Inspect and Lubricate

Inspect all cables and lubricate all areas of the vehicle as recommended in the Periodic Maintenance Chart beginning on page 43.

Battery Maintenance

See pages 67-68 for storage and charging procedures.

Fluid Levels

Inspect the fluid levels. Add or change fluids as recommended in the Periodic Maintenance Chart beginning on page 43.

• Front and rear gearcase fluid (if equipped)

• Transmission fluid

• Brake fluid (change every two years and any time the fluid looks dark or contaminated)

• 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 premeasured 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.

4. 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 ventilated. Cover the vehicle with a genuine POLARIS cover. Do not use plastic or coated materials. They do not allow enough ventilation to prevent condensation, and may promote corrosion and oxidation.

MAINTENANCE

Removal from Storage

1. Check the battery electrolyte level and charge the battery if necessary. Install it in the

vehicle. Make sure the battery vent hose is routed properly and that it's not pinched or restricted in any way.

2. Make sure the spark plug is tight.

3. Fill the fuel tank with fuel.

4. Check all the points 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.

5. 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. Apply the brakes.

2. Place the transmission in PARK.

3. Stop the engine.

4. Secure the fuel cap, oil cap and seat.

5. Always tie the frame of the RANGER to the transporting unit securely with suitable

straps or rope. Do not attach tie straps to the front A-arm bolt pockets.

6. Remove the key to prevent loss during transporting.

SPECIFICATIONS

RANGER 800 Midsize

Maximum Weight Capacity (includes weight of operator, passenger, cargo, accessories)

Dry Weight 1055 lbs. (478.5 kg)

Fuel Capacity 8.8 gal. (33.3 l)

Engine Oil Capacity 2 qts. (1.9 l)

Coolant Capacity 120 oz. (3.5 l)

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. (81x107x29 cm)

Ground Clearance 10 in. (25.4 cm)

Min. Turning Radius 150 in. (381 cm)

Towing Capacity 1250 lbs. (567 kg)

Hitch Tongue Capacity 150 lbs. (68 kg)

Max. Cargo Box Load 500 lbs. (227 kg)

Engine 4 valve 4 stroke twin cylinder with counter balance

Displacement 760 cc

Bore x Stroke (mm) 80 x 76.5

Alternator Output 500 W @ 3000 RPM

Compression Ratio 10.0:1

Starting System Electric

Fuel System Electronic Fuel Injection

Ignition Timing 30° @ 5000 RPM

Spark Plug / Gap RC7YC3 /.035 in. (0.9 mm)

Lubrication System Dry 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

1000 lbs. (454 kg)

SPECIFICATIONS

RANGER 800 Midsize

Driving System Type PVT

Shift Type 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 25 x 8 - 12

Tire Size - Rear 25 x 11 - 12

Tire Pressure - Front 10 psi (68.9 kPa)

Tire Pressure - Rear 12 psi (82.7 kPa)

Brakes, 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. (3.1W)

Indicator Light 1.0 W

Clutching

See your POLARIS dealer for clutching specifications.

POLARIS PRODUCTS

Part Number Description

Engine Lubricant

2870791 Fogging Oil (12 oz./355 ml Aerosol)

2876244 PS-4 PLUS Performance Synthetic 2W-50 4-Cycle Oil (qt./.95 l)

2876245 PS-4 PLUS Performance Synthetic 2W-50 4-Cycle Oil (gal./3.8 l)

Gearcase / Transmission Lubricants

2878068 AGL PLUS Transmission Fluid (qt./.95 l)

2878069 AGL PLUS Transmission Fluid (gal./3.8 l)

2877922 Demand Drive Plus Fluid (qt./.95 l)

2877923 Demand Drive Plus Fluid (gal./3.8 l)

2871653 Premium ATV Angle Drive Fluid (8 oz./237 ml)

2872276 Premium ATV Angle Drive Fluid (2.5 gal./9.5 l)

2870465 Pump for Gallon (3.8 l) 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 oz./89 ml cartridge)

2871423 Premium All Season Grease (14 oz./414 ml cartridge)

2871460 Starter Drive Grease

2871515 Premium U-Joint Lube (3 oz./89 ml cartridge)

2871551 Premium U-Joint Lube (14 oz./414 ml cartridge)

2871329

Dielectric Grease (Nyogel

2872073 Chain Lube, Aerosol (6.25 oz.)

2872348 Chain Lube, Aerosol (16 oz.)

2871326 Carbon Clean Plus

2872189 DOT 4 Brake Fluid

2871956

2871076

Loctite

565 Thread Sealant

POLARIS Battery Tender

)

Additives / Miscellaneous

Charger

TROUBLESHOOTING

Drive Belt Wear/Burn

Possible Cause Solution

Driving onto a pickup or tall trailer in high range

Starting out going up a steep incline

Driving at low RPM or ground speed (3-7 MPH)

Insufficient warm-up at low ambient temperatures

Slow/easy clutch engagement Use the throttle quickly and effectively.

Towing/pushing at low RPM/low ground speed

Utility use/plowing Use low range only.

Stuck in mud or snow Shift the transmission to low range and carefully use fast, aggressive throt-

Climbing over large objects from a stopped position

Belt slippage from water or snow ingestion into the PVT system

Clutch malfunction See your POLARIS dealer.

Poor engine performance Check for fouled plugs or foreign material in fuel tank or fuel lines. See

Slippage from failure to warm up belt

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.

Use low range during loading.

Use low range. See warnings on page 35.

Drive at a higher speed or use low range more frequently. See page 53.

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.

Use low range only.

tle application to engage clutch. WARNING: Excessive throttle may cause loss of control and vehicle over-

turn.

Shift the transmission to low range and carefully use fast, brief, aggressive throttle application to engage clutch.

WARNING: Excessive throttle may cause loss of control and vehicle overturn.

Dry out the PVT. See page 54. Inspect clutch seals for damage if repeated leaking occurs.

your dealer.

Always warm up the belt by operating below 30 MPH for one mile (5 miles or more when temperature is below freezing).

TROUBLESHOOTING

Engine Doesn't Turn Over

Possible Cause Solution

Low battery voltage 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 Solution

Out of fuel Refuel

Water is present in fuel Drain the fuel system 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 Immediately see your POLARIS dealer

Low battery voltage Recharge the battery to 12.8 VDC

Mechanical failure See your dealer

Engine Backfires

Possible Cause Solution

Weak spark from spark plug 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

Incorrectly installed spark plug wires See your dealer

Incorrect ignition timing See your dealer

Mechanical failure See your dealer

Loose ignition connections Check all connections and tighten

Water present in fuel Replace with fresh recommended fuel

TROUBLESHOOTING

Engine Pings or Knocks

Possible Cause Solution

Poor quality or low octane fuel Replace with recommended fuel

Incorrect ignition timing See your dealer

Incorrect spark plug gap or heat range Set gap to specs or replace plugs

Engine Runs Irregularly, Stalls or Misfires

Possible Cause Solution

Fouled or defective spark plugs Inspect, clean and/or replace spark plugs

Worn or defective spark plug wires See your dealer

Incorrect spark plug gap or heat range Set gap to specs or replace plugs

Loose ignition connections Check all connections and tighten

Water present in fuel Replace with new fuel

Low battery voltage Recharge battery 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 See your dealer

Possible Lean Fuel Cause Solution

Low or contaminated fuel Add or change fuel, clean the fuel system

Low octane fuel Replace with recommended fuel

Possible Rich Fuel Cause Solution

Fuel is very high octane 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 your dealer

Incorrect spark plug gap or heat range Set gap to specs or replace plug

Loose ignition connections Check all connections and tighten

Low battery voltage Recharge the battery to 12.8 VDC

Incorrect fuel Replace with fresh recommended fuel

Clogged air filter Inspect and clean or replace

Other mechanical failure See your dealer

Overheated engine Clean radiator screen and core, clean engine exterior,

see your dealer

WARRANTY

LIMITED WARRANTY

POLARIS Sales Inc., 2100 Highway 55, Medina, MN 55340, gives a SIX MONTH LIMITED WARRANTY on all components of the POLARIS RANGER against defects in material or workmanship. POLARIS also gives a one year limited warranty on the final drive chain for failure due to defects. This warranty covers the parts and labor charges for repair or replacement of defective parts which are covered by this warranty. This warranty 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. Purchasing 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, normal wear and tear, abuse or improper handling. This warranty also does not cover any vehicle that has been altered structurally, modified, neglected, improperly maintained, 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 contamination for which they were not designed or not intended, including but not limited to the following items:

• Wheels and tires • Finished and unfinished surfaces

• Suspension components • Carburetor/Throttle body components

• Brake components • Engine components

• Seat components • Drive belts

• Clutches and components • Hydraulic components

• Steering components • 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 following items are excluded from warranty coverage in the event of a warranty claim:

• Spark Plugs • Lubricants such as oil, grease, etc.

• Filters • Batteries (unless defective)

• Fuel • Cosmetic damage/repair

• Sealants • Coolants

• Hotel fees • Meals

• Towing charges • Shipping/ handling fees

• Mileage • Product pick-up/delivery

• Rentals/Loss of product use • Loss of vacation/personal time

WARRANTY

LIMITATIONS OF WARRANTIES AND REMEDIES

This warranty also excludes failures resulting from improper lubrication; improper engine timing; improper fuel; surface imperfections caused by 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 foreign substance ingestion/contamination; improper maintenance; modified components; use of aftermarket components 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 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 WARRANTY. POLARIS SHALL HAVE NO LIABILITY TO ANY PERSON FOR INCIDENTAL, CONSEQUENTIAL OR SPECIAL DAMAGES OF ANY DESCRIPTION, WHETHER ARISING OUT OF EXPRESS OR IMPLIED WARRANTY OR ANY OTHER CONTRACT, NEGLIGENCE, OR OTHER TORT OR OTHERWISE. THIS EXCLUSION OF CONSEQUENTIAL, INCIDENTAL, AND SPECIAL DAMAGES IS INDEPENDENT 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 a POLARIS Servicing Dealer. When requesting warranty service you must present your copy of the Warranty Registration 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 accordance with POLARIS recommendations.

WARRANTY

Exported Vehicles

EXCEPT WHERE SPECIFICALLY REQUIRED BY LAW, THERE IS NO WARRANTY OR SERVICE BULLETIN 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 POLARIS 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 outside 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 traveling 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 required 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 register 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 register 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 procedure 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 outside 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

WARRANTY

U.S.A. EPA Emissions Limited Warranty

This emissions limited warranty is in addition to the POLARIS standard limited warranty for your vehicle. POLARIS Industries Inc. warrants that at the time it is first purchased, this emissions-certified vehicle is designed, built and equipped so it conforms with applicable U.S. Environmental Protection Agency emission regulations. POLARIS warrants that the vehicle is free from defects in materials and workmanship that would cause it to fail to meet these regulations.

The warranty period for this emissions-certified vehicle starts on the date the vehicle is first purchased and continues for a period of 500 hours of engine operation, 5000 kilometers (3100 miles) of vehicle travel, or 30 calendar months from the date of purchase, whichever comes first.

This emissions limited warranty covers components whose failure increases the vehicle’s regulated emissions, and it covers components of systems whose only purpose is to control emissions. Repairing or replacing other components not covered by this warranty is the responsibility of the vehicle owner. This emissions limited warranty 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

• Fuel system • Exhaust gas recirculation systems

The following parts are also considered emission-related components for exhaust emissions:

• Aftertreatment devices • Sensors

• Crankcase ventilation valves • Electronic control units

The following parts are considered emission-related components for evaporative emissions:

• Fuel Tank • Vacuum Control Diaphragms*

• Fuel Cap • Control Cables*

• Fuel Line • Control Linkages*

• Fuel Line Fittings • Purge Valves

• Clamps* • Vapor Hoses

• Pressure Relief Valves* • Liquid/Vapor Separator

• Control Valves* • Carbon Canister

• Control Solenoids* • Canister Mounting Brackets

• Electronic Controls* • Carburetor Purge Port Connector

*As related to the evaporative emission control system.

WARRANTY

U.S.A. EPA Emissions Limited Warranty

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 LIMITED WARRANTY ARE THE ONLY REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF THIS WARRANTY. POLARIS SHALL HAVE NO LIABILITY TO ANY PERSON FOR INCIDENTAL, CONSEQUENTIAL OR SPECIAL DAMAGES OF ANY DESCRIPTION,WHETHER ARISING OUT OF EXPRESS OR IMPLIED WARRANTY OR ANY OTHER CONTRACT, NEGLIGENCE OR OTHER TORT OR OTHERWISE. THIS EXCLUSION OF CONSEQUENTIAL, INCIDENTAL, AND SPECIAL DAMAGES IS INDEPENDENT FROM AND SHALL SURVIVE ANY FINDING THAT THE EXCLUSIVE REMEDY FAILED OF ITS ESSENTIAL PURPOSE.

ALL 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 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 effectiveness 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 Warranty Department at 1-888-704-5290.

Use the following chart to record periodic maintenance.

MAINTENANCE LOG

DATE MILES (KM)

OR HOURS

TECHNICIAN SERVICE PERFORMED / COMMENTS

MAINTENANCE LOG

DATE MILES (KM)

OR HOURS

TECHNICIAN SERVICE PERFORMED / COMMENTS

INDEX

Accessory Outlets . . . . . . . . . . . . . . . . . . . . . . . . . 18

Adjustment

Shock Spring . . . . . . . . . . . . . . . . . . . . 60

Throttle Freeplay . . . . . . . . . . . . . . . . . 58

Air Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

All Wheel Drive . . . . . . . . . . . . . . . . . . . . . . . . . . 41

All Wheel Drive Switch . . . . . . . . . . . . . . . . . . . . 19

Auxiliary Outlets. . . . . . . . . . . . . . . . . . . . . . . . . . 18

Axle Nut Torque . . . . . . . . . . . . . . . . . . . . . . . . . . 61

Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65-68

Charging (Conventional) . . . . . . . . . . . 68

Charging (Sealed) . . . . . . . . . . . . . . . . 68

Fluid (Conventional) . . . . . . . . . . . . . . 65

Installation . . . . . . . . . . . . . . . . . . . . . . 67

Removal . . . . . . . . . . . . . . . . . . . . . . . . 66

Storage . . . . . . . . . . . . . . . . . . . . . . . . . 67

Warnings . . . . . . . . . . . . . . . . . . . . . . . 65

Belt Burning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

Belt Life . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Belt Replacement . . . . . . . . . . . . . . . . . . . . . . . . . 53

Belt Wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

Boots . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Brake Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

Brake Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . 59

Brake Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

Brake Pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

Braking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Break-In Period. . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Cab Frame, ROPS. . . . . . . . . . . . . . . . . . . . . . . . . 23

Cab Nets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Cargo. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Cargo Box, Dumping . . . . . . . . . . . . . . . . . . . . . . 39

Chart, Periodic Maintenance. . . . . . . . . . . . . . 43-45

Check Engine Indicator . . . . . . . . . . . . . . . . . . . . 28

Chrome Wheel Care . . . . . . . . . . . . . . . . . . . . . . . 70

Cleaning and Storage . . . . . . . . . . . . . . . . . . . 69-72

Cleaning the Exhaust System . . . . . . . . . . . . . . . . 57

Cleaning the Spark Arrestor . . . . . . . . . . . . . . . . . 57

Clothing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Clutching. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

Component Locations . . . . . . . . . . . . . . . . . . . . . . 17

Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Coolant Level, Overflow Bottle . . . . . . . . . . . . . . 52

Coolant Level, Radiator . . . . . . . . . . . . . . . . . . . . 52

Coolant, Adding or Changing. . . . . . . . . . . . . . . . 51

Cooling Fan. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

Cooling System. . . . . . . . . . . . . . . . . . . . . . . . 51-52

Corrosion Removal, Chrome . . . . . . . . . . . . . . . . 70

Crankcase Emission Control System . . . . . . . . . . 42

Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

Differential Lock Switch . . . . . . . . . . . . . . . . . . . 19

Differential Operation. . . . . . . . . . . . . . . . . . . . . . 40

Disengaging AWD . . . . . . . . . . . . . . . . . . . . . . . . 41

Display Units, Standard/Metric . . . . . . . . . . . . . . 26

Drive Belt Wear . . . . . . . . . . . . . . . . . . . . . . . . . . 77

Drivetrain Break-In. . . . . . . . . . . . . . . . . . . . . . . . 29

Driving Downhill . . . . . . . . . . . . . . . . . . . . . . . . . 35

Driving in Reverse . . . . . . . . . . . . . . . . . . . . . . . . 37

Driving on a Sidehill. . . . . . . . . . . . . . . . . . . . . . . 35

Driving on Slippery Surfaces . . . . . . . . . . . . . . . . 34

Driving Over Obstacles . . . . . . . . . . . . . . . . . . . . 33

Driving Procedure. . . . . . . . . . . . . . . . . . . . . . . . . 32

Driving Through Water . . . . . . . . . . . . . . . . . . . . 36

Driving Uphill. . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Driving with a Passenger . . . . . . . . . . . . . . . . . . . 33

Driving, After Driving in Water . . . . . . . . . . . . . . 54

Drying the Transmission. . . . . . . . . . . . . . . . . . . . 54

Dumping the Cargo Box. . . . . . . . . . . . . . . . . . . . 39

Emissions Limited Warranty . . . . . . . . . . . . . 83-84

Engaging AWD . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Engine Break-In . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Engine Fogging. . . . . . . . . . . . . . . . . . . . . . . . . . . 72

Engine Idle Speed. . . . . . . . . . . . . . . . . . . . . . . . . 58

Engine Oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . 46-47

Engine Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Engine Stopping . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Equipment Modifications . . . . . . . . . . . . . . . . . . . 12

Error Codes, Engine . . . . . . . . . . . . . . . . . . . . . . . 28

Exhaust Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . 57

Exhaust Emission Control System . . . . . . . . . . . . 42

Exhaust System Warning . . . . . . . . . . . . . . . . . . . 57

Eye Protection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Fastener Torque, Cylinder Head/Base . . . . . . . . . 55

Filter Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

Filter, Air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

Fluid, Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

Fluid Change

Engine Oil . . . . . . . . . . . . . . . . . . . . . . 47

Front Gearcase . . . . . . . . . . . . . . . . . . . 49

Main Gearcase . . . . . . . . . . . . . . . . . . . 48

Transmission . . . . . . . . . . . . . . . . . . . . 48

Fluid Level

Coolant (Overflow Bottle) . . . . . . . . . . 52

Coolant (Radiator) . . . . . . . . . . . . . . . . 52

Engine Oil . . . . . . . . . . . . . . . . . . . . . . 46

Front Gearcase . . . . . . . . . . . . . . . . . . . 49

Main Gearcase . . . . . . . . . . . . . . . . . . . 48

Transmission . . . . . . . . . . . . . . . . . . . . 48

Fluid Levels During Storage. . . . . . . . . . . . . . . . . 72

INDEX

Fluid Recommendation

Coolant . . . . . . . . . . . . . . . . . . . . . . . . 51

Engine Oil . . . . . . . . . . . . . . . . . . . . . . 46

Gearcases . . . . . . . . . . . . . . . . . . . . . . 48

Fluid, Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

Fogging the Engine . . . . . . . . . . . . . . . . . . . . . . . 72

Fouled Plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

Freeplay Adjustment, Throttle. . . . . . . . . . . . . . . 58

Front Gearcase . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

Fuel Cap. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Fuel Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Fuel Stabilizer . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

Fuel Tank Filler Cap . . . . . . . . . . . . . . . . . . . . . . 20

Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

Gap, Spark Plug . . . . . . . . . . . . . . . . . . . . . . . . . . 50

Gasoline Handling . . . . . . . . . . . . . . . . . . . . . . . . 14

Gear Selector . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Gearcase Specification Chart. . . . . . . . . . . . . . . . 48

Gearcase, Front . . . . . . . . . . . . . . . . . . . . . . . . . . 49

Gearcase, Main . . . . . . . . . . . . . . . . . . . . . . . . . . 48

Gearcases . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48-49

Gears, Shifting . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Gloves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Hauling Cargo . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Headlight Beam Adjustment . . . . . . . . . . . . . . . . 64

Headlight Lamp Replacement . . . . . . . . . . . . . . . 63

Helmet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Hitch Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Hitch Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Idle Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

Ignition Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Immersion of Vehicle . . . . . . . . . . . . . . . . . . . . . 55

Indicator Lamps . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Instrument Cluster . . . . . . . . . . . . . . . . . . . . . . 24-28

Key, Periodic Maintenance Chart . . . . . . . . . . . . 43

Light Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63-64

Brake Lights . . . . . . . . . . . . . . . . . . . . 64

Headlight Beam Adjustment. . . . . . . . 64

Headlight Lamp Replacement . . . . . . 63

Lubricants, Gearcase . . . . . . . . . . . . . . . . . . . . . . 48

Lubrication Recommendations . . . . . . . . . . . . . . 45

Main Gearcase . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

Maintenance Log . . . . . . . . . . . . . . . . . . . . . . . . . . 85

Maintenance, Periodic . . . . . . . . . . . . . . . . . . . 43-45

Metric Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Mode Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Modifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Noise Emission Control System . . . . . . . . . . . . . . 42

Obstacles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Oil, Engine. . . . . . . . . . . . . . . . . . . . . . . . . . . . 46-47

Oil Change

Engine . . . . . . . . . . . . . . . . . . . . . . . . . 47

Front Gearcase . . . . . . . . . . . . . . . . . . 49

Main Gearcase . . . . . . . . . . . . . . . . . . 48

Transmission. . . . . . . . . . . . . . . . . . . . 48

Oil Level

Engine . . . . . . . . . . . . . . . . . . . . . . . . . 46

Front Gearcase . . . . . . . . . . . . . . . . . . 49

Main Gearcase . . . . . . . . . . . . . . . . . . 48

Transmission. . . . . . . . . . . . . . . . . . . . 48

Oil Recommendation

Engine Oil. . . . . . . . . . . . . . . . . . . . . . 46

Gearcases . . . . . . . . . . . . . . . . . . . . . . 48

Operation on Public Lands . . . . . . . . . . . . . . . . . . 42

Operator Safety . . . . . . . . . . . . . . . . . . . . . . . . 10-16

Outlets, Auxiliary . . . . . . . . . . . . . . . . . . . . . . . . . 18

Parking on an Incline. . . . . . . . . . . . . . . . . . . . . . . 37

Parking the Vehicle . . . . . . . . . . . . . . . . . . . . . . . . 37

Periodic Maintenance Chart . . . . . . . . . . . . . . 43-45

Plug Gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

Plug Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

Plug, Accessory . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Plugs, Fouled . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

Polaris Products . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

Polishing the Vehicle. . . . . . . . . . . . . . . . . . . . . . . 70

Pre-Ride Inspection . . . . . . . . . . . . . . . . . . . . . . . . 30

PVT Break-In . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

PVT Drying . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

PVT System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

PVT System Operation . . . . . . . . . . . . . . . . . . . . . 53

PVT Warning. . . . . . . . . . . . . . . . . . . . . . . . . . 53-54

PVT, Cleaning Debris . . . . . . . . . . . . . . . . . . . . . . 53

INDEX

Radiator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

Radiator Coolant Level. . . . . . . . . . . . . . . . . . . . . 52

Removing the Vehicle from Storage . . . . . . . . . . 73

Reverse Operation. . . . . . . . . . . . . . . . . . . . . . . . . 37

Rider Information Center . . . . . . . . . . . . . . . . 25-28

Riding Gear. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Rollover Protective Structure . . . . . . . . . . . . . . . . 23

ROPS Cab Frame . . . . . . . . . . . . . . . . . . . . . . . . . 23

Safety Labels. . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8

Safety Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Safety Warnings . . . . . . . . . . . . . . . . . . . . . . . 13-16

Seat Belt Inspection . . . . . . . . . . . . . . . . . . . . . . . 21

Seat Belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Seat Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Severe Use Definition. . . . . . . . . . . . . . . . . . . . . . 43

Shifter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Shifting Gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Shock Spring Adjustment . . . . . . . . . . . . . . . . . . . 60

Signal Words. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Spark Arrester Warning . . . . . . . . . . . . . . . . . . . . 57

Spark Arrestor, Cleaning . . . . . . . . . . . . . . . . . . . 57

Spark Plug Gap . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

Spark Plug Inspection . . . . . . . . . . . . . . . . . . . . . . 50

Spark Plug Recommendations . . . . . . . . . . . . . . . 50

Spark Plug Torque . . . . . . . . . . . . . . . . . . . . . . . . 50

Spark Plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

Spark Plugs, Fouled . . . . . . . . . . . . . . . . . . . . . . . 50

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . 74-75

Specifications, Gearcase . . . . . . . . . . . . . . . . . . . . 48

Speed, Towing . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Speedometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Starting the Engine . . . . . . . . . . . . . . . . . . . . . . . . 31

Steering Wheel Inspection . . . . . . . . . . . . . . . . . . 60

Stopping the Engine . . . . . . . . . . . . . . . . . . . . . . . 31

Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69-72

Storage Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

Storage Tips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

Storage, Battery . . . . . . . . . . . . . . . . . . . . . . . . . . 67

Storage, Covers. . . . . . . . . . . . . . . . . . . . . . . . . . . 72

Storage, Removal from . . . . . . . . . . . . . . . . . . . . . 73

Switches

AWD Switch . . . . . . . . . . . . . . . . . . . . 19

Differential Lock Switch . . . . . . . . . . . 19

Ignition Switch. . . . . . . . . . . . . . . . . . . 19

Light Switch. . . . . . . . . . . . . . . . . . . . . 19

Tachometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Throttle Freeplay Adjustment. . . . . . . . . . . . . . . . 58

Throttle Freeplay Inspection. . . . . . . . . . . . . . . . . 58

Throttle Pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Throttle System. . . . . . . . . . . . . . . . . . . . . . . . . . . 58

Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61-62

Nut Torque . . . . . . . . . . . . . . . . . . . . . . 61

Tread Depth . . . . . . . . . . . . . . . . . . . . . 61

Wheel Installation . . . . . . . . . . . . . . . . 62

Wheel Removal . . . . . . . . . . . . . . . . . . 62

Torque, Spark Plug . . . . . . . . . . . . . . . . . . . . . . . . 50

Towing Loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Towing Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Trailer Hitch Bracket . . . . . . . . . . . . . . . . . . . . . . 20

Transmission. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

Transmission Operation . . . . . . . . . . . . . . . . . 53-54

Transmission System . . . . . . . . . . . . . . . . . . . . . . 54

Transmission Warning . . . . . . . . . . . . . . . . . . 53-54

Transmission, Drying . . . . . . . . . . . . . . . . . . . . . . 54

Transporting the Vehicle . . . . . . . . . . . . . . . . . . . 73

Vehicle Identification Numbers . . . . . . . . . . . . . . . 6

Vehicle Immersion . . . . . . . . . . . . . . . . . . . . . . . . 55

Vehicle Transport . . . . . . . . . . . . . . . . . . . . . . . . . 73

Warning Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Warning, Transmission Modification. . . . . . . 53-54

Washing the Vehicle . . . . . . . . . . . . . . . . . . . . . . . 69

Wheel Installation. . . . . . . . . . . . . . . . . . . . . . . . . 62

Wheel Nut Torque . . . . . . . . . . . . . . . . . . . . . . . . 61

Wheel Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 62

The text is printed on 100% recycled

with 40% post-consumer waste (PCW).

WARNING

Improper vehicle use can result in SEVERE INJURY or DEATH

NEVER Operate:

If you are under age 16 and without a valid driver’s license.

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 another vehicle. With more than ONE passenger, or with passengers 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, eye protection, gloves, long-sleeve shirt, long pants and over-the-anke boots.

Reduce speed and use extra caution when carrying passengers. Avoid sharp turns or turns while applying heavy throttle. Operate slowly in reverse - avoid sharp turns or sudden braking. Make sure passenger reads and understands all safety labels. Watch for branches or other hazards that could enter vehicle.

READ OWNER’S MANUAL.

FOLLOW ALL INSTRUCTIONS AND WARNINGS.

For your nearest Polaris dealer, call 1-800-POLARIS or visit www.polarisindustries.com Polaris Sales Inc. 2100 Hwy. 55 Medina, MN 55340 Phone 1-888-704-5290 Part No. 9923960 Rev 01 Printed in USA

Polaris Ranger 800 Midsize User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual