Owners Manual
Page 15
... check for fuel safety warnings. • Always remove the ignition key when the vehicle is not in reverse. See page 20. • Always apply the brakes before engaging or releasing the park brake. • Always stop the engine before descending a hill. Never open the throttle suddenly or make sudden gear changes. When it's safe to operate over the top of flame or sparks. Never go...
... check for fuel safety warnings. • Always remove the ignition key when the vehicle is not in reverse. See page 20. • Always apply the brakes before engaging or releasing the park brake. • Always stop the engine before descending a hill. Never open the throttle suddenly or make sudden gear changes. When it's safe to operate over the top of flame or sparks. Never go...
Owners Manual
Page 21
... could cause transmission damage. See your dealer if you experience any shifting problems. Using Low Range Always shift into low gear for the RANGER. When the engine is important to power an auxiliary light or other optional accessories or lights. Always shift when the vehicle is stationary and the engine is the primary driving range for any of the driver's seat. FEATURES AND CONTROLS Console Park Brake Lever Gear Selector (Shifter) Instrument Cluster 12V Auxiliary...
... could cause transmission damage. See your dealer if you experience any shifting problems. Using Low Range Always shift into low gear for the RANGER. When the engine is important to power an auxiliary light or other optional accessories or lights. Always shift when the vehicle is stationary and the engine is the primary driving range for any of the driver's seat. FEATURES AND CONTROLS Console Park Brake Lever Gear Selector (Shifter) Instrument Cluster 12V Auxiliary...
Owners Manual
Page 22
... the switch to unlock the differential and allow the two rear drive wheels to the ON position when released. OFF ON START The engine is in rear wheel drive. The key returns to operate independently. FEATURES AND CONTROLS Switches Ignition Switch The ignition switch is located on the instrument cluster. AWD/Differential Switch Ignition Switch Light Switch Mode Button Mode Button The MODE button is a three-position, key-operated switch. Press the bottom of the rocker switch toward the dash to turn off...
... the switch to unlock the differential and allow the two rear drive wheels to the ON position when released. OFF ON START The engine is in rear wheel drive. The key returns to operate independently. FEATURES AND CONTROLS Switches Ignition Switch The ignition switch is located on the instrument cluster. AWD/Differential Switch Ignition Switch Light Switch Mode Button Mode Button The MODE button is a three-position, key-operated switch. Press the bottom of the rocker switch toward the dash to turn off...
Owners Manual
Page 23
... damage, always heed the warnings and towing capacities outlined on the right-hand side of 87 R+M/2 octane. FEATURES AND CONTROLS Trailer Hitch Bracket This vehicle is at the desired position. Lift and hold the adjustment lever toward you while moving or idle. Fuel Cap The fuel tank filler cap is turned to increase engine speed. Electronic Power Steering (EPS) Electronic power steering (if equipped) engages when the ignition key is located on pages 37...
... damage, always heed the warnings and towing capacities outlined on the right-hand side of 87 R+M/2 octane. FEATURES AND CONTROLS Trailer Hitch Bracket This vehicle is at the desired position. Lift and hold the adjustment lever toward you while moving or idle. Fuel Cap The fuel tank filler cap is turned to increase engine speed. Electronic Power Steering (EPS) Electronic power steering (if equipped) engages when the ignition key is located on pages 37...
Owners Manual
Page 29
... displays time in the fuel tank. A flashing wrench symbol alerts the operator that the vehicle is at start-up for scheduled maintenance. Turf Mode Indicator - To change to display, an open or short circuit has occurred in the instrument cluster. When the last segment clears, a low fuel warning is on 4X4). 8. Information Display Area - Drive at the factory. If the instrument E F cluster fails to illuminate, a battery RPM...
... displays time in the fuel tank. A flashing wrench symbol alerts the operator that the vehicle is at start-up for scheduled maintenance. Turf Mode Indicator - To change to display, an open or short circuit has occurred in the instrument cluster. When the last segment clears, a low fuel warning is on 4X4). 8. Information Display Area - Drive at the factory. If the instrument E F cluster fails to illuminate, a battery RPM...
Owners Manual
Page 33
... the recommended oil as recommended. Drive slowly at sustained idle. 5. PVT Break-in (Clutches/Belt) A proper break-in period. If a belt fails, always clean any debris from the duct and from the engine compartment. 29 No single action on your new RANGER is as important as a proper break-in of this manual. See page 30. Review the fuel warnings on the daily...
... the recommended oil as recommended. Drive slowly at sustained idle. 5. PVT Break-in (Clutches/Belt) A proper break-in period. If a belt fails, always clean any debris from the duct and from the engine compartment. 29 No single action on your new RANGER is as important as a proper break-in of this manual. See page 30. Review the fuel warnings on the daily...
Owners Manual
Page 36
... warm up. 6. Vehicle handling may change with a passenger and/or cargo on the steering wheel, slowly release the brakes and depress the throttle with the seat belt secured, put both hands on board. Start the engine and allow it to a passenger. 9. Make sure all cab nets are wearing an approved helmet and eye protection. 4. Allow more than the recommended number of driving experience with a Passenger 1. See page...
... warm up. 6. Vehicle handling may change with a passenger and/or cargo on the steering wheel, slowly release the brakes and depress the throttle with the seat belt secured, put both hands on board. Start the engine and allow it to a passenger. 9. Make sure all cab nets are wearing an approved helmet and eye protection. 4. Allow more than the recommended number of driving experience with a Passenger 1. See page...
Owners Manual
Page 44
... front wheels will automatically engage any time the rear wheels lose traction. If the rear wheels are at least 10 feet (3 m). 3. Always switch to AWD while the rear wheels have traction or are spinning, release the throttle before getting into low gear and drive forward. 5. Perform the following these instructions, see your dealer for at rest. Stop completely. 4. There is moving. Shift into conditions where front wheel drive may remain locked...
... front wheels will automatically engage any time the rear wheels lose traction. If the rear wheels are at least 10 feet (3 m). 3. Always switch to AWD while the rear wheels have traction or are spinning, release the throttle before getting into low gear and drive forward. 5. Perform the following these instructions, see your dealer for at rest. Stop completely. 4. There is moving. Shift into conditions where front wheel drive may remain locked...
Owners Manual
Page 49
... oil change E Fuel system Radiator (if applicable) Cooling Hoses (if applicable) Engine mounts Exhaust muffler/pipe Spark plug E Ignition timing 100 H 100 H 100 H 100 H 100 H 100 H 100 H 12 M 12 M 12 M 12 M 12 M 12 M 12 M - Wiring Clutches (drive and driven) Front wheel bearings Brake fluid 100 H 100 H 200 H 300 H 12 M 12 M 24 M 36 M - - clean; replace if necessary Inspect duct for leaks at tank cap, lines, fuel valve, filter, pump, throttle body; replace...
... oil change E Fuel system Radiator (if applicable) Cooling Hoses (if applicable) Engine mounts Exhaust muffler/pipe Spark plug E Ignition timing 100 H 100 H 100 H 100 H 100 H 100 H 100 H 12 M 12 M 12 M 12 M 12 M 12 M 12 M - Wiring Clutches (drive and driven) Front wheel bearings Brake fluid 100 H 100 H 200 H 300 H 12 M 12 M 24 M 36 M - - clean; replace if necessary Inspect duct for leaks at tank cap, lines, fuel valve, filter, pump, throttle body; replace...
Owners Manual
Page 70
.... Remove the wheel nuts and washers. Apply the brakes. Engage the park brake. Carefully lower the vehicle to specification. Power Steering Unit If your POLARIS dealer. 5. Clean these areas thoroughly. Remove the wheel. Loosen the wheel nuts slightly. Attach the wheel nuts and washers and finger tighten. 6. See page 65. MAINTENANCE Tires Wheel Removal 1. 2. 3. 4. 5. 1. 2. 3. 4. Place the wheel in gear. Improperly installed wheels can adversely affect tire wear and vehicle handling, which can...
.... Remove the wheel nuts and washers. Apply the brakes. Engage the park brake. Carefully lower the vehicle to specification. Power Steering Unit If your POLARIS dealer. 5. Clean these areas thoroughly. Remove the wheel. Loosen the wheel nuts slightly. Attach the wheel nuts and washers and finger tighten. 6. See page 65. MAINTENANCE Tires Wheel Removal 1. 2. 3. 4. 5. 1. 2. 3. 4. Place the wheel in gear. Improperly installed wheels can adversely affect tire wear and vehicle handling, which can...
Owners Manual
Page 71
... console brake light comes on after about 10 mm (0.4 in.) of the lamp. Depress the brake pedal. Always make sure lights are adjusted properly for best visibility. Oil from the wiring harness. Wiring Harness 2. Reinstall the harness assembly into the headlight assembly. When servicing a halogen lamp, don't touch the lamp with bare fingers. Allow lamps to the ON position. 2. Turn the ignition switch to cool before each ride. 1. The brake light...
... console brake light comes on after about 10 mm (0.4 in.) of the lamp. Depress the brake pedal. Always make sure lights are adjusted properly for best visibility. Oil from the wiring harness. Wiring Harness 2. Reinstall the harness assembly into the headlight assembly. When servicing a halogen lamp, don't touch the lamp with bare fingers. Allow lamps to the ON position. 2. Turn the ignition switch to cool before each ride. 1. The brake light...
Owners Manual
Page 82
... Box Load* Overall Length Overall Width (box) Overall Width (tires) Overall Height Wheelbase Cargo Box Dimensions (Inside) Ground Clearance Min. SPECIFICATIONS RANGER 4X4 Maximum Weight Capacity Dry Weight Fuel Capacity Engine Oil Capacity Coolant Capacity Towing Capacity Hitch Tongue Capacity Max. Turning Radius Engine Displacement Bore x Stroke Alternator Output Compression Ratio Starting System Fuel System Ignition System Spark Plug / Gap Front Suspension Rear Suspension Lubrication System Engine Oil 1500 lbs. (681 kg) (including operator, passenger, cargo, accessories) 1100 lbs. (299...
... Box Load* Overall Length Overall Width (box) Overall Width (tires) Overall Height Wheelbase Cargo Box Dimensions (Inside) Ground Clearance Min. SPECIFICATIONS RANGER 4X4 Maximum Weight Capacity Dry Weight Fuel Capacity Engine Oil Capacity Coolant Capacity Towing Capacity Hitch Tongue Capacity Max. Turning Radius Engine Displacement Bore x Stroke Alternator Output Compression Ratio Starting System Fuel System Ignition System Spark Plug / Gap Front Suspension Rear Suspension Lubrication System Engine Oil 1500 lbs. (681 kg) (including operator, passenger, cargo, accessories) 1100 lbs. (299...
Owners Manual
Page 84
....0:1 Electric Electronic Fuel Injection Bosch EFI ECU Controlled RC7YC3 /.035 in. (0.9 mm) Dual a-arm w/9.6 in. (24.4 cm) of travel Independent w/9 in. (23 cm) of travel Independent w/9 in. (23 cm) of travel Pressurized Wet Sump POLARIS 2W-50 80 Cargo Box Load Overall Length Overall Width (box) Overall Width (tires) Overall Height Wheelbase Cargo Box Dimensions (Inside) Ground Clearance Min. SPECIFICATIONS RANGER 6X6 Maximum Weight Capacity Dry Weight Fuel Capacity Engine Oil Capacity Coolant Capacity Towing Capacity...
....0:1 Electric Electronic Fuel Injection Bosch EFI ECU Controlled RC7YC3 /.035 in. (0.9 mm) Dual a-arm w/9.6 in. (24.4 cm) of travel Independent w/9 in. (23 cm) of travel Independent w/9 in. (23 cm) of travel Pressurized Wet Sump POLARIS 2W-50 80 Cargo Box Load Overall Length Overall Width (box) Overall Width (tires) Overall Height Wheelbase Cargo Box Dimensions (Inside) Ground Clearance Min. SPECIFICATIONS RANGER 6X6 Maximum Weight Capacity Dry Weight Fuel Capacity Engine Oil Capacity Coolant Capacity Towing Capacity...
Owners Manual
Page 86
....5 500 W @ 3000 RPM 10.0:1 Electric Electronic Fuel Injection Bosch EFI ECU Controlled RC7YC3 /.035 in. (0.9 mm) Dual a-arm w/9.6 in. (24.4 cm) of travel Independent w/9 in. (23 cm) of travel Pressurized Wet Sump POLARIS 2W-50 82 SPECIFICATIONS RANGER CREW Maximum Weight Capacity Dry Weight Fuel Capacity Engine Oil Capacity Coolant Capacity Towing Capacity Hitch Tongue Capacity Max. Cargo Box Load Overall Length Overall Width (box) Overall Width (tires) Overall Height Wheelbase Cargo Box Dimensions (Inside) Ground Clearance Min.
....5 500 W @ 3000 RPM 10.0:1 Electric Electronic Fuel Injection Bosch EFI ECU Controlled RC7YC3 /.035 in. (0.9 mm) Dual a-arm w/9.6 in. (24.4 cm) of travel Independent w/9 in. (23 cm) of travel Pressurized Wet Sump POLARIS 2W-50 82 SPECIFICATIONS RANGER CREW Maximum Weight Capacity Dry Weight Fuel Capacity Engine Oil Capacity Coolant Capacity Towing Capacity Hitch Tongue Capacity Max. Cargo Box Load Overall Length Overall Width (box) Overall Width (tires) Overall Height Wheelbase Cargo Box Dimensions (Inside) Ground Clearance Min.
Owners Manual
Page 94
... time 90 WARRANTY COVERAGE AND EXCLUSIONS: LIMITATIONS OF WARRANTIES AND REMEDIES The POLARIS limited warranty excludes any vehicle that are considered part of normal maintenance or part of completing an effective repair. The following items: Wheels and tires Suspension components Brake components Seat components Clutches and components Steering components Batteries Light bulbs/Sealed beam lamps Finished and unfinished surfaces Carburetor/Throttle body components Engine components Drive belts Hydraulic components Circuit breakers/Fuses Electronic components Warranty...
... time 90 WARRANTY COVERAGE AND EXCLUSIONS: LIMITATIONS OF WARRANTIES AND REMEDIES The POLARIS limited warranty excludes any vehicle that are considered part of normal maintenance or part of completing an effective repair. The following items: Wheels and tires Suspension components Brake components Seat components Clutches and components Steering components Batteries Light bulbs/Sealed beam lamps Finished and unfinished surfaces Carburetor/Throttle body components Engine components Drive belts Hydraulic components Circuit breakers/Fuses Electronic components Warranty...
Owners Manual
Page 95
... maintenance; Warranty will not apply to a POLARIS Servicing Dealer. The 50-state RANGER 800 4X4 models are identified by the manufacturer. Lubricants 1. WARRANTY LIMITATIONS OF WARRANTIES AND REMEDIES This warranty also excludes failures resulting from the use of non-recommended lubricants may not be covered by warranty. 91 use of POLARIS engine oil. 2. When requesting warranty service you must present your original selling dealer; Should your vehicle requires warranty service...
... maintenance; Warranty will not apply to a POLARIS Servicing Dealer. The 50-state RANGER 800 4X4 models are identified by the manufacturer. Lubricants 1. WARRANTY LIMITATIONS OF WARRANTIES AND REMEDIES This warranty also excludes failures resulting from the use of non-recommended lubricants may not be covered by warranty. 91 use of POLARIS engine oil. 2. When requesting warranty service you must present your original selling dealer; Should your vehicle requires warranty service...
Owners Manual
Page 97
... POLARIS, repair or replacement of the vehicle owner. POLARIS DISCLAIMS ALL EXPRESS WARRANTIES NOT STATED IN THIS WARRANTY. POLARIS Industries Inc. The warranty period for this emissions-certified vehicle starts on how long an implied warranty lasts, so the above limitation may not apply if it is first purchased, this warranty is to the POLARIS standard limited warranty for evaporative emissions: Fuel Tank Fuel Cap Fuel Line Fuel Line Fittings Clamps* Pressure Relief Valves* Control Valves* Control...
... POLARIS, repair or replacement of the vehicle owner. POLARIS DISCLAIMS ALL EXPRESS WARRANTIES NOT STATED IN THIS WARRANTY. POLARIS Industries Inc. The warranty period for this emissions-certified vehicle starts on how long an implied warranty lasts, so the above limitation may not apply if it is first purchased, this warranty is to the POLARIS standard limited warranty for evaporative emissions: Fuel Tank Fuel Cap Fuel Line Fuel Line Fittings Clamps* Pressure Relief Valves* Control Valves* Control...
Owners Manual
Page 100
... Driving Procedure ...32 Driving Through Water ...35 Driving Uphill ...34 Driving with a Passenger...32 Driving, After Driving in Water ...59 Drying the Transmission ...59 Dumping the Cargo Box ...39 E Electromagnetic Interference...42 Electronic Power Steering ...19 Emission Control, Crankcase ...42 Emission Control, Exhaust ...42 Emission Control, Noise ...42 Emissions Limited Warranty ...93-94 Engaging AWD ...40 Engine Break-In...29 Engine Fogging ...76 Engine Idle Speed ...62 Engine Intake Restrictor Plate ...47 Engine Oil ...47-48 Engine Starting ...31 C Cab Frame, ROPS ...Cab...
... Driving Procedure ...32 Driving Through Water ...35 Driving Uphill ...34 Driving with a Passenger...32 Driving, After Driving in Water ...59 Drying the Transmission ...59 Dumping the Cargo Box ...39 E Electromagnetic Interference...42 Electronic Power Steering ...19 Emission Control, Crankcase ...42 Emission Control, Exhaust ...42 Emission Control, Noise ...42 Emissions Limited Warranty ...93-94 Engaging AWD ...40 Engine Break-In...29 Engine Fogging ...76 Engine Idle Speed ...62 Engine Intake Restrictor Plate ...47 Engine Oil ...47-48 Engine Starting ...31 C Cab Frame, ROPS ...Cab...
Owners Manual
Page 101
... Transmission (6X6) ...51 Fluid Levels During Storage...Fluid Part Numbers ...Fogging the Engine ...Fouled Plugs ...Front Gearcase ...Fuel Cap ...Fuel Safety ...Fuel Stabilizer ...Fuel Tank Filler Cap ...Fuel Vent Line Filter...Fuses ...56 60 60 60 60 H Hauling Cargo...37 Headlight Beam Adjustment...68 Headlight Lamp Replacement ...67 Helmet...9 Hitch ...19 Hitch Weight...38 I Idle Speed ...62 Ignition Switch ...18 Indicator Lamps ...24 Inspection, Pre-Ride ...30 Instrument Cluster ...24-28 Intake Restrictor Plate...47 Interference, Electromagnetic...42 K Key, Periodic Maintenance Chart...
... Transmission (6X6) ...51 Fluid Levels During Storage...Fluid Part Numbers ...Fogging the Engine ...Fouled Plugs ...Front Gearcase ...Fuel Cap ...Fuel Safety ...Fuel Stabilizer ...Fuel Tank Filler Cap ...Fuel Vent Line Filter...Fuses ...56 60 60 60 60 H Hauling Cargo...37 Headlight Beam Adjustment...68 Headlight Lamp Replacement ...67 Helmet...9 Hitch ...19 Hitch Weight...38 I Idle Speed ...62 Ignition Switch ...18 Indicator Lamps ...24 Inspection, Pre-Ride ...30 Instrument Cluster ...24-28 Intake Restrictor Plate...47 Interference, Electromagnetic...42 K Key, Periodic Maintenance Chart...
Owners Manual
Page 103
... Steering Wheel Inspection ...64 Steering Wheel, Adjustment ...19 Stopping the Engine ...31 Storage ...74-76 Storage Area ...76 Storage Compartments ...23 Storage, Battery ...72 Storage, Covers ...76 Storage, Fluid Levels ...76 Storage, Oil and Filter...75 Storage, Removal ...77 Suspension Adjustment, Rear ...64 Switches AWD Switch ...18 Differential Lock Switch ...18 Ignition ...18 Light ...18 Mode Button ...17 T Torque, Axle Nuts ...65 Torque, Spark Plug ...55 Torque, Wheel Nut ...65 Towing Loads ...38 Towing Speed ...38 Trailer Hitch ...19 Transmission...
... Steering Wheel Inspection ...64 Steering Wheel, Adjustment ...19 Stopping the Engine ...31 Storage ...74-76 Storage Area ...76 Storage Compartments ...23 Storage, Battery ...72 Storage, Covers ...76 Storage, Fluid Levels ...76 Storage, Oil and Filter...75 Storage, Removal ...77 Suspension Adjustment, Rear ...64 Switches AWD Switch ...18 Differential Lock Switch ...18 Ignition ...18 Light ...18 Mode Button ...17 T Torque, Axle Nuts ...65 Torque, Spark Plug ...55 Torque, Wheel Nut ...65 Towing Loads ...38 Towing Speed ...38 Trailer Hitch ...19 Transmission...