Polaris 2013 Ranger 800 Midsize- Manuals

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, e...

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 o...

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 instructio...

8 SAFETY Safety Labels and Locations Discretionary Warning (800 Midsize) 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 publi...

9 SAFETY Safe Riding Gear Always wear appropriate clothing when riding a POLARIS vehicle. Wear protec-tive clothing for comfort and to reduce the chance of injury. Helmet Wearing a helmet can prevent a severe head injury. Whenever riding this POLARIS vehicle, always wear a helmet that meets or excee...

10 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 procedures described.• Never allow anyone under age ...

11 SAFETY Operator Safety • 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...

12 SAFETY Operator Safety Equipment Modifications We strongly recommend that consumers do not install on a POLARIS RANGER any equip- ment that may increase the speed or power of the vehicle, or make any other modifications to the vehicle for these purposes. Any modifications to the original equipmen...

13 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...

14 SAFETY Operator Safety Cab Nets Riding in this vehicle without using the cab nets increases the risk of serious injury or death in the event of an accident or overturn. Always use the cab nets while riding in this vehicle. Always keep hands and feet inside the vehicle at all times. Failure to Ins...

17 FEATURES AND CONTROLS Component Locations Your vehicle is equipped with cab nets on both sides of the vehicle. Cab nets must be used by both operator and passengers at all times. The vehicle illustrated below is shown without cab nets only to allow component identification. Always use the cab net...

18 FEATURES AND CONTROLS Console Auxiliary Outlet The 12-volt receptacle has spade connections on the back that may be used to power an auxiliary light or other optional accessories or lights. The connections are behind the con-sole, under the hood. Mode Button The yellow button located in the instr...

19 FEATURES AND CONTROLS Switches Ignition Switch/Light Switch The ignition switch is a four-position, key-operated switch. The key can be removed from the switch when it is in the OFF position. AWD/Differential Lock Switch The AWD/Differential Switch has three positions: All Wheel Drive (AWD), Diff...

20 FEATURES AND CONTROLS Trailer Hitch Bracket This vehicle is equipped with a receiver hitch bracket for a trailer hitch. Trailer towing equip-ment is not supplied with this vehicle. To avoid injury and property damage, always heed the warnings and towing capacities out-lined on pages 38-39. Brake ...

21 FEATURES AND CONTROLS Seat Belts This POLARIS vehicle is equipped with three-point lap and diagonal seat belts on all external seats. Always make sure the seat belts are secured for all riders before operating. WARNING! Falling from a moving vehicle could result in serious injury or death. Always...

22 FEATURES AND CONTROLS Cab Nets Riding in this vehicle without using the cab nets increases the risk of serious injury or death in the event of an accident or overturn. Cab nets must be used by both operator and passen- gers at all times. Make sure all latches are secure before operating the vehic...

23 FEATURES AND CONTROLS Rollover Protective Structure (ROPS) The Rollover Protective Structure (ROPS) on this vehicle meets OSHA 1928.53 rollover performance requirements. Always have your authorized POLARIS dealer thoroughly inspect the ROPS if it ever becomes damaged in any way. No device can ass...

24 FEATURES AND CONTROLS Instrument Cluster High water pressure may damage components. Wash the vehicle by hand or with a garden hose using mild soap. Do not use alcohol to clean the instrument cluster. Do not allow insect sprays to contact the lens. Speedometer The speedometer displays vehicle spee...

25 FEATURES AND CONTROLS Instrument Cluster Rider Information Center The rider information center is located in the instrument cluster. All segments will light up for one sec-ond at start-up. If the instrument cluster fails to illuminate, a battery over-voltage may have occurred and the instrument c...

26 FEATURES AND CONTROLS Instrument Cluster Rider Information Center Use the MODE button to toggle through the information area options. Display Units (Standard/Metric) The display can be changed to display either standard or metric units of measurement. Tip: To exit the set-up mode at any time, wai...

27 FEATURES AND CONTROLS Instrument Cluster Rider Information Center Odometer Mode The odometer records and displays the distance traveled by the vehicle. Trip Meter Mode The trip meter records the distance traveled by the vehicle if reset before each trip. To reset, select the trip meter mode. Pres...

28 FEATURES AND CONTROLS Instrument Cluster Rider Information Center Engine Error Codes The error screen displays only when the CHECK ENGINE light is on or when it goes on and off during one ignition cycle. Error codes are not stored. When the key is turned OFF, the code and message is lost, but wil...

29 OPERATION Failure to operate the vehicle properly can result in a collision, loss of control, accident or overturn, which may result in serious injury or death. Read and understand all safety warnings outlined in the safety section of this owner’s manual. Break-In Period The break-in period for y...

30 OPERATION Pre-Ride Inspection Failure to inspect and verify that the vehicle is in safe operating condition before operating increases the risk of an accident. Always inspect the vehicle before each use to make sure it's in safe operating condition. Item Remarks Page Brake system/pedal travel Ens...

31 OPERATION Starting Engine 1. Always start the engine outdoors or in a well-ventilated area. 2. Sit in the driver's seat and fasten the seat belt. Secure the cab nets. 3. Apply the brakes. Place the transmission in PARK. 4. Do not press the throttle pedal while starting the engine. Turn the igniti...

32 OPERATION Driving Procedure 1. Wear a helmet, eye protection, gloves, long-sleeve shirt, long pants and over-the-ankle boots. 2. Sit in the driver's seat and fas- ten the seat belt. 3. Start the engine and allow it to warm up. 4. Always use the cab nets while riding in this vehicle. 5. Apply the ...

33 OPERATION Driving with a Passenger 1. Perform the pre-ride inspection. See page 30. 2. Make sure all passengers are at least 12 years of age and tall enough to comfortably and safely sit in a passenger seat with the seat belt secured, put both feet on the floor and grasp the hand hold. 3. Make su...

34 OPERATION Driving On Slippery Surfaces Skidding or sliding can cause loss of control or overturn (if tires regain traction unexpectedly). When operating on slippery surfaces such as ice or loose gravel, reduce speed and use extra caution to reduce the chance of skidding or sliding out of control....

35 OPERATION Driving Uphill Whenever traveling uphill, follow these pre-cautions: 1. Always travel straight uphill. 2. Avoid steep hills (15° maximum). 3. Keep both feet on the floor. 4. Always check the terrain carefully before ascending any hill. 5. Never climb hills with excessively slip- pery or...

36 OPERATION Driving Through Water Your POLARIS RANGER can operate through water up to a maximum recommended depth equal to the floorboards. NOTICE: Immersion can result in major damage if the vehicle isn't serviced correctly and promptly. After immersion, always take the vehicle to your dealer serv...

37 OPERATION Driving in Reverse Follow these precautions when operating in reverse: 1. Always check for obstacles or people behind the vehicle. Always inspect left and right fields of vision before backing. 2. Always avoid backing downhill. 3. Back slowly. 4. Apply the brakes lightly for stopping. 5...

38 OPERATION Hauling Cargo Hauling cargo improperly can alter vehicle handling and may cause loss of control or brake instability, which can result in serious injury or death. Always follow these precautions when hauling cargo: Never exceed the maximum weight capacity of the vehicle. When determinin...

39 OPERATION Towing Loads Towing improperly can alter vehicle handling and may cause loss of control or brake insta-bility. Always follow these precautions when towing:1. Never load more than 150 lbs. (68.1 kg) tongue weight on the towing bracket.2. Do not operate the vehicle faster than 10 MPH (16 ...

40 OPERATION Differential Operation Modes The 4X4 rear axle is equipped with a lockable differential that allows the operator to choose between an open differential or a closed differential. AWD Press the top of the rocker switch to engage All Wheel Drive (AWD). When in AWD, the rear wheels rotate a...

41 OPERATION All Wheel Drive (AWD) The illuminated amber AWD switch indicates that the vehicle is in AWD. When the AWD switch is on, the front gearcase will automatically engage any time the rear wheels lose traction. When the rear wheels regain traction, the front gearcase will automati-cally disen...

42 EMISSION CONTROL SYSTEMS Noise Emission Control System Do not modify the engine, intake or exhaust components, as doing so may affect compliance with U.S.A. EPA noise control requirements (40 CFR 205) and local noise level require-ments. Operation on Public Lands in the U.S.A. Your POLARIS vehicl...

43 MAINTENANCE Periodic Maintenance Chart Careful periodic maintenance will help keep your vehicle in the safest, most reliable condi-tion. Inspection, adjustment and lubrication of important components are explained in the periodic maintenance chart. Inspect, clean, lubricate, adjust and replace pa...

46 MAINTENANCE Engine Oil Always check and change the engine oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 43. Always change the oil filter whenever changing oil. WARNING! Vehicle operation with insufficient, deteriorated, or contaminated engine oil will cause acc...

47 MAINTENANCE Engine Oil Oil and Filter Change Always change the oil and filter at the intervals outlined in the Periodic Maintenance Chart beginning on page 43. Always change the oil filter whenever changing oil. 1. Position the vehicle on a level surface. 2. Place the transmission in PARK. 3. Sta...

48 MAINTENANCE Gearcases Gearcase Specification Chart Transmission (Main Gearcase) Always check and change the transmission oil at the intervals outlined in the Periodic Main-tenance Chart beginning on page 43. Maintain the oil level even with the bottom of the fill plug hole threads. Refer to the G...

49 MAINTENANCE Gearcases Front Gearcase Always check and change the front gearcase oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 43. Maintain the oil level even with the bottom thread of the fill plug hole. Refer to the Gearcase Specifications Chart on page 48 for...

50 MAINTENANCE Spark Plugs Spark Plug Recommendations Refer to the specifications section beginning on page 74 for the recommended spark plug type for your vehicle. Always torque spark plugs to specification. NOTICE: Using non-recommended spark plugs can result in serious engine damage. Always use P...

51 MAINTENANCE Cooling System The engine coolant level is controlled or maintained by the recovery system. The recovery system components are the overflow bottle, radiator filler neck, radiator pressure cap and connecting hose. As coolant operating temperature increases, the expanding (heated) exces...

52 MAINTENANCE Cooling System Overflow Bottle Coolant Level Always check and change the coolant at the intervals outlined in the Periodic Maintenance Chart beginning on page 43. Maintain the coolant level between the min-imum and maximum marks on the bottle (when the fluid is cool). 1. Position the ...

53 MAINTENANCE POLARIS Variable Transmission (PVT) System Failure to comply with the instructions in this warning can result in severe injury or death. Do not modify any component of the PVT system. Doing so may reduce its strength so that a failure may occur at a high speed. The PVT system has been...

54 MAINTENANCE POLARIS Variable Transmission (PVT) System PVT Drying There may be some instances when water is ingested into the PVT system. Use the following instructions to dry it out before operating. 1. Position the vehicle on a level surface. 2. Remove the drain plug. Allow the water to drain c...

55 MAINTENANCE Vehicle Immersion NOTICE: If your vehicle becomes immersed, major engine damage can result if the machine is not thoroughly inspected. Take the vehicle to your dealer before starting the engine. If it's impossible to take your RANGER to a dealer before starting it, follow the steps ou...

56 MAINTENANCE Filter Systems Air Filter Always change the air filter at the intervals outlined in the Periodic Maintenance Chart beginning on page 43. Service the air filter more frequently if the vehicle is operated in wet conditions or at high throttle openings for extended periods. 1. Lift the c...

57 MAINTENANCE Spark Arrester Failure to heed the following warnings while servicing the spark arrester could result in serious injury or death. • Do not perform service on the spark arrester while the system is hot. Exhaust system temperatures can reach 1000° F. Allow components to cool sufficientl...

58 MAINTENANCE Throttle System Failure to check or maintain proper operation of the throttle system can result in an accident and lead to serious injury or death if the throttle pedal sticks during operation. Always check the pedal for free movement and return before starting the engine and occasion...

59 MAINTENANCE Brakes The front and rear brakes are hydraulic disc type brakes. Press down on the brake pedal to engage the brakes. See page 20. Brake Fluid Inspect the brake system routinely. Inspect the level of the brake fluid before each operation. WARNING! After opening a bottle of brake fluid,...

60 MAINTENANCE Steering Wheel Inspection Check the steering wheel for specified freeplay and smooth operation at the intervals out-lined in the Periodic Maintenance Chart beginning on page 43. 1. Position the vehicle on a level surface. 2. Lightly turn the steering wheel left and right. 3. There sho...

61 MAINTENANCE Tires Operating your vehicle with worn tires, improperly inflated tires, non-standard tires or improperly installed tires will affect vehicle handling and could cause an accident resulting in serious injury or death. Always follow all tire maintenance procedures as outlined in this ma...

62 MAINTENANCE Tires Wheel Removal 1. Apply the brakes. 2. Place the transmission in PARK. 3. Stop the engine. 4. Loosen the wheel nuts slightly. 5. Elevate the side of the vehicle by placing a suitable stand under the frame. 6. Remove the wheel nuts and washers. Remove the wheel. Wheel Installation...

63 MAINTENANCE Fuses If the engine stops or will not start, or if you expe-rience other electrical failures, a fuse may need replacement. Locate and correct any short circuits that may have caused the blown fuse, then replace the fuse. Spare fuses are provided in the fuse box. If you suspect that a ...

64 MAINTENANCE Lights Headlight Beam Adjustment 1. Place the vehicle on a level surface with the headlight approximately 25 ft. (7.6 m) from a wall. 2. Measure the distance from the floor to the center of the headlight and make a mark on the wall at the same height. 3. Apply the brakes. Start the en...

65 MAINTENANCE Battery Battery electrolyte is poisonous. It contains sulfuric acid. Serious burns can result from contact with skin, eyes or clothing. Antidote: External : Flush with water. Internal : Drink large quantities of water or milk. Follow with milk of magnesia, beaten egg, or vegetable oil...

66 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)...

67 MAINTENANCE Battery Battery Installation Using a new battery that has not been fully charged can damage the battery and result in a shorter life. It can also hinder vehicle performance. Follow the battery charging instructions on page 68 before installing the battery. 1. Ensure that the battery i...

68 MAINTENANCE Battery Battery Charging (Conventional Battery) 1. Remove the battery from the vehicle to prevent damage from leaking or spilled electro- lyte during charging. See page 66. 2. Charge the battery with a charging output no larger than 1/10 of the battery’s amp/hr rat- ing. Charge as nee...

69 MAINTENANCE Cleaning and Storage Washing the Vehicle Keeping your POLARIS vehicle clean will not only improve its appearance but it can also extend the life of various components. NOTICE: High water pressure may damage components. POLARIS recommends washing the vehicle by hand or with a garden ho...

70 MAINTENANCE Cleaning and Storage Polishing the Vehicle POLARIS recommends the use of common household aerosol furniture polish for polishing the finish on your POLARIS vehicle. Follow the instructions on the container.• Avoid the use of automotive products, some of which can scratch the finish of...

71 MAINTENANCE Cleaning and Storage Storage Tips NOTICE: Starting the engine during the storage period will disturb the protective film created by fogging and damage could occur. Never start the engine during the storage period. Clean the Exterior Make any necessary repairs and clean the vehicle as ...

72 MAINTENANCE Cleaning and Storage Storage Tips Inspect and Lubricate Inspect all cables and lubricate all areas of the vehicle as recommended in the Periodic Main-tenance Chart beginning on page 43. Battery Maintenance See pages 67-68 for storage and charging procedures. Fluid Levels Inspect the f...

73 MAINTENANCE Removal from Storage 1. Check the battery electrolyte level and charge the battery if necessary. Install it in the vehicle. Make sure the battery vent hose is routed properly and that it's not pinched or restricted in any way. 2. Make sure the spark plug is tight. 3. Fill the fuel tan...

74 SPECIFICATIONS RANGER 800 Midsize Maximum Weight Capacity (includes weight of operator, passenger, cargo, accessories) 1000 lbs. (454 kg) Dry Weight 1055 lbs. (478.5 kg) Fuel Capacity 8.8 gal. (33.3 l) Engine Oil Capacity 2 qts. (1.9 l) Coolant Capacity 120 oz. (3.5 l) Overall Length 108 in. (274...

75 SPECIFICATIONS Clutching See your POLARIS dealer for clutching specifications. RANGER 800 Midsize Driving System Type PVT Shift Type Single Lever (console) Gear Reduction - 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...

76 POLARIS PRODUCTS Part Number Description Engine Lubricant 2870791 Fogging Oil (12 oz./355 ml Aerosol) 2876244 PS-4 PLUS Performance Synthetic 2W-50 4-Cycle Oil (qt./.95 l) 2876245 PS-4 PLUS Performance Synthetic 2W-50 4-Cycle Oil (gal./3.8 l) Gearcase / Transmission Lubricants 2878068 AGL PLUS Tr...

77 TROUBLESHOOTING Drive Belt Wear/Burn Possible Cause Solution Driving onto a pickup or tall trailer in high range Use low range during loading. Starting out going up a steep incline Use low range. See warnings on page 35. Driving at low RPM or ground speed (3-7 MPH) Drive at a higher speed or use ...

78 TROUBLESHOOTING Engine Doesn't Turn Over Engine Turns Over, Fails to Start Engine Backfires Possible Cause Solution Low battery voltage Recharge the battery to 12.8 VDC Loose battery connections Check all connections and tighten Loose solenoid connections Check all connections and tighten Loose e...

79 TROUBLESHOOTING Engine Pings or Knocks Engine Runs Irregularly, Stalls or Misfires Engine Stops or Loses Power Possible Cause Solution Poor quality or low octane fuel Replace with recommended fuel Incorrect ignition timing See your dealer Incorrect spark plug gap or heat range Set gap to specs or...

80 WARRANTY LIMITED WARRANTY POLARIS Sales Inc., 2100 Highway 55, Medina, MN 55340, gives a SIX MONTH LIMITED WARRANTY on all components of the POLARIS RANGER against defects in material or workmanship. POLARIS also gives a one year limited warranty on the final drive chain for failure due to defect...

81 WARRANTY LIMITATIONS OF WARRANTIES AND REMEDIES This warranty also excludes failures resulting from improper lubrication; improper engine timing; improper fuel; surface imperfections caused by external stress, heat, cold or contamination; operator error or abuse; improper component alignment, ten...

82 WARRANTY Exported Vehicles EXCEPT WHERE SPECIFICALLY REQUIRED BY LAW, THERE IS NO WARRANTY OR SERVICE BUL-LETIN COVERAGE ON THIS VEHICLE IF IT IS SOLD OUTSIDE THE COUNTRY OF THE SELLING DEALER'S AUTHORIZED LOCATION.This policy does not apply to vehicles that have received authorization for export...

85 MAINTENANCE LOG Use the following chart to record periodic maintenance. DATE MILES (KM) OR HOURS TECHNICIAN SERVICE PERFORMED / COMMENTS

87 INDEX A Accessory Outlets . . . . . . . . . . . . . . . . . . . . . . . . . 18 Adjustment Shock Spring . . . . . . . . . . . . . . . . . . . . 60Throttle Freeplay . . . . . . . . . . . . . . . . . 58 Air Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56All Wheel Drive . . ...

If you are under age 16 and without a valid driver’s license. 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 another vehicle.With more than ONE passenger, or with passengers u...