Polaris RANGER 800 EPS Midsize Page 82 Owner'S Manual Download | Manualshive

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80

MAINTENANCE

Battery

Battery Removal

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. Remove the seat.

2. On conventional batteries, remove the battery vent

tube.

3. Disconnect the black (-) battery cable first. Discon-

nect the red (+) battery cable last.

4. Remove the battery hold-down strap.

5. Lift the battery out of the vehicle. Be careful not to tip

a conventional battery sideways, which could spill
electrolyte.

NOTICE:

If electrolyte spills, immediately wash it off with a solution of one tablespoon baking soda
and one cup water to prevent damage to the vehicle.

WARNING

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Summary of Contents for RANGER 800 EPS Midsize

Page 1: ...PMS 419 Owner s Manual for Maintenance and Safety RANGER 800 EFI Midsize RANGER 800 EPS Midsize...

Page 2: ...ns 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 th...

Page 3: ...and recreational vehicles manufactured in the world today Many years of experience have gone into the engineering design and development of your POLARIS vehicle making it the finest machine we ve ever...

Page 4: ...al vehicle and the information presented in this publication Depictions and or procedures in this publication are intended for reference use only No liabil ity can be accepted for omissions or inaccur...

Page 5: ...Introduction 4 Safety 8 Features and Controls 21 Operation 33 Winch Guide 47 Emission Control Systems 56 Maintenance 57 Specifications 88 POLARIS Products 90 Troubleshooting 91 Warranty 94 Maintenanc...

Page 6: ...ential personal injury hazard DANGER A DANGER indicates a hazardous situation that if not avoided will result in death or serious injury WARNING A WARNING indicates a hazardous situation that if not a...

Page 7: ...fety DVD and take the free online Recreational Off Highway Vehicle Association ROHVA training course at www rohva org This vehicle is an ADULT VEHICLE ONLY You MUST be at least age 16 and have a valid...

Page 8: ...t with one of your existing keys The ignition switch must be replaced if all keys are lost Vehicle Model Number ________________________________________________________________________ Frame VIN _____...

Page 9: ...condition The environment was controlled as indicated by the test procedure s The uncertainty of vibration exposure measurement is dependent on many factors including Instrument and calibration uncert...

Page 10: ...a helmet that meets or exceeds established safety standards Approved helmets in the USA and Canada bear a U S Department of Transportation DOT label Approved helmets in Europe Asia and Oceania bear th...

Page 11: ...nd protection Never ride a POLARIS vehicle with bare feet or sandals Clothing Wear long sleeves and long pants to protect arms and legs Rider Comfort Under certain operating conditions heat generated...

Page 12: ...ack against seat feet flat on the floor and hands on steering wheel or hand holds Stay completely inside the vehicle Drive Responsibly Avoid loss of control and rollovers Avoid abrupt maneuvers sidewa...

Page 13: ...ESSURE OR OVERLOADING CAN CAUSE LOSS OF CONTROL RESULTING IN SERIOUS INJURY OR DEATH Reduce speed and allow greater distance for braking when carrying cargo Overloading or carrying tall off center or...

Page 14: ...gine or clutch Doing so can cause part failure pos sible imbalance and excessive engine RPM which can result in seri ous injury or death 7175488 Shift Caution CAUTION To avoid transmission damage shif...

Page 15: ...ver the ankle boots and seat belt at all times Always use the cab nets or doors while riding in this vehicle Always keep hands and feet inside the vehicle at all times Always keep both hands on the st...

Page 16: ...s manual for traveling downhill and for braking on hills See page 39 Check the terrain carefully before descending a hill Never travel downhill at high speed Avoid going downhill at an angle which wou...

Page 17: ...ge 18 for fuel safety warnings Always remove the ignition key when the vehicle is not in use to prevent unauthorized use by someone under the age of 16 or without a driver s license and proper trainin...

Page 18: ...on different types of terrain All operators must read and understand the Owner s Manual and all warning and instruction labels before operating the vehicle All operators should review the safety DVD p...

Page 19: ...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...

Page 20: ...chemicals known to cause cancer birth defects or other reproductive harm Operate this vehicle only outdoors or in well ventilated areas Operating a Damaged Vehicle Operating a damaged vehicle can resu...

Page 21: ...to use extra caution when operating on unfamiliar terrain could result in an accident or rollover Unfamiliar terrain may contain hidden rocks bumps or holes that could cause loss of control or rollov...

Page 22: ...cle and or the operator fall through the ice Never operate the vehicle on a frozen body of water unless you have first verified that the ice is sufficiently thick to support the weight and moving forc...

Page 23: ...e illustrated below is shown without cab nets only to allow component identification Always use the cab nets or doors Not all models come with all features Refer to the specifications section beginnin...

Page 24: ...on in PARK To change gears stop the vehicle and with the engine idling move the lever to the desired gear Do not attempt to shift gears with engine speed above idle or while the vehicle is mov ing Tip...

Page 25: ...nd operate in two wheel drive 2WD See page 45 for Differential Lock operating instructions Press the bottom of the switch to unlock the differential and allow the rear drive wheels to operate independ...

Page 26: ...87 R M 2 octane Do not use fuel with ethanol content greater than 10 percent such as E 85 fuel Seat Removal Pull up on the front of the seat and slide it toward the front of the vehicle Install the se...

Page 27: ...it will self tighten Tip The center belt must be tightened manually by pulling on the strap 4 To release the seat belt press the square red button in the buckle s center Seat Belt Inspection Inspect a...

Page 28: ...s Promptly replace worn or dam aged cab nets and latches with new cab nets and latches Please see your authorized POLARIS dealer Securing a Net 1 After entering the vehicle insert the lower net rod in...

Page 29: ...in the event of a rollover Always follow all safe operating practices outlined in this manual to avoid vehicle rollover WARNING Vehicle rollover could cause severe injury or death Always avoid operati...

Page 30: ...mains and the system will automatically reduce engine power EPS Warning This indicator illuminates briefly when the key is turned to the ON position If the light remains on the EPS system is inoperati...

Page 31: ...lash Refuel immediately Tip If the fuel icon fails to display an open or short circuit has occurred in the fuel sensor circuit See your dealer 3 Information Display Area This area displays odometer tr...

Page 32: ...play option 5 Repeat the procedure to change remaining display settings Clock Mode Tip The clock must be reset any time the battery has been disconnected or discharged 1 Turn the key to the ON positio...

Page 33: ...he engine is started When this feature is enabled it provides a convenient reminder to perform routine maintenance The service interval is programmed at 50 hours at the factory Use the following proce...

Page 34: ...tes retrieve the error codes from the display 1 If the error codes are not displayed use the MODE button to toggle until Ck ENG displays on the main line of the display 2 Press and hold the MODE butto...

Page 35: ...ine Review the fuel warnings on page 18 2 Check the oil level See page 60 Add the recommended oil as needed to maintain the oil level in the normal safe operating range 3 Drive slowly at first Select...

Page 36: ...n 74 Tires Inspect condition and pressure 11 75 Wheels fasteners Inspect ensure fastener tightness 75 Frame nuts bolts fasteners Inspect ensure tightness Fuel and oil Ensure proper levels 24 60 Coolan...

Page 37: ...ghtly with the throttle to aid in warm up until the engine idles smoothly NOTICE Operating the vehicle immediately after starting could cause engine damage Allow the engine to warm up for several minu...

Page 38: ...ng in this vehicle 5 Apply the service brakes and shift the transmission into gear 6 Check your surroundings and determine your path of travel 7 Keeping both hands on the steering wheel slowly release...

Page 39: ...erating conditions Avoid unexpected or aggressive maneuvers that could cause discomfort or injury to a passenger 9 Vehicle handling may change with a passenger and or cargo on board Allow more time an...

Page 40: ...weather follow these precautions 1 Do not operate on excessively rough slippery or loose terrain 2 Slow down before entering slippery areas 3 Maintain a high level of alertness reading the trail and...

Page 41: ...could be on the other side of the hill Driving on a Sidehill Sidehilling Driving on a sidehill is not recommended Improper procedure could cause loss of control or rollover Avoid crossing the side of...

Page 42: ...ntering water 2 Choose a crossing where both banks have gradual inclines 3 Proceed slowly avoiding rocks and obsta cles 4 Avoid operating through deep or fast flowing water WARNING The large tires on...

Page 43: ...rakes Stop the vehicle on a level surface 2 When parking inside a garage or other structure be sure that the structure is well venti lated and that the vehicle is not close to any source of flame or s...

Page 44: ...ly fasten the load and operate with extra caution Always attach the tow load to the hitch point designated for your vehicle HEAVY LOADS CAN CAUSE BRAKING AND CONTROL PROBLEMS Use extreme caution when...

Page 45: ...ng See page 42 Towing a trailer increases braking distance 5 Do not tow more than the recommended weight for the vehicle See the towing capacity chart below and the specifications charts beginning on...

Page 46: ...the operator or bystanders Never operate the dump lever without ensuring that the load is positioned evenly or at the front of the box 6 Stand clear and pull up on the cargo box release lever Lift th...

Page 47: ...in two wheel drive 2WD Locking the differen tial in slippery or low traction conditions helps improve traction When the rear differential is locked both rear wheels rotate at the same speed OFF Diffe...

Page 48: ...sengage until the rear wheels regain traction Engage the AWD before getting into conditions where front wheel drive may be needed If the rear wheels are spinning release the throttle before switching...

Page 49: ...e winch winch cable and load clear of people especially children and distractions while operating the winch 8 Always turn the vehicle ignition power OFF when it and the winch are not being used 9 Alwa...

Page 50: ...un through your hands even if wearing heavy gloves 18 Never release the clutch on the winch when the winch cable is under load 19 Never use the winch for lifting or transporting people 20 Never use th...

Page 51: ...strategy if it is not working Always remember that your winch is very powerful There are simply some situations that you and your winch will not be able to deal with Do not be afraid to ask others to...

Page 52: ...rts available at your authorized POLARIS dealer C If possible keep the winch cable aligned with the centerline of the winching vehicle This will help the spooling of the winch cable and reduce the loa...

Page 53: ...moving when using the winch is when that vehicle itself is stuck The winch equipped vehicle should NEVER be in motion to shock load the winch cable in an attempt to move a second stuck vehicle See th...

Page 54: ...is complete especially if winching at an angle it may be necessary to re distribute the winch cable across the winch drum You will need an assistant to perform this task A Release the clutch on the wi...

Page 55: ...cable has already been permanently and severely damaged Promptly discontinue use of a winch cable in this condition B A kinked winch cable made of wire rope that has been straightened out is shown at...

Page 56: ...ing This puts extra load on the winch winch cable and generates excessive heat from the motor This is a form of shock loading 3 Never tow a vehicle or other object with your winch Towing an object wit...

Page 57: ...tivation of the winch 4 For your safety always replace POLARIS winch parts including the cable with genuine POLARIS replacement parts available at your authorized POLARIS dealer 5 Some winch models us...

Page 58: ...uipped with a closed crankcase system Blow by gases are forced back to the combustion chamber by the intake system All exhaust gases exit through the exhaust system Exhaust Emission Control System Exh...

Page 59: ...inition Frequent immersion in mud water or sand Frequent or prolonged operation in dusty environments Racing or race style high RPM use Prolonged low speed heavy load operation Extended idle Short tri...

Page 60: ...Brake pad wear 10 H Monthly Inspect periodically Battery 20 H Monthly Check terminals clean test Clutch Intake pre filter 25 H Monthly Inspect clean with compressed air replace if necessary E Engine...

Page 61: ...tle body replace lines every 2 years Radiator if applicable 100 H 12 M Inspect clean external surfaces Cooling Hoses 100 H 12 M Inspect for leaks Engine mounts 100 H 12 M Inspect Exhaust muffler pipe...

Page 62: ...e damage Always use the recommended oil Never substitute or mix oil brands Oil Check The oil tank is located under the seat 1 Position the vehicle on a level surface Place the trans mission in PARK 2...

Page 63: ...r scratches 8 Reinstall the drain plug Torque to 20 ft lbs 27 Nm 9 Remove the seat 10 Place shop towels beneath the oil filter Using an oil filter wrench turn the filter counter clockwise to remove it...

Page 64: ...he level check fill plug Check the oil level 3 Remove the rear fill plug and add the recommended oil as needed 4 Reinstall both fill plugs Torque to specification Oil Change The drain plug is located...

Page 65: ...on the right side of the front gearcase 1 Position the vehicle on a level surface 2 Remove the fill plug Check the oil level 3 Add the recommended oil as needed 4 Reinstall the fill plug Torque to spe...

Page 66: ...e spark plug cap Using the spark plug wrench provided in the tool kit remove the plug by rotating it counter clockwise 3 Reverse the procedure for spark plug installation Torque to specification Norma...

Page 67: ...mmends the use of POLARIS Antifreeze 60 40 premix or a 50 50 mixture of high quality aluminum compatible anti freeze coolant and distilled water POLARIS Antifreeze is already premixed and ready to use...

Page 68: ...radiator fins at the intervals outlined in the Periodic Maintenance Chart beginning on page 57 Do not obstruct or deflect air flow through the radiator by installing unauthorized accesso ries in fron...

Page 69: ...tem 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 Belt Replacement Debris Removal If a belt...

Page 70: ...completely Reinstall the drain plug 3 Place the transmission in PARK 4 Start the engine 5 Apply varying throttle for 10 15 seconds to expel the moisture and air dry the belt and clutches Do not hold t...

Page 71: ...the footrests 2 Dry any water present in the air box Filter replacement is required if water is present 3 Thoroughly dry the air pre cleaner located under the hood 4 Remove the spark plugs Turn the en...

Page 72: ...to access the air box 2 Remove the air box cover and inspect the gasket It should adhere tightly to the cover and seal all the way around Tip Grasp the filter end to prevent damage to the filter pape...

Page 73: ...er the vehicle while it s inclined Use the following procedure to periodically purge accumulated carbon from the exhaust pipe 1 Remove the arrester clean out plug located on the bottom of the muffler...

Page 74: ...the intervals outlined in the Periodic Maintenance Chart beginning on page 57 Adjust the freeplay if necessary 1 Place the transmission in PARK 2 Start the engine Allow it to warm up thoroughly 3 Meas...

Page 75: ...endations 1 Position the vehicle on a level surface 2 View the brake fluid level at the reservoir in the driver s side wheel well The level should be between the upper MAX and lower MIN level lines 3...

Page 76: ...e 2 Lightly turn the steering wheel left and right 3 There should be 0 8 1 0 20 25 mm of freeplay 4 If there is excessive freeplay or strange noises or the steering feels rough or catchy have the stee...

Page 77: ...tires for this vehicle when replacing tires Tire Tread Depth Always replace tires when tread depth is worn to 1 8 3 mm or less Axle and Wheel Nut Torque Specifications Inspect the following items occ...

Page 78: ...ire point toward forward rotation WARNING Improperly installed wheels can adversely affect tire wear and vehicle handling which can result in serious injury or death Always ensure that all nuts are to...

Page 79: ...ght conditions until the headlight is replaced 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...

Page 80: ...k placed on the wall Include the weight of a rider on the seat while performing this step 5 If a headlight needs adjustment locate the adjustment screw at the back of the headlight 6 Loosen the screw...

Page 81: ...con ventional battery A sealed battery can be identified by its flat covers on the top of the bat tery A conventional battery has six filler caps on the top of the battery Always keep battery termina...

Page 82: ...ack cable last 1 Remove the seat 2 On conventional batteries remove the battery vent tube 3 Disconnect the black battery cable first Discon nect the red battery cable last 4 Remove the battery hold do...

Page 83: ...and is securely installed as recommended 4 Coat the terminals with dielectric grease or petroleum jelly 5 Connect and tighten the red cable first Connect and tighten the black cable last 6 Verify that...

Page 84: ...oltage WARNING An overheated battery may explode causing severe injury or death Always watch charging times carefully Stop charging if the battery becomes very warm to the touch Allow it to cool befor...

Page 85: ...arsh cleaners which can scratch the finish Do not use a power washer to clean the vehicle Do not use medium to heavy duty compounds on the finish Always use clean cloths and pads for cleaning and poli...

Page 86: ...coastal areas are more susceptible to corrosion if not properly cleaned Clean chrome wheels more often if they re exposed to salt or other corrosive elements 1 Wash chrome wheels frequently Use a mild...

Page 87: ...IS 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 c...

Page 88: ...3 tablespoons of engine oil To access the plug holes use a section of clear 1 4 hose and a small plastic squeeze bottle filled with the pre measured amount of oil Do this carefully If you miss the pl...

Page 89: ...ntervals outlined in the Periodic Maintenance Chart beginning on page 57 Transporting the RANGER Follow these procedures when transporting the vehicle 1 Apply the brakes 2 Place the transmission in PA...

Page 90: ...183 cm Cargo Box Dimensions Inside 32x42x11 5 in 81x107x29 cm Ground Clearance 10 in 25 4 cm Min Turning Radius 150 in 381 cm Towing Capacity 1250 lbs 567 kg Hitch Tongue Capacity 150 lbs 68 kg Max Ca...

Page 91: ...n Low 7 70 1 Gear Reduction Reverse 7 00 1 Gear Reduction High 4 12 1 Drive Ratio Front 3 818 1 Tire Size Front 25 x 8 12 Tire Size Rear 25 x 11 12 Tire Pressure Front 10 psi 68 9 kPa Tire Pressure Re...

Page 92: ...nd Drive Fluid qt 95 l 2877923 Demand Drive Fluid gal 3 8 l 2870465 Pump for Gallon 3 8 l Jug Coolant 2871534 Polaris Antifreeze 60 40 Premix qt 95 l 2871323 Polaris Antifreeze 60 40 Premix gal 3 8 l...

Page 93: ...sion to low range and carefully use fast aggressive throt tle application to engage clutch WARNING Excessive throttle may cause loss of control and vehicle roll over Climbing over large objects from a...

Page 94: ...tive spark plugs 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...

Page 95: ...d air filter Inspect and clean or replace Other mechanical failure See your dealer Possible Lean Fuel Cause Solution Low or contaminated fuel Add or change fuel clean the fuel system Low octane fuel R...

Page 96: ...the original registration and received the customer copy please contact your dealer immediately NO WARRANTY COVERAGE WILL BE ALLOWED UNLESS YOUR VEHICLE IS REGISTERED WITH POLARIS Initial dealer prepa...

Page 97: ...NY PERSON FOR BREACH OF THIS WARRANTY POLARIS SHALL HAVE NO LIABILITY TO ANY PERSON FOR INCIDENTAL CONSEQUENTIAL OR SPECIAL DAMAGES OF ANY DESCRIPTION WHETHER ARISING OUT OF EXPRESS OR IMPLIED WARRANT...

Page 98: ...e selling dealer s authorized location as proof of residence Upon residence verification the servicing dealer will be authorized to perform the warranty repair If you move If you move to another count...

Page 99: ...tside of the country where it was purchased and you have not followed the procedure set above your product will no longer be eligible for warranty or service bulletin coverage of any kind other than s...

Page 100: ...ranty period does not further extend if you purchase additional warranty coverage in the form of a service contract or other paid warranty extension but emission related parts may be covered subject t...

Page 101: ...warranty also does not cover physical damage corrosion or defects caused by fire explosions or other similar causes beyond the control of POLARIS Owners are responsible for performing the scheduled ma...

Page 102: ...100 MAINTENANCE LOG Use the following chart to record periodic maintenance DATE MILES KM OR HOURS TECHNICIAN SERVICE PERFORMED COMMENTS...

Page 103: ...nt Level Overflow Bottle 66 Coolant Level Radiator 66 Coolant Adding or Changing 65 Cooling Fan 65 Cooling System 65 66 Corrosion Removal Chrome 84 Crankcase Emission Control System 56 D Differential...

Page 104: ...s Shifting 22 Gloves 9 H Hauling Cargo 42 Headlight Beam Adjustment 78 Headlight Lamp Replacement 77 Helmet 8 Hitch Bracket 27 Hitch Weight 43 I Idle Speed 72 Ignition Switch 23 Immersion of Vehicle 6...

Page 105: ...lug Torque 64 Spark Plugs 64 Spark Plugs Fouled 64 Specifications 88 89 Specifications Gearcase 62 Speed Towing 43 Speedometer 28 S Starting the Engine 35 Steering Wheel Inspection 74 Stopping the Eng...

Page 106: ...our seat belt Vehicle rollover can cause severe injury or death Reduce speed and use extra caution when carrying passengers Avoid sharp turns or turns while applying heavy throttle Make sure passenger...

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