Polaris Ranger 800 Midsize User Manual
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.
1
POLARIS and RANGER are registered trademarks of POLARIS Industries Inc.
Copyright 2012 POLARIS Sales Inc. All information contained within this publication is based on the latest
product information at the time of publication. Due to constant improvements in the 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
2
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
3
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.
4
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.
5
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
6
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
7
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.
X
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
8
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.
4
E
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.
9
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.
10
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.
11
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.
12
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).
13
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.
14
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.
15
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.
16
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
17
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
18
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.
19
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.
20
FEATURES AND CONTROLS
Seat Belts
This POLARIS vehicle is equipped with three-point lap and
diagonal seat belts on all external seats. Always make sure the
seat belts are secured for all riders before operating.
WARNING! Falling from a moving vehicle could result in serious
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
21
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
22
Rod Mount
Net Rod
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.
23
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.
24
FEATURES AND CONTROLS
1
2
65
4
7
3
8
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
88
km
:
88
FE
RPM
mi
25
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.
26
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