Polaris RANGER 800 HD User manual

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.

The text is printed on 100% recycled
with 40% post-consumer waste (PCW).

1
WELCOME
Thank you for purchasing a POLARIS vehicle, and welcome to our
world-wide family of POLARIS owners. We proudly produce an excit-
ing line of utility and recreational products.
• Snowmobiles
• All-terrain vehicles (ATVs)
•RANGER®utility vehicles
• Victory Motorcycles®
• Low Emission Vehicles (LEVs)
We believe POLARIS sets a standard of excellence for all utility 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 pro-
duced.
For safe and enjoyable operation of your vehicle, be sure to follow the
instructions and recommendations in this owner’s manual. Your manual
contains instructions for minor maintenance, but information about
major repairs is outlined in the POLARIS Service Manual and should be
performed only by a 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 ser-
vice needs during, and after, the warranty period.
We also take great pride in our complete line of apparel, parts and acces-
sories, available through our online store at www.purepolaris.com. Have
your accessories and clothing delivered right to your door!

2
POLARIS, THE WAY OUT, RANGER and RANGER CREW are registered trademarks
of POLARIS Industries Inc.
Copyright 2010 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 production components, some minor discrep-
ancies may result between the actual vehicle and the information presented in this publi-
cation. Depictions and/or procedures in this publication are intended for reference use
only. No liability can be accepted for omissions or inaccuracies. Any reprinting or reuse
of the depictions and/or procedures contained within, whether whole or in part, is
expressly prohibited.
The original instructions for this vehicle are in English. Other languages are provided as
translations of the original instructions.
Printed in U.S.A.
2011 RANGER 800 4X4 / 6X6 / CREW Owner’s Manual
P/N 9923125

3
TABLE OF CONTENTS
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Features and Controls. . . . . . . . . . . . . . . . . . . 20
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Emission Control Systems . . . . . . . . . . . . . . . 56
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Specifications. . . . . . . . . . . . . . . . . . . . . . . . . 104
POLARIS Products. . . . . . . . . . . . . . . . . . . . . 110
Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . .111
Declaration of Conformity. . . . . . . . . . . . . . . 115
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
Maintenance Log . . . . . . . . . . . . . . . . . . . . . . 123
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125

4
INTRODUCTION
The RANGER is an off-road vehicle. Familiarize yourself with all laws
and regulations concerning the operation of this vehicle in your area.
The following signal words and symbols appear throughout this manual
and on your vehicle. Your safety is involved when these words and sym-
bols are used. Become familiar with their meanings before reading the
manual.
The safety alert symbol indicates a potential personal injury hazard.
WARNING
A WARNING indicates a hazardous situation which, if not avoided, may result in
death or serious injury.
CAUTION
A CAUTION indicates a hazardous situation which, if not avoided, may result in
minor or moderate injury.
NOTICE
A NOTICE indicates a situation that may result in property damage.
The Prohibition Safety Sign indicates an action NOT to take in order
to avoid a hazard.
The Mandatory Action Sign indicates an action that NEEDS to be
taken to avoid a hazard.

5
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.
• Read this owner’s manual. Understand all safety warnings, precautions and
operating procedures before operating the vehicle. Keep this manual with the
vehicle.
• This vehicle is an ADULT VEHICLE ONLY. NEVER operate this vehicle if you
are under age 16 and NEVER operate without a valid driver’s license.
• No person under the age of 12 may ride as a passenger in this vehicle. Any
passenger must be able to comfortably reach the floor and hand holds.
• Never permit a guest to operate this vehicle unless the guest has read this
manual and all product labels.
• Always use the cab nets while riding in this vehicle.
• Always keep hands and feet inside the vehicle at all times.
WARNING

6
INTRODUCTION
Vehicle Identification Numbers
Record your vehicle's identification numbers and key number in the
spaces provided. 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.
Vehicle Model Number: __________________________________________________________
Frame VIN: ____________________________________________________________________
Engine Serial Number: ___________________________________________________________
Key Number____________________________________________________________________
Engine Serial Number
Key
Number
VIN (4X4, 6X6)
####
VIN (CREW)

7
SAFETY
Safety Labels and Locations
Warning labels have been placed on the vehicle for your protection.
Read and follow the instructions of the labels on the vehicle carefully. If
any of the labels depicted in this manual differ from the labels on your
vehicle, always read and follow the instructions of the labels on the
vehicle.
If any label becomes illegible or comes off, contact your POLARIS
dealer to purchase a replacement. Replacement safety labels are pro-
vided by POLARIS at no charge. The part number is printed on the
label.
Container/Passenger/Tire Pressure Warning (4X4, 6X6)
WARNING
Remove flammable material containers from
box before filling.
• Passengers can be thrown off. This can
cause serious injury or death.
• Never carry passengers in cargo box.
Maximum 4X4 Box Load 1000 lbs. (455 kg)*
Maximum 6X6 Box Load 1250 lbs. (567 kg),
Storage Box Load 250 lbs. (113 kg)
IMPROPER TIRE PRESSURE OR
OVERLOADING can cause loss of control
resulting in SEVERE INJURY OR DEATH.
TIRE PRESSURE IN PSI (KPa):
RANGER - 4X4 FRONT 10 (69) REAR 10 (69)
RANGER - 6X6 FRONT 10 (69) CENTER 10 (69) REAR 10 (69)
MAXIMUM WEIGHT CAPACITY INCLUDES WEIGHT OF OPERATOR,
PASSENGER, CARGO, AND ACCESSORIES.
RANGER 4X4 is 1500 LBS. (682 KG)*
RANGER 6X6 is 2000 LBS. (907 KG)
Reduce speed and allow greater distance for braking when carrying cargo.
Overloading or carrying tall, off-center, or unsecured loads will increase your risk
of losing control. Loads should be centered and carried as low as possible in
box. For stability on rough or hilly terrain, reduce speed and cargo. Be careful if
load extends over the side of the box.
Read Owner's Manual for more detailed loading information. 7176334
* RANGER 4X4 models sold in California are designed and rated for a box capacity
of 600 lbs. (272 kg). The maximum weight capacity for these vehicles is 1100 lbs.
(499 kg).
H

8
SAFETY
Safety Labels and Locations
Container/Passenger/Tire Pressure Warning (CREW)
WARNING
Remove flammable material containers from box before filling.
WARNING
Passengers can be thrown off. This can cause serious injury or death.
Never carry passengers in cargo box.
WARNING
Multi-Passenger Maximum Box Load 1000 lbs. (455 kg)
WARNING
IMPROPER TIRE PRESSURE OR OVERLOADING can cause loss of control
resulting in SEVERE INJURY OR DEATH.
TIRE PRESSURE IN PSI (KPa):
MULTI-PASSENGER - FRONT 12 (83) REAR 16 (110)
MAXIMUM WEIGHT CAPACITY INCLUDES WEIGHT OF OPERATOR,
PASSENGERS, CARGO, AND ACCESSORIES.
MULTI-PASSENGER is 1750 LBS. (795 KG)
Reduce speed and allow greater distance for braking when carrying cargo.
Overloading or carrying tall, off-center, or unsecured loads will increase your risk
of losing control. Loads should be centered and carried as low as possible in
box. For stability on rough or hilly terrain, reduce speed and cargo. Be careful if
load extends over the side of the box.
Read Owner's Manual for more detailed loading information. 7175214

9
SAFETY
Safety Labels and Locations
Clutch Cover Warning
WARNING
NO STEP
• Moving parts hazard under belt-clutch guard. To prevent serious injury, do not
operate vehicle with guard removed.
• Do not modify engine or clutch. Doing so can cause part failure, possible
imbalance, and excessive engine RPM which can result in serious injury or
death. 7172563
Age 16 Warning
Operating this vehicle if you are under the age of 16 increases your chance of
severe injury or death.
NEVER operate this vehicle if you are under age 16 and NEVER operate this
vehicle without a valid driver’s license. 7175566
Shift Caution
CAUTION
To avoid transmission damage, shift only when vehicle is stationary and at idle.
7172674
Discretionary
Warning
Age 16
Warning Shift
Caution
Clutch Cover
Warning

10
SAFETY
Safety Labels and Locations
Discretionary Warning (4X4/6X6)
WARNING
Improper vehicle use can result in Severe Injury or Death.
NEVER Operate:
• At speeds too fast for your skills or the conditions.
• After or while using Alcohol or Drugs.
• On hills steeper than 15 degrees 15°.
• On public roads, a collision can occur with a another vehicle.
• With more than two passengers, or passengers under age twelve or who
cannot comfortably reach the floor and hand holds.
• 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.
• Wear a helmet and eye protection and keep hands and feet in vehicle at all
times.
• Reduce speed and use extra caution when carrying passengers.
• Avoid sharp turns or turns while applying heavy throttle.
• Operate slowly in reverse - avoid sharp turns or sudden braking.
• Make sure passenger reads and understands all safety labels.
• Watch for branches or other hazards that could enter vehicle.
LOCATE AND READ OWNER’S MANUAL. FOLLOW ALL INSTRUCTIONS
AND WARNINGS. 7176128

11
SAFETY
Safety Labels and Locations
Discretionary Warning (CREW)
WARNING
Improper vehicle use can result in SEVERE INJURY or DEATH.
NEVER Operate:
• At speeds too fast for your skills or the conditions.
• After or while using Alcohol or Drugs.
• On hills steeper than 15 degrees 15°.
• On public roads, a collision can occur with a another vehicle.
• With more than five passengers, or passengers under age twelve or who
cannot comfortably reach the floor and hand holds.
• 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.
• Wear a helmet and eye protection and keep hands and feet in vehicle at all
times.
• Reduce speed and use extra caution when carrying passengers.
• Avoid sharp turns or turns while applying heavy throttle.
• Operate slowly in reverse - avoid sharp turns or sudden braking.
• Make sure passenger reads and understands all safety labels.
• Watch for branches or other hazards that could enter vehicle.
LOCATE AND READ OWNER’S MANUAL. FOLLOW ALL INSTRUCTIONS
AND WARNINGS 7176321

12
SAFETY
Operator Safety
Serious injury or death can result if you do not follow these instructions and
procedures, which are outlined in further detail within your owner's manual.
• Read this manual and all labels carefully. Follow the operating proce-
dures described.
• Never allow anyone under age 16 to operate this vehicle and never
allow anyone without a valid driver's license to operate this vehicle.
• Do not carry a passenger until you have at least two hours of driving
experience with this vehicle.
• No person under the age of 12 may ride as a passenger in this vehicle.
Any passenger must be able to comfortably reach the floor and hand
holds.
• The driver and all passengers must wear helmet, eye protection and
seat belt at all times.
• Always use the cab nets while riding in this vehicle.
• Always keep hands and feet inside the vehicle at all times.
• Always keep both hands on the steering wheel and both feet on the
floorboards of the vehicle during operation.
• Never permit a guest to operate this vehicle unless the guest has read
this manual and all product labels.
• To reduce tipover risk, be especially careful when encountering
obstacles and slopes and when braking on hills or during turns.
• This vehicle is for off road use only. Never operate on public roads.
Always avoid paved surfaces.
• Never consume alcohol or drugs before or while operating this vehi-
cle.
• Never operate at excessive speeds. Always travel at a speed proper
for the terrain, visibility and operating conditions, and your experi-
ence.
• Never attempt jumps or other stunts.
WARNING

13
SAFETY
Operator Safety
• Always inspect the vehicle before each use to make sure it's in safe
operating condition. Always follow the inspection procedures
described in this manual.
• Always travel slowly and use extra caution when operating on unfa-
miliar terrain. Be alert to changing terrain.
• Never operate on excessively rough, slippery or loose terrain.
• Always follow proper procedures for turning. Practice turning at slow
speeds before attempting to turn at faster speeds. Never turn at exces-
sive speeds.
• Always have this vehicle checked by an authorized POLARIS dealer
if it has been involved in an accident.
• Never operate this vehicle on hills too steep for the vehicle or for your
abilities. Practice on smaller hills before attempting larger hills.
• Always follow proper procedures for climbing hills as described in
this manual. Check the terrain carefully before attempting to climb a
hill. Never climb hills with excessively slippery or loose surfaces.
Never open the throttle suddenly or make sudden gear changes. Never
go over the top of a hill at high speed.
• Always follow the proper procedures outlined in this manual for trav-
eling downhill and for braking on hills. Check the terrain carefully
before descending a hill. Never travel downhill at high speed. Avoid
going downhill at an angle, which would cause the vehicle to lean
sharply to one side. Travel straight down the hill where possible.
• Always check for obstacles before operating in a new area. Never
attempt to operate over large obstacles such as rocks or fallen trees.
Always follow the proper procedures outlined in this manual when
operating over obstacles.
• Always be careful of skidding or sliding. On slippery surfaces such as
ice, travel slowly and exercise caution to reduce the chance of skid-
ding or sliding out of control.

14
SAFETY
Operator Safety
• Never operate your vehicle in fast-flowing water or in water deeper
than that specified in this manual. Wet brakes may have reduced stop-
ping ability. Test your brakes after leaving water. If necessary, apply
them lightly several times to let friction dry out the pads.
• Always be sure there are no obstacles or people behind your vehicle
when operating in reverse. When it's safe to proceed in reverse, move
slowly. Avoid turning at sharp angles in reverse.
• Always use the proper size and type of tires specified in this manual.
Always maintain proper tire pressure as specified on safety labels.
• Never modify this vehicle through improper installation or use of
accessories.
• Never exceed the stated load capacity for this vehicle. Cargo should
be properly distributed and securely attached. Reduce speed and fol-
low the instructions in this manual for hauling cargo or pulling a
trailer. Allow a greater distance for braking.
• Always engage the park brake before getting out of the vehicle. See
page 27.
• Always apply the brakes before engaging or releasing the park brake.
• Always stop the engine before refueling. Remove flammable material
containers from the box before filling them with fuel. Make sure the
refueling area is well ventilated and free of any source of flame or
sparks. Gasoline is extremely flammable. See page 17 for fuel safety
warnings.
• Always remove the ignition key when the vehicle is not in use to pre-
vent unauthorized use or accidental starting.
FOR MORE INFORMATION ABOUT SAFETY, call POLARIS at 1-800-
342-3764.

15
SAFETY
Operator Safety
Equipment Modifications
We strongly recommend that consumers do not install on a POLARIS
RANGER any equipment that may increase the speed or power of the
vehicle, or make any other modifications to the vehicle for these pur-
poses. Any modifications to the original equipment of the vehicle create
a substantial safety hazard and increase the risk of bodily injury.
The warranty on your POLARIS RANGER is terminated if any equip-
ment has been added to the vehicle, or if any modifications have been
made to the vehicle, that increase its speed or power.
The addition of certain accessories, including (but not limited to) mow-
ers, blades, tires, sprayers, or large racks, may change the handling char-
acteristics of the vehicle. Use only POLARIS-approved accessories, and
familiarize yourself with their function and effect on the vehicle.

16
SAFETY
Operator Safety
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.
NEVER operate this vehicle if you are under age
16 and NEVER operate without a valid driver’s
license.
No person under the age of 12 may ride as a
passenger in this vehicle. Any passenger must be
able to comfortably reach the floor and hand
holds.
Operating Without Instruction
Operating this vehicle without proper instruction
increases the risk of an accident. The operator
must understand how to operate the vehicle
properly in different situations and 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.
Using Alcohol or Drugs
Operating the vehicle after consuming alcohol
or drugs could adversely affect operator
judgment, reaction time, balance and
perception.
Never drink alcohol or use drugs or medications
before or while operating this vehicle.
Seat Belts
Riding in this vehicle without wearing the seat belt increases the risk of serious
injury in the event of an accident or sudden stop. Riders must wear seat belts at
all times. Seat belts reduce the severity of injury in the event of a sudden stop or
accident. Always make sure the seat belts are secured for both the operator and
passenger before riding.
WARNING