Polaris RANGER 800 Owner's Manual
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Polaris RANGER 800 Owner's Manual

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RANGER® 800
RANGER® 6X6 800
RANGER CREW® 800
Owner's Manual
for Maintenance and Safety

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Summary of Contents for Polaris RANGER 800

  • Page 1 RANGER® 800 RANGER® 6X6 800 RANGER CREW® 800 Owner's Manual for Maintenance and Safety...
  • 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 4 • 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 can cause severe injury or death.
  • Page 5 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.
  • Page 6 POLARIS, THE WAY OUT, RANGER and RANGER CREW 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 produc- tion components, some minor discrepancies may result between the actual vehicle and the information presented in this publication.

  • Page 7: Table Of Contents

    Specifications ........78 POLARIS Products........84 Troubleshooting .

  • Page 8: Introduction

    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 9: Vehicle Identification Numbers

    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.

  • Page 10: Safety

    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.

  • Page 11: Discretionary Warning

    • 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.
  • Page 12 SAFETY Safety Labels and Locations Load/Passenger/Tire Pressure Warning 6x6 Storage Box Load 250 lbs. (113 kg) WARNING • Passengers can be thrown off. This can cause serious injury or death. • Never carry passengers in cargo box. IMPROPER TIRE PRESSURE OR OVERLOADING CAN CAUSE LOSS OF CONTROL RESULTING IN SERIOUS INJURY OR DEATH.

  • Page 13: Safe Riding Gear

    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.

  • Page 14: Operator Safety

    • Always follow proper procedures for turning. Practice turning at slow speeds before attempting to turn at faster speeds. Never turn at excessive speeds. • Always have this vehicle checked by an authorized POLARIS dealer if it has been involved in an accident.
  • Page 15 Gasoline is extremely flammable. See page 12 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.

  • Page 16: Equipment Modifications

    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.

  • Page 17: Age Restrictions

    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. Age Restrictions This vehicle is an ADULT VEHICLE ONLY.

  • Page 18: Exposure To Exhaust

    SAFETY Operator Safety 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.

  • Page 19: Turning Improperly

    SAFETY Operator Safety 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. Operating in Unfamiliar Terrain Failure to use extra caution when operating on unfamiliar terrain could result in an accident or overturn.

  • Page 20: 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.

  • Page 21: Auxiliary Outlets

    FEATURES AND CONTROLS Console Instrument Park Brake Gear Selector Cluster Lever (Shifter) Storage Cup Holder 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 22: Light Switch

    FEATURES AND CONTROLS Switches AWD/Differential Switch Ignition Switch Ignition Switch Light Switch The ignition switch is a three-position, key-operated Mode Button 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.

  • Page 23: 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 37-38. Brake Pedal Throttle Brake Pedal Depress the brake pedal to slow or stop the vehicle.

  • Page 24: Park Brake Lever

    FEATURES AND CONTROLS Park Brake Lever To help prevent the vehicle from rolling, engage the park brake when parking the vehicle. When the park Trip 1 brake is fully engaged, “BRAKE” appears in the rider information display. Engine speed is limited to 1300 RPM in all gears, except neutral.
  • Page 25 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 Latch 1.

  • Page 26: Seat Removal

    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 make sure the seat belts are secured for all riders before operating.

  • Page 27: Storage Compartments

    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.

  • Page 28: Instrument Cluster

    This indicator illuminates briefly when the key is turned to the ON position. If the light remains on, the EPS system is inoperative. See your authorized POLARIS dealer for service. Neutral This lamp illuminates when the transmission is in neutral and the ignition key is in the ON position.
  • Page 29 If this occurs, take the vehicle to your POLARIS dealer for proper diagnosis. The information center is set to dis- play standard units of measurement and a 12-hour clock at the factory.

  • Page 30: Rider Information Center

    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.
  • Page 31 Diagnostic Display Mode The EFI diagnostic display mode is for informational purposes only. Please see your POLARIS dealer for all major repairs. The diagnostic mode is accessible only when the check engine warning indicator activates after the key has been turned on. Leave the key on if you want to view the active code (fail- ure code).
  • Page 32 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.

  • Page 33: Operation

    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 34 Ensure operation Air filter, pre-filter Inspect, clean Air box sediment tube Drain deposits whenever visible Headlamp Check operation, apply POLARIS dielectric grease when lamp is replaced Brake light/tail lamp Check operation, apply POLARIS dielectric grease when lamp is replaced Seat Belts...

  • Page 35: 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 36: Driving With A Passenger

    OPERATION Driving Procedure 1. Wear a helmet, eye protection, gloves, long-sleeve shirt, long pants and over-the-ankle boots. 2. Perform the pre-ride inspection. See page 30. 3. Sit in the driver's seat and fasten the seat belt. 4. Always use the cab nets while rid- ing in this vehicle.

  • Page 37: Driving Over Obstacles

    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. 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.

  • Page 38: Driving Uphill

    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.

  • Page 39: 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. 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 60, and take the vehicle to your dealer at the first opportunity.

  • Page 40: 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 downhill. 3. Back slowly. 4. Apply the brakes lightly for stopping. 5.

  • Page 41: 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 42: Towing Loads

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

  • Page 43: 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. Place the transmission in gear. Engage the park brake. 3.

  • Page 44: Engaging Awd

    OPERATION All Wheel Drive (AWD) Engaging AWD Press the top of the switch to engage All Wheel Drive (AWD). The 4X4 indicator illuminates in the rider information center to indicate that the vehicle is in AWD. See page 25. Differential Lock When the AWD switch is on, the front wheels will automatically engage any time the rear wheels lose traction.

  • Page 45: 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.

  • Page 46: Emission Control Systems

    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.

  • Page 47: Maintenance

    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.

  • Page 48: Periodic Maintenance Chart

    Inspect, lubricate, adjust D Steering 50 H Lubricate Front Suspension 50 H Lubricate Rear Suspension 50 H Lubricate Perform these procedures more often for vehicles subjected to severe use. E Emission-Related Service D Have an authorized POLARIS dealer perform these services.
  • Page 49 D Auxiliary brake (if equipped) Inspect daily; adjust as needed Headlight aim Adjust as needed Perform these procedures more often for vehicles subjected to severe use. E Emission-Related Service D Have an authorized POLARIS dealer perform these services.

  • Page 50: Lubrication Recommendations

    See page 53. Rear Gearcase Oil (6X6) Premium ATV Angle Drive Fluid See page 54. Prop Shaft U-joints (6X6) POLARIS Premium U-Joint Lube Locate fittings and grease. Front Prop Shaft Yoke POLARIS Premium U-Joint Lube Locate fittings and grease (3 pumps maximum).

  • Page 51: Engine Oil

    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 52: Oil And Filter Change

    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.

  • Page 53: Gearcase Specification Chart

    MAINTENANCE Gearcases Gearcase Specification Chart RANGER 4X4 Gearcase Specifications Gearcase Lubricant Capacity Fill Plug(s) 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 Plus 9.3 oz.
  • Page 54 Chart beginning on page 43. Refer to the Gearcase Specifications Chart on page 49 for recommended lubricants, capacities and torque specifications. See page 84 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.
  • Page 55 Refer to the Gearcase Specifications Chart on page 49 for recommended lubricants, capaci- ties and torque specifications. See page 84 for the part numbers of POLARIS products. Oil Check The fill plug is located at the rear of the vehicle.
  • Page 56 Refer to the Gearcase Specifications Chart on page 49 for recommended lubricants, capaci- ties and torque specifications. See page 84 for the part numbers of POLARIS products. Oil Check The front gearcase fill plug is located on the right side of the front gearcase.
  • Page 57 Refer to the Gearcase Specifications Chart on page 49 for recommended lubricants, capaci- ties and torque specifications. See page 84 for the part numbers of POLARIS products. The middle gearcase fill plug is located on the side of the gearcase.
  • Page 58 Refer to the Gearcase Specifications Chart on page 49 for recommended lubricants, capaci- ties and torque specifications. See page 84 for the part numbers of POLARIS products. The rear gearcase fill plug is on the driver's side of the rear gearcase.

  • Page 59: Spark Plugs

    Refer to the specifications section beginning on page 78 for the recommended spark plug type for your vehicle. Always torque spark plugs to specification. NOTICE: Using non-recommended spark plugs can result in serious engine damage. Always use POLARIS-recommended spark plugs. Spark Plug Gap/Torque Model...

  • Page 60: Cooling System

    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 84 for the part numbers of POLARIS products.

  • Page 61: Radiator Coolant Level

    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.
  • Page 62 • 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.

  • Page 63: Pvt Drying

    MAINTENANCE POLARIS Variable Transmission (PVT) System Belt Replacement/Debris Removal If a belt fails, always clean any debris from the duct and from the clutch and engine compartments when replacing the belt. WARNING! Failure to remove ALL debris when replacing the belt could result in vehicle damage and severe injury or death.

  • Page 64: 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, follow the steps outlined below.

  • Page 65: Spark Arrester

    MAINTENANCE Spark Arrester WARNING 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. •...

  • Page 66: Throttle System

    Freeplay should be 1/16 to 1/8 inches (1.6-3.2 mm). Throttle Body/Idle RPM Idle RPM is preset by the manufacturer. If the engine idle speed is not satisfactory, please see your POLARIS dealer for adjustment. Throttle Freeplay Adjustment 1. Remove the seat.

  • Page 67: Brake Fluid

    MAINTENANCE Brakes The front and rear brakes are hydraulic disc type brakes activated by the brake pedal. See page 19. 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.

  • Page 68: Steering Wheel Inspection

    3. 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. Suspension Adjustments The front and rear suspensions can be adjusted to provide a stiffer suspension, if necessary.

  • Page 69: 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.

  • Page 70: Wheel Removal

    Do not service axle nuts that have a cotter pin installed. See your POLARIS dealer. 5. Attach the wheel nuts and washers and finger tighten. 6. Carefully lower the vehicle to the ground.

  • Page 71: 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 72: 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 approximately 25 ft. (7.6 m) from a wall. 2. Place the transmission in gear. Engage the park brake. 3.
  • Page 73 Spare fuses are provided in the fuse box. The power steering fuse (if equipped) is located on the power steering wiring harness near the fuse box. If you suspect that a fuse or relay may not be working properly, please see your POLARIS dealer.
  • Page 74 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 75: 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 76: Battery Installation

    Check battery voltage each month during storage and recharge as needed to maintain a full charge. See page 73. 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 bat- tery if the voltage drops below a pre-determined point.
  • Page 77 MAINTENANCE Battery Battery Charging (Conventional Battery) 1. Remove the battery from the vehicle to prevent damage from leaking or spilled electro- lyte during charging. See page 71. 2. Charge the battery with a charging output no larger than 1/10 of the battery’s amp/hr rat- ing.

  • Page 78: Cleaning And Storage

    NOTICE: Certain products, including insect repellents and chemicals, will damage plastic surfaces. Do not allow these types of products to contact the vehicle. The best and safest way to clean your POLARIS vehicle is with a garden hose and a pail of mild soap and water.

  • Page 79: Storage Tips

    Stabilize the Fuel 1. Fill the fuel tank. 2. Add POLARIS Carbon Clean Fuel Treatment or POLARIS Fuel Stabilizer. Follow the instructions on the container for the recommended amount. Carbon Clean removes water from fuel systems, stabilizes fuel and removes carbon deposits from pistons, rings, valves and exhaust systems.
  • Page 80 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.

  • Page 81: Removal From Storage

    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 Transporting the RANGER Follow these procedures when transporting the vehicle.

  • Page 82: Specifications

    Bosch EFI ECU Controlled Spark Plug / Gap RC7YC3 /.035 in. (0.9 mm) Front Suspension Dual A-arm w/9.6 in. (24.4 cm) of travel Rear Suspension Independent w/9 in. (23 cm) of travel Lubrication System Pressurized Wet Sump Engine Oil POLARIS 2W-50...
  • Page 83 10 psi (69 KPa) Brakes, Front/Rear Foot Activated, 4 wheel hydraulic disc Brake, Park Hand activated, mechanical Hood Headlight 2 single beam, 50W, quartz/halogen Taillights 10 L.E.D. (.28W) Brake Light 10 L.E.D. (3.1W) Clutching See your POLARIS dealer for clutching specifications.
  • Page 84 RC7YC3 /.035 in. (0.9 mm) Front Suspension Dual a-arm w/9.6 in. (24.4 cm) of travel Center Suspension Independent w/9 in. (23 cm) of travel Rear Suspension Independent w/9 in. (23 cm) of travel Lubrication System Pressurized Wet Sump Engine Oil POLARIS 2W-50...
  • Page 85 10 psi (69 kPa) Brakes, Front/Rear Foot Activated, 4 wheel hydraulic disc Brake, Park Hand activated, mechanical Hood Headlight 2 single beam, 50W, quartz/halogen Taillights 10 L.E.D. (.28W) Brake Light 10 L.E.D. (3.1W) Clutching See your POLARIS dealer for clutching specifications.
  • Page 86 Bosch EFI ECU Controlled Spark Plug / Gap RC7YC3 /.035 in. (0.9 mm) Front Suspension Dual a-arm w/9.6 in. (24.4 cm) of travel Rear Suspension Independent w/9 in. (23 cm) of travel Lubrication System Pressurized Wet Sump Engine Oil POLARIS 2W-50...
  • Page 87 16 psi (110 KPa) Brakes, Front/Rear Foot Activated, 4 wheel hydraulic disc Brake, Park Hand activated, mechanical Hood Headlight 2 single beam, 50W, quartz/halogen Taillights 10 L.E.D. (.28W) Brake Light 10 L.E.D. (3.1W) Clutching See your POLARIS dealer for clutching specifications.

  • Page 88: Polaris Products

    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.) Additives / Miscellaneous 2871326 Carbon Clean Plus 2872189 DOT 4 Brake Fluid 2871956 Loctite 565 Thread Sealant 2871076 POLARIS Battery Tender Charger...

  • Page 89: Troubleshooting

    Dry out the PVT. See page 59. Inspect clutch seals for damage if repeated ingestion into the PVT system leaking occurs. Clutch malfunction See your POLARIS dealer. Poor engine performance Check for fouled plugs or foreign material in gas tank or fuel lines. See your dealer.
  • Page 90 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...
  • Page 91 TROUBLESHOOTING 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...

  • Page 92: Warranty

    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 war-...
  • Page 93 California Residents The model year 2011 RANGER 800 4X4 is available in 49-state and 50-state versions. Only the 50-state models are certified for sale in California. The 50-state models available for sale in California are identified by the letter “C”...
  • Page 94 If Purchased From A Private Party: If you purchase a POLARIS product from a private citizen, to be kept and used outside of the country in which the vehicle was originally purchased, all warranty coverage will be denied. You must nonetheless warranty regis- ter your vehicle under your name and address with a local POLARIS dealer in your country to ensure that you receive safety information and notices regarding your vehicle.
  • Page 95 *As related to the evaporative emission control system. The exclusive remedy for breach of this limited warranty shall be, at the exclusive option of POLARIS, repair or replacement of any defective materials, components or products. THE REMEDIES SET FORTH IN THIS LIM- ITED WARRANTY ARE THE ONLY REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF THIS WARRANTY.
  • Page 96 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 effec- tiveness of the vehicle's emission controls.

  • Page 97: Maintenance Log

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

  • Page 98: Index

    INDEX Accessory Outlets ......17 Component Locations ..... . 16 Air Filter .
  • Page 99 INDEX Fan, Cooling ......56 Idle Speed ....... 62 Filter Cleaning, Air .
  • Page 100 Storage, Covers ......76 Polaris Products ......84 Storage, Fluid Levels.

This manual is also suitable for:

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