Owners Manual
Page 1
PMS 419 RANGER® 800 EFI RANGER® 800 EPS RANGER CREW® 800 EFI RANGER® 6X6 Owner's Manual for Maintenance and Safety
PMS 419 RANGER® 800 EFI RANGER® 800 EPS RANGER CREW® 800 EFI RANGER® 6X6 Owner's Manual for Maintenance and Safety
Owners Manual
Page 7
... on the steering wheel (if driving) or on a passenger hand hold. • Never permit a guest to operate this vehicle unless the guest has read this manual and all product labels. • Always use the cab nets (or doors) while riding in this manual with your local POLARIS dealer. INTRODUCTION WARNING Failure to follow the warnings contained in this owner's manual and review the safety DVD that came...
... on the steering wheel (if driving) or on a passenger hand hold. • Never permit a guest to operate this vehicle unless the guest has read this manual and all product labels. • Always use the cab nets (or doors) while riding in this manual with your local POLARIS dealer. INTRODUCTION WARNING Failure to follow the warnings contained in this owner's manual and review the safety DVD that came...
Owners Manual
Page 17
... proper tire pressure as specified on your POLARIS vehicle will be properly distributed and securely attached. Allow a greater distance for the purpose of increasing speed or power. Equipment Modifications Do not install any source of flame or sparks. FOR MORE INFORMATION ABOUT SAFETY, call POLARIS at 1-800-342-3764. The warranty on safety labels. • Never modify this manual. See page 18 for fuel safety warnings...
... proper tire pressure as specified on your POLARIS vehicle will be properly distributed and securely attached. Allow a greater distance for the purpose of increasing speed or power. Equipment Modifications Do not install any source of flame or sparks. FOR MORE INFORMATION ABOUT SAFETY, call POLARIS at 1-800-342-3764. The warranty on safety labels. • Never modify this manual. See page 18 for fuel safety warnings...
Owners Manual
Page 24
... behind the console, under the dash. High gear is the primary driving range for the RANGER. When the engine is important to a complete stop. Tip: Maintaining shift linkage adjustment is idling, move the lever to power an auxiliary light or other optional accessories or lights. Gear Selector H: High Gear L: Low Gear N: Neutral R: Reverse Low gear is intended for any of the driver's seat. To shift gears, brake to assure proper transmission function...
... behind the console, under the dash. High gear is the primary driving range for the RANGER. When the engine is important to a complete stop. Tip: Maintaining shift linkage adjustment is idling, move the lever to power an auxiliary light or other optional accessories or lights. Gear Selector H: High Gear L: Low Gear N: Neutral R: Reverse Low gear is intended for any of the driver's seat. To shift gears, brake to assure proper transmission function...
Owners Manual
Page 25
... the instrument cluster. Turn the key to the START position to the ON position when released. See pages 29-33. Press the top of the rocker switch to engage All Wheel Drive (AWD). Move the rocker switch to the center position to lock the differential and operate in the OFF position. See page 47 for differential lock operating instructions. 23 FEATURES AND CONTROLS Switches Ignition Switch The ignition switch is located on the instrument cluster. Electrical...
... the instrument cluster. Turn the key to the START position to the ON position when released. See pages 29-33. Press the top of the rocker switch to engage All Wheel Drive (AWD). Move the rocker switch to the center position to lock the differential and operate in the OFF position. See page 47 for differential lock operating instructions. 23 FEATURES AND CONTROLS Switches Ignition Switch The ignition switch is located on the instrument cluster. Electrical...
Owners Manual
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.... Electronic Power Steering (EPS) Electronic power steering (if equipped) engages when the ignition key is turned to slow or stop the vehicle. Lift and hold the adjustment lever toward you while moving or idle. Brake Pedal Depress the brake pedal to the ON position. See page 29 for a trailer hitch. Apply the brakes while starting the engine. Spring pressure returns the pedal to increase engine speed. Make sure there's adequate throttle pedal...
.... Electronic Power Steering (EPS) Electronic power steering (if equipped) engages when the ignition key is turned to slow or stop the vehicle. Lift and hold the adjustment lever toward you while moving or idle. Brake Pedal Depress the brake pedal to the ON position. See page 29 for a trailer hitch. Apply the brakes while starting the engine. Spring pressure returns the pedal to increase engine speed. Make sure there's adequate throttle pedal...
Owners Manual
Page 32
... meter, engine hour meter and programmable service hour interval. 4. The clock displays time in the fuel sensor circuit. See page 31 for scheduled maintenance. Service Indicator - A flashing wrench symbol alerts the operator that the vehicle is set to illuminate, a battery RPM Trip 1 over-voltage may have occurred 1 and the instrument cluster may also occur when the engine is at idle and high electrical load (lights, cooling fan, accessories) is...
... meter, engine hour meter and programmable service hour interval. 4. The clock displays time in the fuel sensor circuit. See page 31 for scheduled maintenance. Service Indicator - A flashing wrench symbol alerts the operator that the vehicle is set to illuminate, a battery RPM Trip 1 over-voltage may have occurred 1 and the instrument cluster may also occur when the engine is at idle and high electrical load (lights, cooling fan, accessories) is...
Owners Manual
Page 36
... the clutches and drive belt will result in 1. Break in a collision, loss of this owner's manual. No single action on the daily pre-ride inspection checklist. Vary throttle positions. Perform regular checks on fluid levels, controls and areas outlined on your new RANGER is as important as a proper break-in serious injury or death. Check fluid levels of transmission and all safety warnings outlined...
... the clutches and drive belt will result in 1. Break in a collision, loss of this owner's manual. No single action on the daily pre-ride inspection checklist. Vary throttle positions. Perform regular checks on fluid levels, controls and areas outlined on your new RANGER is as important as a proper break-in serious injury or death. Check fluid levels of transmission and all safety warnings outlined...
Owners Manual
Page 47
... extend belt life, use the lowest gear possible when hauling or towing heavy cargo. 45 See page 44. Always shift to any other location or you may cause loss of the vehicle. 7. Towing a trailer increases braking distance. 5. When towing a disabled RANGER vehicle, place the disabled vehicle's transmission in neutral. Attach a trailer to the trailer hitch bracket only. Never tow a trailer on the towing bracket. 2. See the towing capacity chart below and the specifications...
... extend belt life, use the lowest gear possible when hauling or towing heavy cargo. 45 See page 44. Always shift to any other location or you may cause loss of the vehicle. 7. Towing a trailer increases braking distance. 5. When towing a disabled RANGER vehicle, place the disabled vehicle's transmission in neutral. Attach a trailer to the trailer hitch bracket only. Never tow a trailer on the towing bracket. 2. See the towing capacity chart below and the specifications...
Owners Manual
Page 55
... vehicle. Instead, attach the winch to a suspension component, brush guard, bumper or cargo rack. A damper can help of the winch cable. Always release the tension on page 56. See the Shock Loading section on the winch cable before repositioning the damper. Release the winch clutch and spool out the necessary length of the winch cable length that the damper can be released...
... vehicle. Instead, attach the winch to a suspension component, brush guard, bumper or cargo rack. A damper can help of the winch cable. Always release the tension on page 56. See the Shock Loading section on the winch cable before repositioning the damper. Release the winch clutch and spool out the necessary length of the winch cable length that the damper can be released...
Owners Manual
Page 63
adjust; adjust when parts are replaced Inspect daily; D Clutches (drive and driven) Ź D Front wheel bearings D Brake fluid Spark arrester Idle speed D Toe adjustment D Auxiliary brake (if equipped) Ź Headlight aim 100 H 100 H 200 H 300 H 12 M 12 M 24 M 36 M - - Ź Perform these services. 61 clean external surfaces Inspect for leaks at tank cap, lines, fuel valve, filter, pump, throttle body; clean; lubricate; replace as needed Inspect Inspect for proper sealing/air leaks Inspect; Inspect; adjust as needed...
adjust; adjust when parts are replaced Inspect daily; D Clutches (drive and driven) Ź D Front wheel bearings D Brake fluid Spark arrester Idle speed D Toe adjustment D Auxiliary brake (if equipped) Ź Headlight aim 100 H 100 H 200 H 300 H 12 M 12 M 24 M 36 M - - Ź Perform these services. 61 clean external surfaces Inspect for leaks at tank cap, lines, fuel valve, filter, pump, throttle body; clean; lubricate; replace as needed Inspect Inspect for proper sealing/air leaks Inspect; Inspect; adjust as needed...
Owners Manual
Page 84
... affect tire wear and vehicle handling, which can result in gear. See your model is toward the outside and rotation arrows on the tire point toward forward rotation. Attach the wheel nuts and washers and finger tighten. 6. Engage the park brake. Power Steering Unit If your POLARIS dealer. 5. Engage the park brake. Loosen the wheel nuts slightly. Remove the wheel. Apply the brakes. Wheel Installation WARNING! Do not service axle nuts...
... affect tire wear and vehicle handling, which can result in gear. See your model is toward the outside and rotation arrows on the tire point toward forward rotation. Attach the wheel nuts and washers and finger tighten. 6. Engage the park brake. Power Steering Unit If your POLARIS dealer. 5. Engage the park brake. Loosen the wheel nuts slightly. Remove the wheel. Apply the brakes. Wheel Installation WARNING! Do not service axle nuts...
Owners Manual
Page 85
... low light conditions until the headlight is depressed, the brake light comes on the lamp locates properly in the housing. 5. Oil from the wiring harness. Tip: Make sure the tab on . Brake Lights When the brake pedal is replaced. The brake light should come on after about 10 mm (0.4 in reduced visibility when driving. CAUTION! Wiring Harness 2. Open the hood. Install the new lamp. Reinstall the harness assembly into the headlight assembly...
... low light conditions until the headlight is depressed, the brake light comes on the lamp locates properly in the housing. 5. Oil from the wiring harness. Tip: Make sure the tab on . Brake Lights When the brake pedal is replaced. The brake light should come on after about 10 mm (0.4 in reduced visibility when driving. CAUTION! Wiring Harness 2. Open the hood. Install the new lamp. Reinstall the harness assembly into the headlight assembly...
Owners Manual
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... 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 94 Rollover Protection System (ROPS) Fuel Capacity Engine Oil Capacity Coolant Capacity Towing Capacity Hitch Tongue Capacity Max. SPECIFICATIONS RANGER 800 EFI/EPS Maximum Weight Capacity Dry Weight Test GVW - Cargo Box Load* Overall Length Overall Width (box) Overall Width (tires) Overall Height Wheelbase Cargo Box Dimensions (Inside) Ground Clearance Min...
... 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 94 Rollover Protection System (ROPS) Fuel Capacity Engine Oil Capacity Coolant Capacity Towing Capacity Hitch Tongue Capacity Max. SPECIFICATIONS RANGER 800 EFI/EPS Maximum Weight Capacity Dry Weight Test GVW - Cargo Box Load* Overall Length Overall Width (box) Overall Width (tires) Overall Height Wheelbase Cargo Box Dimensions (Inside) Ground Clearance Min...
Owners Manual
Page 98
... 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 96 Rollover Protection System (ROPS) Fuel Capacity Engine Oil Capacity Coolant Capacity Towing Capacity Max. SPECIFICATIONS RANGER 6X6 Maximum Weight Capacity Dry Weight Test GVW - Cargo Box Load Overall Length Overall Width (box) Overall Width (tires) Overall Height Wheelbase Cargo Box Dimensions (Inside) Ground...
... 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 96 Rollover Protection System (ROPS) Fuel Capacity Engine Oil Capacity Coolant Capacity Towing Capacity Max. SPECIFICATIONS RANGER 6X6 Maximum Weight Capacity Dry Weight Test GVW - Cargo Box Load Overall Length Overall Width (box) Overall Width (tires) Overall Height Wheelbase Cargo Box Dimensions (Inside) Ground...
Owners Manual
Page 100
... 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 98 Cargo Box Load Overall Length Overall Width (box) Overall Width (tires) Overall Height Wheelbase Cargo Box Dimensions (Inside) Ground Clearance Min. Rollover Protection System (ROPS) Fuel Capacity Engine Oil Capacity Coolant Capacity Towing Capacity Hitch Tongue Capacity Max. SPECIFICATIONS RANGER CREW 800 Maximum Weight Capacity Dry Weight Test GVW...
... 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 98 Cargo Box Load Overall Length Overall Width (box) Overall Width (tires) Overall Height Wheelbase Cargo Box Dimensions (Inside) Ground Clearance Min. Rollover Protection System (ROPS) Fuel Capacity Engine Oil Capacity Coolant Capacity Towing Capacity Hitch Tongue Capacity Max. SPECIFICATIONS RANGER CREW 800 Maximum Weight Capacity Dry Weight Test GVW...
Owners Manual
Page 108
... this product's warranty or service coverage if you have other rights which the product was purchased, you should warranty register your product at POLARIS. For questions call POLARIS Customer Assistance: United States & Canada: 1-800-POLARIS (1-800-765-2747) French: 1-800-268-6334 106...warranty issues. This warranty gives you specific legal rights, and you may be done by the Limited Warranty. If you move or are void because of federal, state, local law, all warranty coverage will contact the appropriate person at a local POLARIS dealer in order to perform the warranty repair...
... this product's warranty or service coverage if you have other rights which the product was purchased, you should warranty register your product at POLARIS. For questions call POLARIS Customer Assistance: United States & Canada: 1-800-POLARIS (1-800-765-2747) French: 1-800-268-6334 106...warranty issues. This warranty gives you specific legal rights, and you may be done by the Limited Warranty. If you move or are void because of federal, state, local law, all warranty coverage will contact the appropriate person at a local POLARIS dealer in order to perform the warranty repair...
Owners Manual
Page 109
...; Fuel system • Ignition system • Exhaust gas recirculation systems The following parts are also considered emission-related components for exhaust emissions: • Aftertreatment devices • Crankcase ventilation valves • Sensors • Electronic control units The following parts are considered emission-related components for a period of 250 hours of engine operation, 2500 kilometers (3100 miles) of the vehicle owner. POLARIS Industries Inc. Repairing or replacing...
...; Fuel system • Ignition system • Exhaust gas recirculation systems The following parts are also considered emission-related components for exhaust emissions: • Aftertreatment devices • Crankcase ventilation valves • Sensors • Electronic control units The following parts are considered emission-related components for a period of 250 hours of engine operation, 2500 kilometers (3100 miles) of the vehicle owner. POLARIS Industries Inc. Repairing or replacing...
Owners Manual
Page 112
INDEX A Accessory Outlets ...22 Air Filter ...76 Air Filter Cleaning...76 All Wheel Drive ...47-48 Disengaging AWD ...47 Engaging AWD...47 Locking the Differential ...48 All Wheel Drive Switch...23 Arrester, Spark, Warning...77 Auxiliary Outlets ...22 Axle Nut Inspection...81 Axle Nut Torque ...81 C Component Locations ...21 Console ...22 Coolant Level, Overflow Bottle (Coolant) ...73 Coolant Level, Radiator...73 Coolant, Adding or Changing ...72 Cooling Fan ...72 Cooling System ...72-73 Crankcase Emission Control System...58 D Differential Lock Switch ...23 Differential Locking ...48...
INDEX A Accessory Outlets ...22 Air Filter ...76 Air Filter Cleaning...76 All Wheel Drive ...47-48 Disengaging AWD ...47 Engaging AWD...47 Locking the Differential ...48 All Wheel Drive Switch...23 Arrester, Spark, Warning...77 Auxiliary Outlets ...22 Axle Nut Inspection...81 Axle Nut Torque ...81 C Component Locations ...21 Console ...22 Coolant Level, Overflow Bottle (Coolant) ...73 Coolant Level, Radiator...73 Coolant, Adding or Changing ...72 Cooling Fan ...72 Cooling System ...72-73 Crankcase Emission Control System...58 D Differential Lock Switch ...23 Differential Locking ...48...
Owners Manual
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... Specifications, Gearcase ...65 Speed, Towing ...45 Speedometer ...29 Spring, Shock, Adjustment ...80 Stabilizing the Fuel ...91 Starting the Engine ...36 Steering Wheel Inspection...80 Steering Wheel, Adjustment ...24 Stopping the Engine ...36 Storage ...90-92 Storage Area ...92 Storage Compartments ...28 Storage, Battery ...88 Storage, Covers ...92 Storage, Fluid Levels...92 Storage, Oil and Filter ...91 Storage, Removal ...93 Suspension Adjustment, Rear ...80 Switches AWD Switch...23 Differential Lock Switch ...23 Ignition ...23 Light ...23 Mode Button ...23 P Park Brake...
... Specifications, Gearcase ...65 Speed, Towing ...45 Speedometer ...29 Spring, Shock, Adjustment ...80 Stabilizing the Fuel ...91 Starting the Engine ...36 Steering Wheel Inspection...80 Steering Wheel, Adjustment ...24 Stopping the Engine ...36 Storage ...90-92 Storage Area ...92 Storage Compartments ...28 Storage, Battery ...88 Storage, Covers ...92 Storage, Fluid Levels...92 Storage, Oil and Filter ...91 Storage, Removal ...93 Suspension Adjustment, Rear ...80 Switches AWD Switch...23 Differential Lock Switch ...23 Ignition ...23 Light ...23 Mode Button ...23 P Park Brake...