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MAINTENANCE

Periodic Maintenance Chart

Perform all services at whichever maintenance interval is reached first.

Perform these procedures more often for vehicles subjected to severe use.

Emission-Related Service.

Have an authorized POLARIS dealer perform these services.

Item

Maintenance Interval

(whichever comes first)

Remarks

Hours

Calendar

Miles (Km)

Steering

Pre-Ride

Make adjustments as need ed. See
Pre-Ride Checklist on page 34.

Front suspension
Rear suspension
Tires
Brake fluid level
Brake pedal travel
Brake system
Wheels/fasteners
Frame fasteners
Engine oil level

Air filter, pre-filter

Daily

Inspect; clean often; replace as needed

Air box sediment tube

Daily

Drain deposits when visible

Coolant (if applicable)

Daily

Check level daily, change coolant every
2 years

Power steering unit (if equipped)

Daily

Inspect daily; clean often

Headlamp/tail lamp

Daily

Check operation; apply dielectric
grease if replacing

Air filter, main element

Weekly

Inspect; replace as needed

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

Engine breather filter (if equipped)

25 H

Monthly

Inspect; replace if necessary

Front Gearcase oil (if equipped)

25 H

1 M

Perform a break-in oil level check

Middle Gearcase oil (if equipped)

25 H

1 M

Perform a break-in oil level check

Rear gearcase oil (if equipped)

25 H

1 M

Perform a break-in oil level check

Transmission oil

25 H

1 M

Perform a break-in oil level check

Engine oil change (break-in)

25 H

1 M

Perform a break-in oil change at one
month

General lubrication

50 H

3 M

Lubricate all fittings, pivots, cables, etc.

Shift Linkage

50 H

6 M

Inspect, lubricate, adjust

Steering

50 H

6 M

Lubricate

Front Suspension

50 H

6 M

Lubricate

Rear Suspension

50 H

6 M

Lubricate

D
E

Throttle cable

50 H

6 M

Inspect; adjust; lubricate; replace if nec-
essary

Throttle body air intake ducts/
flange

50 H

6 M

Inspect duct for proper sealing/air leaks

Drive belt

50 H

6 M

Inspect; adjust; replace as needed

Cooling system (if applicable)

50 H

6 M

Inspect coolant strength seasonally;
pressure test system yearly

Содержание RANGER 800 EPS Midsize

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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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