Polaris Ranger 800 HD Owner's Manual
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Polaris Ranger 800 HD Owner's Manual

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  • Page 2 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.
  • Page 3 The text is printed on 100% recycled with 40% post-consumer waste (PCW).
  • Page 5 WELCOME Thank you for purchasing a POLARIS vehicle, and welcome to our world-wide family of POLARIS owners. We proudly produce an excit- ing line of utility and recreational products. • Snowmobiles • All-terrain vehicles (ATVs) • RANGER utility vehicles ® •...
  • Page 6 POLARIS, THE WAY OUT, RANGER and RANGER CREW are registered trademarks of POLARIS Industries Inc. Copyright 2010 POLARIS Sales Inc. All information contained within this publication is based on the latest product information at the time of publication. Due to constant...

  • Page 7: Table Of Contents

    TABLE OF CONTENTS Introduction ......4 Safety ....... . . 7 Features and Controls .

  • Page 8: Introduction

    INTRODUCTION The RANGER is an off-road vehicle. Familiarize yourself with all laws and regulations concerning 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 sym- bols are used.
  • Page 9 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.

  • Page 10: Vehicle Identification Numbers

    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.

  • Page 11: Safety

    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.
  • Page 12 SAFETY Safety Labels and Locations Container/Passenger/Tire Pressure Warning (CREW) WARNING Remove flammable material containers from box before filling. WARNING Passengers can be thrown off. This can cause serious injury or death. Never carry passengers in cargo box. WARNING Multi-Passenger Maximum Box Load 1000 lbs. (455 kg) WARNING IMPROPER TIRE PRESSURE OR OVERLOADING can cause loss of control resulting in SEVERE INJURY OR DEATH.
  • Page 13 SAFETY Safety Labels and Locations Discretionary Shift Age 16 Warning Caution Warning Clutch Cover Warning Clutch Cover Warning WARNING NO STEP • 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.
  • Page 14 SAFETY Safety Labels and Locations Discretionary Warning (4X4/6X6) 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. •...
  • Page 15 SAFETY Safety Labels and Locations Discretionary Warning (CREW) 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. •...
  • Page 16 SAFETY Operator Safety WARNING 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 proce- dures described.
  • Page 17 SAFETY Operator Safety • Always inspect the vehicle before each use to make sure it's in safe operating condition. Always follow the inspection procedures described in this manual. • Always travel slowly and use extra caution when operating on unfa- miliar terrain.
  • Page 18 SAFETY Operator Safety • Never operate your vehicle in fast-flowing water or in water deeper than that specified in this manual. Wet brakes may have reduced stop- ping ability. Test your brakes after leaving water. If necessary, apply them lightly several times to let friction dry out the pads. •...

  • Page 19: Equipment Modifications

    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 pur- poses.

  • Page 20: Seat Belts

    SAFETY Operator Safety WARNING 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.
  • Page 21 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.
  • Page 22 SAFETY Operator Safety 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, your skills and your passenger’s skills. Operating on Pavement This vehicle's tires are designed for off-road use only, not for use on pavement.
  • Page 23 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 46. 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.

  • Page 24: Features And Controls

    FEATURES AND CONTROLS 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. Any illustrations without cab nets are only to allow component identification. Always use the cab nets.

  • Page 25: Component Locations

    FEATURES AND CONTROLS Component Locations 6X6 Storage Box Storage Compartment Tailgate Tailgate Latch Release Receiver Hitch CV Boot/Rear Caliper Muffler (Spark Arrestor)

  • Page 26: Auxiliary Outlets

    FEATURES AND CONTROLS Console Instrument Park Brake Gear Selector Cluster Lever Mode (Shifter) Button Cup Holder Storage 12V Auxiliary Storage Tray Outlets Compartment Auxiliary Outlets The 12-volt receptacles have spade connections on the back that may be used to power an auxiliary light or other optional accessories or lights.

  • Page 27: Gear Selector

    FEATURES AND CONTROLS Console Mode Button The MODE button is located on the instrument cluster. Use the MODE button to toggle through mode options available in the instrument clus- ter. See pages 33-39. Gear Selector H: High Gear L: Low Gear N: Neutral R: Reverse Low gear is the primary driving range for the RANGER.

  • Page 28: Ignition Switch

    FEATURES AND CONTROLS Switches Light AWD/Differential Switch Switch Ignition Switch Ignition Switch The ignition switch is a three-position, key-operated switch. The key can be removed from the switch when it is in the OFF position. The engine is off. Electrical circuits are off, except Acc, 12V. Electrical circuits are on.
  • Page 29 FEATURES AND CONTROLS Switches AWD/Differential Lock Switch The AWD/Differential Switch has three positions: • All Wheel Drive (AWD) • Differential Lock (2WD) Differential Lock • Differential Unlock Press the top of the rocker switch to Differential Unlock engage All Wheel Drive (AWD). See page 54 for operating instructions.

  • Page 30: Trailer Hitch Bracket

    FEATURES AND CONTROLS Trailer Hitch Bracket This vehicle is equipped with a receiver hitch bracket for a trailer hitch. To avoid injury and property damage, always heed the warnings and towing capacities outlined on pages 50-52. Brake Pedal Throttle Depress the brake pedal to slow or Brake Pedal stop the vehicle.
  • Page 31 FEATURES AND CONTROLS Park Brake Lever To help prevent the vehicle from roll- ing, engage the park brake when park- Trip 1 ing the vehicle. When the park brake is fully engaged, “BRAKE” appears in the rider information display. Engine speed is limited to 1300 RPM in all gears, except neutral.

  • Page 32: Fuel Cap

    FEATURES AND CONTROLS Seat Removal Pull up on the front of the seat and slide it toward the front of the vehi- cle. 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.
  • Page 33 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.
  • Page 34 FEATURES AND CONTROLS Seat Belts This POLARIS vehicle is equipped with three-point lap and diagonal seat belts on all external seats.The center seat is equipped with a lap-style seat belt. Always Latch Plate make sure the seat belts are secured for all riders before operating.

  • Page 35: Seat Belt Inspection

    FEATURES AND CONTROLS Seat Belts 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.

  • Page 36: Storage Compartments

    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 autho- rized 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.

  • Page 37: Indicator Lamps

    FEATURES AND CONTROLS Instrument Cluster Indicator Lamps High water pressure may Speedometer 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.

  • Page 38: Instrument Cluster

    FEATURES AND CONTROLS Instrument Cluster Rider Information Center The rider information center is located in the instrument cluster. All seg- ments 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 speedome- ter.
  • Page 39 FEATURES AND CONTROLS Instrument Cluster Rider Information Center 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.
  • Page 40 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 automati- cally exits and returns to the odometer display.
  • Page 41 FEATURES AND CONTROLS Instrument Cluster Rider Information Center Clock Mode Tip: The clock must be reset any time the battery has been disconnected or dis- charged. 1. Turn the key to the ON position. Use the MODE button to toggle to the odometer display.
  • Page 42 FEATURES AND CONTROLS Instrument Cluster Rider Information Center 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.
  • Page 43 FEATURES AND CONTROLS Instrument Cluster Rider Information Center Engine Error Codes Suspect Parameter The error screen displays Error Code Number (SPN) Number (0-9) only when the CHECK ENGINE light is on or when it goes on and off during one ignition cycle. Error codes are not stored.

  • Page 44: Break-In Period

    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 warnings outlined in the safety section of this manual. Break-In Period The break-in period for your new RANGER is the first twenty hours of operation, or the time it takes to use the first two tanks full of fuel.

  • Page 45: Pre-Ride Inspection

    OPERATION Pre-Ride Inspection Failure to inspect and verify that the vehicle is in safe operating condi- tion 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...

  • Page 46: Starting The Engine

    OPERATION Starting the Engine 1. Always start the engine outdoors or in a well-ventilated area. 2. Sit in the driver's seat and fasten the seat belt. Secure the cab nets. 3. Apply the brakes. Engage the park brake. 4. Shift the transmission to neutral. 5.

  • Page 47: Driving Procedure

    OPERATION Driving Procedure 1. Wear a helmet and eye protection. 2. Perform the pre-ride inspection. See page 41. 3. Sit in the driver's seat and fasten the seat belt. 4. Always use the cab nets while riding in this vehicle. 5.

  • Page 48: Driving With A Passenger

    OPERATION Driving with a Passenger 1. Perform the pre-ride inspection. See page 41. 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.

  • Page 49: Driving On Slippery Surfaces

    OPERATION Driving on Slippery Surfaces WARNING 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.

  • Page 50: Driving Over Obstacles

    OPERATION Driving Over Obstacles Follow these precautions when operating over obstacles: 1. Always check for obsta- cles before operating in a new area. 2. Look ahead and learn to read the terrain. Be con- stantly alert for hazards such as logs, rocks and low hanging branches.

  • Page 51: Driving Downhill

    OPERATION 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.

  • Page 52: Driving Through Water

    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. After immersion, always take the vehicle to your dealer service.

  • Page 53: Driving In Reverse

    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 down- hill. 3. Back slowly. 4.

  • Page 54: Hauling Cargo

    OPERATION Hauling Cargo WARNING 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.
  • Page 55 OPERATION Hauling Cargo 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.

  • Page 56: Towing Loads

    OPERATION Towing Loads Towing improperly can alter vehicle handling and may cause loss of control or brake instability. Always follow these precautions when tow- ing: 1. Never load more than 150 lbs. (68.1 kg) tongue weight on the tow- ing bracket. 2.

  • Page 57: Dumping The Cargo Box

    OPERATION 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 gear. 4. Engage the park brake. 5.

  • Page 58: Engaging Awd

    OPERATION All Wheel Drive (AWD) Engaging AWD Press the top of the switch to engage All Wheel Drive (AWD). The 4X4 indica- tor illuminates in the rider information center to indicate that the vehicle is in AWD. See page 35. Differential Lock When the AWD switch is on, the front wheels will automatically engage any...

  • Page 59: Locking The Differential

    OPERATION All Wheel Drive (AWD) Locking the Differential NOTICE: Damage to the differential can occur if it is engaged while the vehicle is traveling at high speeds or while the rear wheels are spinning. Slow the vehicle to nearly stopped before engaging the differential. Locking the differential in slippery or low traction conditions helps improve traction.

  • Page 60: Emission Control Systems

    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 arrestor that was tested and quali- fied to be in accordance with the USFS standard 5100-1c.

  • Page 61: Maintenance

    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.

  • Page 62: Periodic Maintenance Chart

    MAINTENANCE Periodic Maintenance Chart 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.) Have an authorized POLARIS dealer perform these services. WARNING! Improperly performing the procedures marked with a n could result in component failure and lead to serious injury or death.
  • Page 63 MAINTENANCE Periodic Maintenance Chart Perform all services at whichever maintenance interval is reached first. Item Maintenance Interval Remarks (whichever comes first) Hours Calendar Miles (Km) Brake pad wear 10 H Monthly Inspect periodically Battery 20 H Monthly Check terminals; clean; test Front Gearcase Oil 25 H Monthly...
  • Page 64 MAINTENANCE Periodic Maintenance Chart Item Maintenance Interval Remarks (whichever comes first) Hours Calendar Miles (Km) E Fuel system 100 H 12 M Check for leaks at tank cap, lines, fuel valve, filter, pump, throttle body; replace lines every two years Fuel filter 100 H 12 M...

  • Page 65: Lubrication Recommendations

    MAINTENANCE Lubrication Recommendations Check and lubricate all components at the intervals outlined in the Peri- odic Maintenance Chart beginning on page 57, 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.

  • Page 66: Engine Intake Restrictor Plate

    MAINTENANCE Engine Intake Restrictor Plate Some RANGER 800 models are equipped with an intake restrictor plate in order to meet vehicle class regulations. This plate MUST NOT be removed for any reason. Removal of the intake restrictor plate will void the warranty on the vehicle.
  • Page 67 MAINTENANCE Engine Oil Always check and change the oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 57. Always use the recommended engine oil. Oil Check The oil dipstick and fill tube is located on the engine. 1.
  • Page 68 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 57. Always change the oil filter whenever changing oil. 1. Position the vehicle on a level surface. 2.
  • Page 69 MAINTENANCE Engine Oil Oil and Filter Change 13. Remove the dipstick and fill the sump with two quarts (1.9 l) of rec- ommended oil. 14. Shift the transmission to neutral. 15. Apply the brakes. Engage the park brake. 16. Start the engine. Allow it to idle for one to two minutes. 17.

  • Page 70: Gearcase Specification Chart

    MAINTENANCE Gearcases Gearcase Specification Chart RANGER 4X4 Gearcase Specifications Gearcase Lubricant Capacity Fill Plug Drain Plug Torque Torque Main Gearcase AGL PLUS 34 oz. 12 ft. lbs. 12 ft. lbs. (Transmission) Transmission Fluid (1000 ml) (16.3 Nm) (16.3 Nm) Front Gearcase Demand Drive 9.3 oz.
  • Page 71 MAINTENANCE Gearcases Transmission (Main Gearcase) (4X4/CREW) Always check and change the transmission oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 57. Maintain the oil level even with the bottom of the fill plug hole threads. Refer to the Gearcase Specifications Chart on page 66 for recommended lubricants, capacities and torque specifications.

  • Page 72: Transmission: Oil Check/Change

    MAINTENANCE Gearcases Transmission (Main Gearcase) (6X6) Always check and change the transmission oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 57. Maintain the oil level even with the bottom of the fill plug hole. Refer to the Gearcase Specifications Chart on page 66 for recommended lubricants, capacities and torque specifications.

  • Page 73: Front Gearcase

    MAINTENANCE Gearcases Front Gearcase Always check and change the front gearcase oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 57. Maintain the oil level even with the bottom thread of the fill plug hole. Refer to the Gearcase Specifications Chart on page 66 for recommended lubricants, capacities and torque specifications.

  • Page 74: Gearcases: Oil Check/Change

    MAINTENANCE Gearcases Middle Gearcase (6X6) Always check and change the middle gearcase oil at the intervals out- lined in the Periodic Maintenance Chart beginning on page 57. Maintain the oil level even with the bottom thread of the fill plug hole. Refer to the Gearcase Specifications Chart on page 66 for recommended lubricants, capacities and torque specifications.

  • Page 75: Rear Gearcase (6X)

    MAINTENANCE Gearcases Rear Gearcase (6X6) Always check and change the rear gearcase oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 57. Refer to the Gearcase Specifications Chart on page 66 for recommended lubricants, capacities and torque specifications. See page 110 for the part numbers of POLARIS products.

  • Page 76: Spark Plugs

    MAINTENANCE Spark Plugs Spark Plug Recommendations Refer to the specifications section beginning on page 104 for the recom- mended spark plug type for your vehicle. Always torque spark plugs to specification. NOTICE: Using non-recommended spark plugs can result in serious engine damage.

  • Page 77: Cooling System

    MAINTENANCE Cooling System The engine coolant level is controlled or maintained by the recovery system. The recovery system components are the overflow bottle, radia- tor 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.
  • Page 78 MAINTENANCE Cooling System Radiator and Cooling Fan Always check and clean the screen and radiator fins at the intervals out- lined in the Periodic Maintenance Chart beginning on page 57. Do not obstruct or deflect air flow through the radiator by installing unautho- rized accessories in front of the radiator or behind the cooling fan.

  • Page 79: Radiator Coolant Level

    MAINTENANCE Cooling System 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.
  • Page 80 MAINTENANCE POLARIS Variable Transmission (PVT) System WARNING 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.

  • Page 81: Pvt System

    MAINTENANCE PVT System PVT Drying There may be some instances when water is accidently ingested into the PVT system. Use the following instructions to dry it out before operat- ing. 1. Position the vehicle on a level surface. 2. Remove the drain plug. Allow the water to drain completely. Rein- stall the drain plug.

  • Page 82: Vehicle Immersion

    MAINTENANCE Vehicle Immersion NOTICE: If your vehicle becomes immersed, major engine damage can result if the machine is not thoroughly inspected. Take the vehicle to your dealer before starting the engine. If it's impossible to take your RANGER to a dealer before starting it, fol- low the steps outlined below.

  • Page 83: Filter Systems

    MAINTENANCE Filter Systems Air Filter Always change the air filter at the intervals outlined in the Periodic Maintenance Chart beginning on page 57. Service the air filter more fre- quently if the vehicle is operated in wet conditions or at high throttle openings for extended periods.

  • Page 84: Spark Arrestor

    MAINTENANCE Spark Arrestor WARNING Failure to heed the following warnings while servicing the spark arrestor could result in serious injury or death. Do not perform service on the spark arrestor while the system is hot. Exhaust system temperatures can reach 1000° F. Allow components to cool sufficiently before proceeding.

  • Page 85: Spark Arrestor

    MAINTENANCE Spark Arrestor Use the following procedure to periodically purge accumulated carbon from the exhaust pipe. 1. Remove the arrestor clean-out plugs located on the bottom of the muffler. 2. Place the transmission in neutral. 3. Engage the park brake. 4.

  • Page 86: Throttle Freeplay

    MAINTENANCE Throttle System WARNING 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.

  • Page 87: Throttle Freeplay Adjustment

    MAINTENANCE Throttle System 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.

  • Page 88: Brake Fluid

    MAINTENANCE Brakes The front and rear brakes are hydraulic disc type brakes activated by the brake pedal. See page 26. 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.

  • Page 89: Brake Inspection

    MAINTENANCE Brakes 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. Inspect the brake disc spline and pad wear surface for excessive wear.

  • Page 90: Steering Wheel Inspection

    MAINTENANCE Brakes Park Brake Adjustment Inspect and adjust park brake cable tension after the first 25 hours of operation and every 100 hours thereafter to ensure proper cable tension. Loss of tension in the park brake cable may cause “BRAKE” to display in the rider information center, along with activation of the limiting fea- ture.
  • Page 91 MAINTENANCE Suspension Adjustments The front and rear suspensions can be adjusted to provide a stiffer sus- pension, if necessary. 1. Remove the top shock mounting bolts from the inside mounting holes. 2. Reposition the shocks to the outside mounting holes. 3.

  • Page 92: Tire Tread Depth

    MAINTENANCE Tires WARNING 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.

  • Page 93: Wheel Removal

    MAINTENANCE Tires Wheel Removal 1. Apply the brakes. Engage the park brake. 2. Stop the engine. Place the transmission in gear. 3. Loosen the wheel nuts slightly. 4. Elevate the side of the vehicle by placing a suitable stand under the frame.

  • Page 94: Headlight Lamp Replacement

    MAINTENANCE 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.

  • Page 95: Headlight Beam Adjustment

    MAINTENANCE Lights Headlight Beam Adjustment 8" (20 cm) 25 ft. (7.6 m) 1. Place the vehicle on a level surface with the headlight approxi- mately 25 ft. (7.6 m) from a wall. 2. Place the transmission in gear. Engage the park brake. 3.
  • Page 96 MAINTENANCE Fuses If the engine stops or will not start, or if you experi- ence other electrical fail- ures, 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.
  • Page 97 MAINTENANCE Battery WARNING Battery electrolyte is poisonous. It contains sulfuric acid. Serious burns can result from contact with skin, eyes or clothing. Antidote: External: Flush with water. Internal: Drink large quantities of water or milk. Follow with milk of magnesia, beaten egg, or vegetable oil.

  • Page 98: Battery Removal

    MAINTENANCE Battery Battery Removal WARNING 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.

  • Page 99: Battery Installation

    MAINTENANCE Battery Battery Installation Using a new battery that has not been fully charged can damage the bat- tery and result in a shorter life. It can also hinder vehicle performance. Follow the battery charging instructions on page 96 before installing the battery.

  • Page 100: Battery Storage

    MAINTENANCE Battery 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.
  • Page 101 MAINTENANCE Battery Battery Charging (Sealed 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.

  • Page 102: Cleaning And Storage

    MAINTENANCE Cleaning and Storage Washing the Vehicle Keeping your POLARIS vehicle clean will not only improve its appear- ance but it can also extend the life of various components. NOTICE: High water pressure may damage components. POLARIS recommends washing the vehicle by hand or with a garden hose, using mild soap.

  • Page 103: Polishing The Vehicle

    MAINTENANCE Cleaning and Storage Washing the Vehicle 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 follow- ing items: •...
  • Page 104 MAINTENANCE Cleaning and Storage Chrome Wheel Care (if equipped) Proper maintenance will protect chrome wheels from corrosion, pre- serve 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.
  • Page 105 MAINTENANCE Cleaning and Storage Storage Tips NOTICE: Starting the engine during the storage period will disturb the protective film created by fogging and damage could occur. Never start the engine during the storage period. Clean the Exterior Make any necessary repairs and clean the vehicle as recommended. See page 98.
  • Page 106 MAINTENANCE Cleaning and Storage Storage Tips Fluid Levels Inspect the fluid levels. Add or change fluids as recommended in the Periodic Maintenance Chart beginning on page 57. • Front gearcase fluid • Rear and Middle gearcase fluids (6X6) • Transmission fluid •...

  • Page 107: Removal From Storage

    MAINTENANCE Removal from Storage 1. Check the battery electrolyte level and charge the battery if neces- sary. 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.

  • Page 108: Specifications

    SPECIFICATIONS RANGER 4X4 Maximum Weight Capacity* 1500 lbs. (681 kg) (includes weight of operator, passenger, cargo, accessories) Dry Weight 1237 lbs. (561 kg) Fuel Capacity 8.8 gal. (33.3 l) Engine Oil Capacity 1.9 qts. (1.8 l) Coolant Capacity 3.25 qts. (3 l) Towing Capacity 2000 lbs.
  • Page 109 SPECIFICATIONS RANGER 4X4 Lubrication System Pressurized Wet Sump Engine Oil POLARIS 2W-50 Driving System Type PVT, 4-wheel independent shaft, lockable differ- ential Shift Type Single Lever (H/L/N/R) Gear Reduction - Low 7.70:1 Gear Reduction - Reverse 7.00:1 Gear Reduction - High 3.6:1 Drive Ratio - Front: 3.818:1...
  • Page 110 SPECIFICATIONS RANGER 6X6 Maximum Weight Capacity 2000 lbs. (907 kg) (includes weight of operator, passenger, cargo, accessories) Dry Weight 1551 lbs. (703.5 kg) Fuel Capacity 8.8 gal. (33.3 l) Engine Oil Capacity 2 qts. (1.9 l) Coolant Capacity 3.25 qts. (3 l) Towing Capacity 2000 lbs.
  • Page 111 SPECIFICATIONS RANGER 6X6 Lubrication System Pressurized Wet Sump Engine Oil POLARIS 2W-50 Driving System Type Shift Type Single Lever, Console (H/L/N/R) Gear Reduction - Low 8.71:1 Gear Reduction - Reverse 7.91:1 Gear Reduction - High 3.85:1 Drive Ratio - Front: 3.818:1 Drive Ratio - Final 3.70:1...
  • Page 112 SPECIFICATIONS RANGER CREW Maximum Weight Capacity 1750 lbs. (795 kg) (includes weight of operator, passengers, cargo, accessories) Dry Weight 1495 lbs. (678 kg) Fuel Capacity 8.8 gal. (33.3 l) Engine Oil Capacity 2 qts. (1.9 l) Coolant Capacity 1.6 gal. (6 l) Towing Capacity 2000 lbs.
  • Page 113 SPECIFICATIONS RANGER CREW Lubrication System Pressurized Wet Sump Engine Oil POLARIS 2W-50 Driving System Type PVT, 4-wheel independent shaft, lockable differ- ential Shift Type Single Lever (H/L/N/R) Gear Reduction - Low 7.70:1 Gear Reduction - Reverse 7.0:1 Gear Reduction - High 4.63:1 Drive Ratio - Front: 3.818:1...

  • Page 114: Polaris Products

    POLARIS PRODUCTS Part Description Number 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...

  • Page 115: Troubleshooting

    TROUBLESHOOTING Drive Belt Wear/Burn Possible Cause Solution Driving onto a pickup or Use low range during loading. tall trailer in high range Starting out going up a Use low range. See warnings on page 46. steep incline Driving at low RPM or Drive at a higher speed or use low range more frequently.
  • Page 116 TROUBLESHOOTING Park Brake Engine Limiting Feature Fails to Disengage Possible Cause Solution Park brake is not completely disengaged Ensure lever is in forward-most position Park brake connector malfunction or Disconnect the connector if temporary switch movement or failure continued operation is necessary, see your dealer promptly for service Engine Doesn't Turn Over Possible Cause...
  • Page 117 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...
  • Page 118 TROUBLESHOOTING 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...

  • Page 119: Declaration Of Conformity

    DECLARATION OF CONFORMITY Polaris Industries Inc., 2100 Hwy 55, Medina, MN 55340 U.S.A. Telephone 763-542-0500 April 22, 2010 We, Polaris Industries Inc., declare that the vehicles listed below conform to the essential health and safety requirements applicable to off-road all-terrain vehicles. APPLICABLE EUROPEAN DIRECTIVES TEST / EVALUATION METHODS 2006/42/EC as amended (Machinery Directive)

  • Page 120: Warranty

    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 (if equipped) for failure due to defects.
  • Page 121 WARRANTY LIMITATIONS OF WARRANTIES AND REMEDIES 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: •...
  • Page 122 WARRANTY LIMITATIONS OF WARRANTIES AND REMEDIES ALL IMPLIED WARRANTIES (INCLUDING BUT NOT LIMITED TO THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PAR- TICULAR PURPOSE) ARE LIMITED IN DURATION TO THE ABOVE SIX MONTH WARRANTY PERIOD. POLARIS FURTHER DISCLAIMS ALL EXPRESS WARRANTIES NOT STATED IN THIS WARRANTY.
  • Page 123 WARRANTY Exported Vehicles EXCEPT WHERE SPECIFICALLY REQUIRED BY LAW, THERE IS NO WAR- RANTY OR SERVICE BULLETIN COVERAGE ON THIS VEHICLE IF IT IS SOLD OUTSIDE THE COUNTRY OF THE SELLING DEALER'S AUTHORIZED LOCA- TION. This policy does not apply to vehicles that have received authorization for export from POLARIS Industries.
  • Page 124 WARRANTY How to Get Service 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.
  • Page 125 WARRANTY U.S.A. EPA Emissions Limited Warranty This emissions limited warranty is in addition to the POLARIS standard limited war- ranty for your vehicle. POLARIS Industries Inc. warrants that at the time it is first pur- chased, this emissions-certified vehicle is designed, built and equipped so it conforms with applicable U.S.
  • Page 126 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 WAR- RANTY.

  • Page 127: Maintenance Log

    MAINTENANCE LOG Use the following chart to record periodic maintenance. DATE MILES (KM) TECHNICIAN SERVICE PERFORMED / COMMENTS OR HOURS...
  • Page 128 MAINTENANCE LOG DATE MILES (KM) TECHNICIAN SERVICE PERFORMED / COMMENTS OR HOURS...

  • Page 129: Index

    INDEX Accessory Outlets ....22 Charts Air Filter ..... . 79 Gearcase Specifications .
  • Page 130 INDEX Emission Control, Noise ..56 Fluid Levels During Storage ..102 Emissions Limited Warranty . . 121-122 Fluid Part Numbers ... . . 110 Engaging AWD .
  • Page 131 INDEX Lamp Replacement, Headlight ..90 Park Brake ....27 Light Switch ....24 Park Brake Adjustment.
  • Page 132 INDEX Shifting Gears ....23 Tachometer ....37 Shock Spring Adjustment .

This manual is also suitable for:

Ranger 800 xpRanger 800 6x6Ranger 800 crew

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