Maintenance - ASAP All Terrain
Contents
1. IMPORTANT If the filter has been soaked with fuel or oil it must be replaced Do not attempt to wash the air filter If cleaning is required replace the filter Airbox Filter Clamp Breather Hose 2 13 9923499 2011 2012 RANGER 800 Service Manual Copyright 2011 Polaris Sales Inc MAINTENANCE Installation 1 Clean airbox of any oil or water deposits and apply a small amount of grease to the sealing surfaces of the filter Verify plastic sealing ring is installed on filter sealing area 2 Reinstall the air filter cover into the airbox container Align tab and notch for proper fit Be sure the filter cover fits tightly to the air box and engage the 4 clips onto the airbox 2 14 Engine Air Intake Inspection 1 Open the hood to access the engine intake air baffle box 2 Remove the filter element from the baffle box Fiker Element 3 If the filter element is dirty clean it with a high flash point solvent followed by hot soapy water Rinse and dry the filter element thoroughly Inspect element for tears or damage Replace if necessary 4 Reinstall the filter element into the air baffle box PVT Air Intake Inspection 1 Lift the cargo box to access the PVT air intake baffle box 2 Remove the filter element from the baffle box e r Filter Element j 3 If the filter element is dirty clean it with a high flash point solvent followed by hot soapy water Rinse and2. 1 Qt 12 Count AGL Plus Gearcase Lubricant 1 Gal 4 Count AGL Plus Gearcase Lubricant 2 5 Gal 2 Count ATV Angle Drive Fluid Quart 12 count ATV Angle Drive Fluid 2 5 Gallon 2 Count 2870465 Oil Pump for 1 Gallon Jug 2878069 2878070 2876160 2872276 Grease Specialized Lubricants Premium All Season Grease FIRE 3 oz cartridge 24 Count Premium All Season Grease 14 oz cartridge 10 Count 2871460 Starter Drive Grease 12 Count 2871515 Premium U Joint Lube 3 oz 24 Count 2871551 Premium U Joint Lube 14 oz 10 Count 2871312 Grease Gun Kit 2871329 Dielectric Grease Nyogel 2871423 Coolant 2871323 60 40 Coolant Gallon 6 Count 2871534 60 40 Coolant Quart 12 Count 2 7 9923499 2011 2012 RANGER 800 Service Manual Copyright 2011 Polaris Sales Inc MAINTENANCE FLUID MAINTENANCE REFERENCES Component Quick Reference Performance Synthetic 4 Cycle Engine Oil dipstick lll Item Lube Rec Method Frequency Change after 1st month or first 25 hours of operation 100 hours Engine Oil ROBE Roser us Add oil to proper level on thereafter Change more often 25 hours in severe duty conditions or short trip cold weather operation Maintain coolant level in Polaris 60 40 Coolant coolant reservoir bottle 2 Engine Coolant Check level daily change c
3. SPRING PRE LOAD ADJUSTMENT 0 2 37 SHOCK POSITION ADJUSTMENT 0 2 37 SUSPENSION WALKER EVANS 3 00203 nn ae a ded dave de 2 38 SPRING PRELOAD ADJUSTMENT 2 38 SHOCK COMPRESSION ADJUSTMENT 2 38 BRAKE SYSTEM a uta as Faq 2 39 BRAKE FLUID INSPECTION 2 2 39 BRAKE HOSE AND FITTING INSPECTION 2 39 BRAKE PAD DISC INSPECTION 2 39 PARKING BRAKE CABLE ADJUSTMENT 2 40 PARKING BRAKE PAD INSPECTION 2 40 MAINTENANCE LOG act soii ge gy Seem INOS EG ERE AO 2 41 2 2 9923499 2011 2012 RANGER 800 Service Manual Copyright 2011 Polaris Sales Inc MAINTENANCE PERIODIC MAINTENANCE CHART Periodic Maintenance Overview Inspection adjustment and lubrication of important components are explained in the periodic maintenance chart Inspect clean lubricate adjust and replace parts as necessary When inspection reveals the need for replacement parts use genuine Pure Polaris parts available from your Polaris dealer NOTE Service and adjustments are critical If you re not familiar with safe service and adjustment procedures have a qualified dealer perform these operations Maintenance intervals in t
4. 2 Locate the throttle cable adjustment at the throttle body ES 7 Throttle Cable Adjuster 3 Slide back the cable adjuster boot 4 Using a 14 mm open end wrench loosen the adjustment jam nut Using a 12 mm open end wrench move the cable adjuster until 1 16 to 1 8 1 5 3 mm of freeplay is achieved at the throttle pedal La NOTE While adjusting lightly move the throttle pedal in and out 5 Re tighten the jam nut after final adjustment is made 6 Apply a small amount of grease to the inside of the boot and slide it over the cable adjuster to its original position 7 Reinstall the lower seat base 8 Start the engine 9 Disengage the parking brake and field test unit to ensure proper throttle operation Air Filter Service It is recommended the air filter be replaced annually When riding in extremely dusty or wet conditions or at wide open throttle for extended periods replacement is required more often The filter should be inspected periodically see Periodic Maintenance Chart Removal 1 Lift the rear cargo box to access the airbox cover Unhook the 4 clips from airbox cover and remove cover Inspect the cover seal It should adhere tightly to the cover 3 Remove air filter assembly by using a pulling twisting motion Be sure not to damage the filter element 4 Inspect the air filter element and replace if necessary Do not attempt to clean the air filter
5. 2 28 FINAL DRIVE WHEEL AND TIRE nd teehee ates dre nie oie we Re ee 2 30 WHEEL AND HUB TORQUE TABLE 2 2 30 CV SHAFT BOOT INSPECTION 2 30 WHEEL REMOVAL INSTALLATION 2 2 31 TIREMINSPEGTION 3 22 2eme cee Eden RU Gal tenses RER ese Qc bene gates Dani 2 31 TIRE PRESSURE 3 25 ote oe a Deny eed ae Pees 2 31 2 1 9923499 2011 2012 RANGER 800 Service Manual Copyright 2011 Polaris Sales Inc MAINTENANCE ELECTRICAL AND IGNITION SYSTEM 2 32 BATTERY MAINTENANCE FLUID LEVEL CONVENTIONAL BATTERY 2 32 BATTERY REMOVAL pirs oies chaise Aa e ee eae RS 2 32 BATTERY INSTALLATION ooo 2 33 BATTERY STORAGE viii eos nei chs eck Sig Er gue RO Sade eon be 2 33 BATTERY CHARGING rsi ok wad qe Alaa at ea Sells eel ite date eee kal ee oh 2 33 SPARK PLUG SERVICE ica tutes ta bebe pen Boe ie Pa eet el 2 34 ENGINE TO FRAME GROUND 2 2 2 34 STEERING 2asupodrsti id L a he en goad ees aud Ba he Balas 2 35 TIE ROD END STEERING INSPECTION 2 35 WHEEL TOE ALIGNMENT INSPECTION 2 35 TOE E ADJUSTMENT a du maps di en anon ark aug che alate Le 2 36 SUSPENSION STANDARD cios kite Sw is dre oe Saw es EN 2 37 SUSPENSION INSPECTION 2 37
6. WARNING Never remove the pressure cap when the engine is warm or hot Escaping steam can cause severe burns The engine must be cool before removing the pressure cap 4 Remove the pressure cap Using a funnel add coolant to the top of the radiator filler neck 5 Reinstall the pressure cap NOTE Use of a non standard pressure cap will not allow the recovery system to function properly 6 Remove the recovery bottle cap 7 Fill the recovery bottle to the MAX mark with Polaris Premium 60 40 Anti Freeze Coolant or a 50 50 mixture of antifreeze coolant and distilled water as required for freeze protection in your area 8 Reinstall the recovery bottle cap 9 If coolant was required start engine and check for leaks Make sure radiator fins are clean to prevent overheating 9923499 2011 2012 RANGER 800 Service Manual Copyright 2011 Polaris Sales Inc MAINTENANCE Coolant Strength Type Radiator Inspection Cleaning Test coolant strength by using an antifreeze hydrometer 1 Check radiator air passages for restrictions or damage Fan Motor Flush radiator Antifreeze Hydrometer in this direction A 50 50 or 60 40 mixture of antifreeze and distilled water will provide the optimum cooling corrosion protection and antifreeze protection Do not use tap water straight antifreeze or straight water in the system Tap water contains minerals and impurities which build up in the ee
7. dry the filter element thoroughly Inspect element for tears or damage Replace if necessary 4 Reinstall the filter element into the air baffle box 9923499 2011 2012 RANGER 800 Service Manual Copyright 2011 Polaris Sales Inc MAINTENANCE Air Intake Exploded View Engine Air Intake Baffling Box rear To Throttle Airbox Filter N p j i S hi va XX N i Engine Air Intake Baffling Box front oA Hose rear Hose lower _ Clamp aa ye es ST 7 front De Engine Intake Duct gt PVT Air Intake AS a Baffling Box located behind seat back y Clamp Pa CREW y PA Models p r OQ E a PVT Intake Hose To PVT Cover 2 15 9923499 2011 2012 RANGER 800 Service Manual Copyright 2011 Polaris Sales Inc MAINTENANCE ENGINE Compression and Leakdown Test NOTE This engine does NOT have decompression components Compression readings will vary in proportion to cranking speed during the test Average compression measured is about 165 185 psi during a compression test A smooth idle generally indicates good compression Low engine compression is rarely a factor in running condition problems above idle speed Abnormally high compression can be caused by carbon deposits in the combustion chamber or worn damaged exhaust cam lobes Inspect camshaft and combustion chamber if compression is abnormally high A cylinder leakdown test is
8. 2871095 Shock Position Adjustment The front and rear shock position may be adjusted to provide a stiffer suspension if necessary 1 Elevate the vehicle and safely support the main frame CAUTION Serious injury may result if machine tips or falls Be sure machine is secure before adjusting 2 Remove the top shock mounting bolts on each side 3 Reposition the shocks to the outside mounting holes Front Shock Position Adjustment Inside Rear Shock Position Adjustment Outside Stiff soft 4 Reinstall the shock mounting bolts and torque to specification Shock Mounting Bolts 30 ft Ibs 41 Nm 2 37 9923499 2011 2012 RANGER 800 Service Manual Copyright 2011 Polaris Sales Inc MAINTENANCE SUSPENSION WALKER EVANS Spring Preload Adjustment The front and rear shocks have a preload adjustment Suspension spring preload may be adjusted to suit different riding conditions or vehicle payloads A WARNING Uneven adjustment may cause poor handling of the vehicle which could result in an accident and serious injury or death Always adjust both the left and right spring preloads equally 1 Raise and safely support front or rear of the vehicle off the ground to allow the suspension to fully extend 2 Turn the adjustment collar 1 clockwise to increase preload or counter clockwise to decrease preload Decrease Prel
9. 3 Measure the distance between the marks and record the measurement Call this measurement A 4 Rotate the tires 180 by moving the vehicle forward Position chalk marks facing rearward even with the hub axle center line 2 35 9923499 2011 2012 RANGER 800 Service Manual O Copyright 2011 Polaris Sales Inc MAINTENANCE 5 Again measure the distance between the marks and NOTE Be sure steering wheel is straight ahead record Call this measurement B Subtract before determining which tie rod needs adjustment measurement B from measurement A The difference between measurements A and B is the vehicle toe alignment The recommended vehicle toe A CAUTION tolerance is 1 8 to 1 4 3 to 6 cm toe out This means the measurement at the front of the tire A is During tie rod adjustment it is very important that 1 8 to 1 4 3 to 6 cm wider than the measurement the following precautions be taken when at the rear B tightening tie rod end jam nuts If the rod end is positioned incorrectly it will not y pivot and may break 5 In mm N To adjust toe alignment Wheel Toe Out e Hold tie rod end to keep it from rotating A B 1 8 to 1 4 3 to 6 cm Loosen jam nuts at both end of the tie rod e Shorten or lengthen the tie rod until alignment is as required to achieve the proper toe setting as specified in Wheel Toe Alignment e IMPORTANT
10. Fill Plug 8 10 ft Ibs 11 14 Nm 9 Reinstall the fill plug and torque to specification Drain Fill Plug 8 10 ft Ibs 11 14 Nm 8 Check for leaks Dispose of used fluid properly Front Gearcase Fluid Change 9 Reinstall the front bumper The drain plug is located on the bottom side of the front gearcase Access the drain plug through the skid plate 1 Remove the fill plug refer to Front Gearcase Fluid ES DA e 30 ft Ibs Level Check My OEP Sy 41 Nm 2 Place a drain pan under the front gearcase drain plug 3 Remove the drain plug and allow fluid to drain completely Fill Plug 8 10 ft Ibs 11 14 Nm 10 Install the fasteners on each side of the upper portion of the bumper Torque fasteners to 30 ft Ibs 41 Nm 11 Install the 3 bolts in the lower portion of the bumper Torque bolts to 14 ft Ibs 19 Nm Drain Plug 12 Install the 2 T27 Torx head screws retaining the 8 10 ft Ibs fascia screen Torque screws to 4 6 ft Ibs 6 8 Nm 11 14 Nm 2 23 9923499 2011 2012 RANGER 800 Service Manual Copyright 2011 Polaris Sales Inc MAINTENANCE Mid Gearcase Lubrication 6x6 NOTE It is important to follow the mid gearcase maintenance intervals described in the Periodic Maintenance Chart Regular fluid level inspections should be performed as well The gearcase lubricant level should be checked and changed in accordance with the maintenance
11. Model Front Rear XP HD 6X6 8 12 psi 8 12 psi CREW 12 psi 16 psi 2 31 9923499 2011 2012 RANGER 800 Service Manual Copyright 2011 Polaris Sales Inc MAINTENANCE ELECTRICAL AND IGNITION SYSTEM Battery Maintenance Keep battery terminals and connections free of corrosion If cleaning is necessary remove the corrosion with a stiff wire brush Wash with a solution of one tablespoon baking soda and one cup water Rinse well with tap water and dry off with clean shop towels Coat the terminals with dielectric grease or petroleum jelly Be careful not to allow cleaning solution or tap water into the battery A WARNING CALIFORNIA PROPOSITION 65 WARNING Batteries battery posts terminals and related accessories contain lead and lead compounds and other chemicals known to the State of California to cause cancer and birth defects or other reproductive harm WASH HANDS AFTER HANDLING WARNING 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 Call physician immediately Eyes Flush with water for 15 minutes and get prompt medical attention Batteries produce explosive gases Keep sparks flame cigarettes etc away Ventilate when charging or using in a
12. front left side of the front gearcase Access the fill plug from the front of the vehicle Maintain the fluid level even with the bottom threads of the fill plug hole 1 Position vehicle on a level surface 2 Begin by removing the front bumper to gain access to the gearcase fill plug 3 Remove the 2 T27 Torx head screws retaining the fascia screen and remove the screen Remove Remove T27 Screws Remove 4 Remove the 3 bolts from the lower portion of the bumper 5 Remove the fasteners from each side of the upper portion of the bumper 6 Carefully remove the bumper from the vehicle 9923499 2011 2012 RANGER 800 Service Manual Copyright 2011 Polaris Sales Inc MAINTENANCE 7 Remove the fill plug and check the fluid level 4 Clean the drain plug magnetic surface Fill Plug 5 Reinstall drain plug with a new O ring and torque to 8 10 ft Ibs Le specification 11 14 Nm a 6 Add the recommended amount of fluid through the fill hole Maintain the fluid level even with the bottom threads of the fill plug hole Recommended Front Gearcase Fluid Polaris Demand Drive Plus Gearcase fluid flush hi the bolton ot PN 2877922 Quart thread area Capacity 9 oz 265 ml 8 If fluid level is not even with the bottom threads add 7 Reinstall fill plug with a new O ring and torque to the recommended fluid as needed Do not overfill specification g T Drain
13. grease if Head Lamp Tail Lamp Daily replacing gt Air Filter E Main Element Weekly Inspect replace as needed gt Brake Pad Wear Inspect PE m Parking Brake Pads 10H Monthly 100 160 Inspect periodically Battery 20H Monthly 200 320 Check terminals clean test 4 Paring Blake Cane 25H Inspect adjust tension after first 25 hours m Adjustment Perform these procedures more often for vehicles subjected to severe use E Emission Control System Service California m Have an authorized Polaris dealer perform these services 2 4 9923499 2011 2012 RANGER 800 Service Manual Copyright 2011 Polaris Sales Inc MAINTENANCE 25 100 Hour Maintenance Interval Maintenance Interval whichever comes first Item Remarks Miles Hours Calendar KM Inspect level change yearly change gt Front Gearcase Lubricant 25H Monthly 250 400 demand drive fluid every 25 hours if exposed to extreme use Mid Gearcase Lubricant 6x6 25H Monthly 250 400 Inspect level change yearly gt e Gearcase Fuphcan 25H Monthly 250 400 Inspect level change yearly gt Transmission Lubricant 25H Monthly 250 400 Inspect level change yearly gt Engine Breather f E Filter if equipped 25H Monthly 250 400 Inspect replace if necessary gt Engine Oil Change 25H iM a Perform a break in oil change after the first E Break In Period 25 hours or one mon
14. hose Allow the coolant to radiator fitting may distort completely drain Properly dispose of the used Radiator hose clamp torque is 36 in Ibs 4 Nm coolant 2 27 9923499 2011 2012 RANGER 800 Service Manual Copyright 2011 Polaris Sales Inc MAINTENANCE Radiator Removal 4 Remove the 2 screws that retain the front cab assembly to the hood liner 1 Open the hood and disconnect the headlights 2 Remove the 4 upper screws that retain the hood to the frame 5 Remove the 11 remaining screws and 6 push rivets retaining the front cab 3 Remove the 8 fasteners retaining the front bumper assembly and remove the bumper from the vehicle 6 Lift up on the front cab and slide it up the cab frame far enough to access the hood liner Support the front cab to keep it from sliding down 7 Disconnect and remove the battery from the vehicle 8 Loosen the hose clamp and remove the engine air intake baffle box 2 28 9923499 2011 2012 RANGER 800 Service Manual Copyright 2011 Polaris Sales Inc MAINTENANCE 9 Remove the 4 screws that retain the hood liner to the 14 Allow the vehicle to cool down if recently operated frame WARNING Never remove the pressure cap when the engine is warm or hot Escaping steam can cause severe burns The engine must be cool before removing the pressure cap 15 Slowly open the radiator pressure cap to relieve system
15. plug and torque to specification 7 Check for leaks Dispose of used lubricant properly Make sure vent is unobstructed Fill to bottom of fill plug hole Fill Plug 14 ft Ibs 19 Nm threads 6 75 oz Bottom View Drain Plug 14 ft Ibs 19 Nm 9923499 2011 2012 RANGER 800 Service Manual Copyright 2011 Polaris Sales Inc MAINTENANCE Rear Gearcase Lubrication 6x6 NOTE It is important to follow the rear gearcase maintenance intervals described in the Periodic Maintenance Chart Regular fluid level inspections should be performed as well The rear gearcase lubricant level should be checked and changed in accordance with the maintenance schedule e Be sure vehicle is positioned on a level surface when checking or changing the lubricant e Check vent hose to be sure it is routed properly and unobstructed Rear Gearcase Lubricant Level Check The fill plug is located on the right side of the rear gearcase Maintain the lubricant level even with the bottom threads of the fill plug hole 1 Position the vehicle on a level surface 2 Remove the fill plug and check the lubricant level Fill Plug 40 50 ft Ibs 54 68 Nm Gearcase lubricant flush with the bottom of thread area 3 If lubricant level is not even with the bottom threads add the recommended lubricant as needed Do not overfill 4 Reinstall fill plug and torque to specification E T Fill Plug 40 5
16. plug is used 2 34 7 Apply a small amount of anti seize compound to the spark plug threads 8 Install spark plug and torque to specification Recommended Spark Plug Champion RC7YC3 Spark Plug Torque 18 ft Ibs 24 Nm Engine To Frame Ground Inspect engine ground cable connection Be sure they are clean and tight The ground cable runs from the engine to the terminal block located under the hood next to the battery Engine Block Ground Cable Under Hood Under Hood ITERMINAL BLOCK ACC GND B ololelelo gt j 9923499 2011 2012 RANGER 800 Service Manual Copyright 2011 Polaris Sales Inc MAINTENANCE STEERING Steering Inspection The steering components should be checked periodically for loose fasteners worn tie rod ends and damage Also check to make sure all cotter pins are in place If cotter pins are removed they must not be re used Always use new cotter pins Replace any worn or damaged steering components Steering should move freely through entire range of travel without binding Check routing of all cables hoses and wiring to be sure the steering mechanism is not restricted or limited NOTE Whenever steering components are replaced check front end alignment Use only genuine Polaris parts WARNING Due to the critical nature of the procedures outlined in this chapter Polaris recommends steering component repair and adjustment be p
17. skid plate A WARNING Personal injury can occur when handling used oil Hot oil can cause burns or skin damage 3 Place a drain pan beneath the crankcase and remove drain plug CAUTION Oil may be hot Do not allow hot oil to come into contact with skin as serious burns may result 4 Allow oil to drain completely 5 Replace the sealing washer on the drain plug NOTE The sealing surface on the drain plug should be clean and free of burrs nicks or scratches 2 17 9923499 2011 2012 RANGER 800 Service Manual O Copyright 2011 Polaris Sales Inc MAINTENANCE 6 Reinstall drain plug and torque to specification Engine Crankcase Drain Plug 16 2 ft Ibs 21 7 2 7 Nm 7 Remove the lower seat base 8 Remove the storage container located under the driver s side of the seat 9 Place shop towels beneath oil filter Using Oil Filter Wrench PU 50105 turn the filter counter clockwise to remove it Oil Filter Wrench PU 50105 2 5 64 mm 10 Using aclean dry cloth clean filter sealing surface on crankcase 11 Lubricate O ring on new oil filter with a film of fresh engine oil Check to make sure the O ring is in good condition 12 Install new filter and turn by hand until filter gasket contacts the sealing surface then turn an additional 1 2 turn E T Oil Filter Torque Turn by hand until filter gasket contacts sealing surface then turn an addit
18. the best indication of engine condition Follow manufacturer s instructions to perform a cylinder leakage test never use high pressure leakage testers as crankshaft seals may dislodge and leak Cylinder Compression Standard 165 185 PSI Cylinder Leakdown Service Limit 15 Inspect for cause if test exceeds 15 Breather Hose Inspection The engine is equipped with a breather hose A Inspect the breather hose for possible kinks or wear The hose is formed for a proper fit Follow the breather hose from the side of the airbox to the engine valve cover NOTE Make sure line is not kinked or pinched 2 16 Engine Oil Level The twin cylinder domestic engine is a wet sump engine meaning the oil is contained in the bottom of the crankcase To check the oil level follow the procedure listed below 1 Set machine on a level surface and set the parking brake 2 Stop the engine and allow it to cool down before removing the dipstick IMPORTANT Do not run the machine and then check the dipstick 3 Remove the seat base and storage container 4 Unlock the dipstick lever Remove dipstick and wipe dry with a clean cloth ESS na ZIP O y Dipstick eX f gt 5 Reinstall dipstick and push it into place Do not lock the dipstick NOTE Make certain the dipstick is inserted all the way into the filler tube to keep the angle and depth of dipstick consistent When reinstalling the dip
19. thread area 3 If lubricant level is not even with the bottom threads remove the fill plug and add the recommended lubricant as needed Do not overfill 4 Reinstall the fill plug and check plug Torque the plugs to specification Fill Check Plug 10 14 ft Ibs 14 19 Nm 9923499 2011 2012 RANGER 800 Service Manual Copyright 2011 Polaris Sales Inc MAINTENANCE Transmission Lubricant Change 2012 Transmission Lubrication 6x6 The drain plug is located on the bottom of the NOTE It is important to follow the transmission transmission Access the drain plug through the skid plate maintenance intervals described in the Periodic Maintenance Chart Regular fluid level inspections 1 Remove the fill plug should be performed as well Place a drain pan under the transmission drain plug The transmission lubricant level should be checked and Remove the drain plug and allow lubricant to drain changed in accordance with the maintenance schedule completely e Be sure vehicle is positioned on a level surface Fill Plug when checking or changing the lubricant 10 14 ft Ibs 14 19 Nm e Check vent hose to be sure it is routed properly and unobstructed Transmission Lubricant Level Check The fill plug is located on the right side of the transmission Access the fill plug from the rear right hand side of the vehicle Maintain the fluid level even with the bottom threads of the fill plug hole
20. tread depth is worn to 1 8 3 mm or Wheel Installation less 1 With the transmission in gear and the parking brake 5 locked place the wheel in the correct position on the Fai n Tread n wheel hub Be sure the valve stem is toward the Depth 1 8 3 mm outside and rotation arrows on the tire point toward forward rotation 2 Install the washers if applicable and wheel nuts and finger tighten them Pre PR Pd 5 A ww ms iy 3 Lower the vehicle to the ground 4 Securely tighten the wheel nuts to the proper torque listed in the torque table at the beginning of this section WARNING Wheel Nuts 4 pa F Operating a RANGER with worn tires will E f l ase y increase the possibility of the vehicle skidding C easily with possible loss of control ES HEC LOC ml Worn tires can cause an accident Xe a j Fa Front Hub Nut LALA 80 ft Ibs 108 Nm ARN Y Always replace tires when the tread depth measures 1 8 3 cm or less lt MY 9 QU N AT Tire Pressure Mid Rear Hub Nut 110 ft Ibs 150 Nm CAUTION CAUTION Maintain proper tire pressure Refer to the warning tire pressure decal If wheels are improperly installed it could affect applied to the vehicle vehicle handling and tire wear On vehicles with tapered rear wheel nuts make sure tapered end of nut goes into taper on wheel Tire Pressure Inspection PSI Cold
21. 0 ft Ibs 54 68 Nm Rear Gearcase Lubricant Change The drain plug is located on the bottom right side of the rear gearcase Access the drain plug from the rear of the vehicle through the skid plate 1 Remove the fill plug refer to Rear Gearcase Lubricant Level Check 2 Place a drain pan under the rear gearcase drain plug 3 Remove the drain plug and allow the lubricant to drain completely Fill Plug 40 50 ft Ibs 54 68 Nm Drain Plug 30 45 in Ibs 3 5 Nm 4 Clean the drain plug magnetic surface 5 Reinstall drain plug with a new O ring and torque to specification E T Drain Plug 30 45 in Ibs 3 5 Nm Add the recommended amount of lubricant through the fill hole Maintain the lubricant level even with the bottom threads of the fill plug hole N Recommended Rear Gearcase Lubricant ATV Angle Drive Fluid PN 2876160 Capacity 18 oz 532 ml 7 Reinstall fill plug with a new O ring and torque to specification 8 Check for leaks Dispose of used lubricant properly 2 25 9923499 2011 2012 RANGER 800 Service Manual Copyright 2011 Polaris Sales Inc MAINTENANCE COOLING SYSTEM Liquid Cooling System Overview The engine coolant level is controlled or maintained by the recovery system The recovery system components are the recovery bottle radiator filler neck radiator pressure cap and connecting hose As coolant ope
22. 1 Position vehicle on a level surface 2 Remove the fill plug and check the lubricant level Check Plug Drain Plug 10 14 ft Ibs 10 14 ft Ibs 14 19 Nm 14 19 Nm Fill Plug 10 14 ft Ibs 14 19 Nm 4 Clean the drain plug magnetic surface Reinstall drain plug with a new O ring and torque to specification Remove the check plug Add the recommended amount of lubricant through the fill plug hole Maintain the lubricant level at the bottom of the check plug hole when filling the transmission Do not overfill refer to Transmission Lubricant Level Check SS tia 0 Transmission lubricant flush with the bottom of thread area Recommended Transmission Lubricant AGL Plus PN 2878068 Quart 3 If lubricant level is not even with the bottom threads add the recommended lubricant as needed Do not Capacity 33 8 oz 1000 ml overfill 7 Reinstall fill plug and check plug with new O rings 4 Reinstall the fill plug and torque to specification Torque the plugs to specification E T Drain Fill Plug Fill Check Drain Plug 10 14 ft Ibs 14 19 Nm 10 14 ft Ibs 14 19 Nm 8 Check for leaks Dispose of used lubricant properly 2 21 9923499 2011 2012 RANGER 800 Service Manual Copyright 2011 Polaris Sales Inc MAINTENANCE Transmission Lubricant Change Access the drain plug on the right hand side of the vehicle through the sk
23. AKE INSPECTION 2 14 PVT AIR INTAKE INSPECTION 2 14 AIR INTAKE EXPLODED VIEW ooocccccocccco nn rr rrr 2 15 ENGINE Sie ananas IA ae beans ety ath 2 16 COMPRESSION AND LEAKDOWN TEST 2 16 BREATHER HOSE INSPECTION 2 16 ENGINE OIMLEVEb ccd ns toi Marne ates Re wh a ep te td 2 16 ENGINE OIL AND FILTER CHANGE 2 17 EXHAUST PIPE cocacola EE ate we 2 18 TRANSMISSION AND GEARCASES 2 19 2011 TRANSMISSION LUBRICATION XP HD CREW 2 19 2012 TRANSMISSION LUBRICATION XP HD CREW 2 20 TRANSMISSION LUBRICATION 6X6 2 21 FRONT GEARCASE LUBRICATION 2 22 MID GEARCASE LUBRICATION 6X6 2 24 REAR GEARCASE LUBRICATION 6X6 2 25 COBLINE SES TEM and tid ne eels Ula BUN A oe ahead tN eA a es 2 26 COOLANT LEVEL INSPECTION 2 26 COOLANT STRENGTH TYPE ooccccocccc a E S A EENE 2 27 COOLING SYSTEMHOSES ccoo rutas mi a ete ve re at en 2 27 RADIATOR INSPECTION CLEANING 2 27 COOLANT DRAIN ua a dive i nals Stee ie 2 27 RADIATOR REMOVAL c i Dii eitr art 2
24. MAINTENANCE CHAPTER 2 MAINTENANCE PERIODIC MAINTENANCE CHART 44 44 24080 2 3 BREAK IN PERIOD MAINTENANCE CHART KEY 2 3 PRE RIDE 25 HOUR MAINTENANCE INTERVAL 2 4 25 100 HOUR MAINTENANCE INTERVAL 0 2 5 100 500 HOUR MAINTENANCE INTERVAL 2 6 GREASE LUBRICATION POINTS 2 6 SERVICE PRODUCTS AND LUBRICANTS 2 7 FLUID MAINTENANCE REFERENCES 2 8 GENERAL VEHICLE INSPECTION AND MAINTENANCE 2 10 PRE RIDE DAILY INSPECTION 2 10 FRAME NUTS BOLTS AND FASTENERS 2 10 SHIFT CABLE INSPECTION 2325428 a Sie shoals Mey eka Seen tebe 2 10 SHIFT CABLE ADJUSTMENT XP HD CREW 2 10 SHIFT CABLE ADJUSTMENT 6X6 2 11 FUEL SYSTEM AND AIR INTAKE 62 oras pt e 2 12 FUELLINES VENT LINES res lt Satie aed aioe hie eurent oa EU a 2 12 FUEL PUMP FUEL FILTERS ocio iio tee idee eee ten ee ee 2 12 THROTTLE PEDAL INSPECTION 2 12 THROTTLE FREEPLAY ADJUSTMENT 2 12 AIR FILETER SERVIGE acto dace late Oona se be nek edie cho bed aici 2 13 ENGINE AIR INT
25. When tightening the tie rod end jam nuts the rod ends must be held parallel to prevent rod end damage and premature wear Damage may not be immediately apparent if done incorrectly Toe Adjustment If toe alignment is incorrect measure the distance between vehicle center and each wheel This will tell you which tie rod needs adjusting After alignment is complete torque jam nuts to specification T Tie Rod End Jam Nut 12 14 ft Ibs 16 19 Nm Measure Distances measurements should be equal 2 36 al 9923499 2011 2012 RANGER 800 Service Manual O Copyright 2011 Polaris Sales Inc MAINTENANCE SUSPENSION STANDARD Suspension Inspection Compress and release the suspension Damping should be smooth throughout the range of travel e Check all suspension components and mounting fasteners for wear or damage e Inspect each shock body for leakage Spring Pre Load Adjustment The front and rear shock absorber springs are adjustable front only on HD models Rotate the adjuster cam either direction to increase or decrease spring tension Always adjust both left and right sides equally Lowest amount of spring pre load Highest amount of spring pre load Shock Pre Load Adjustment Vehicle loads effect suspension spring pre load requirements Use Spanner Wrench PN 2871095 to adjust pre load as necessary to avoid bottoming of the shocks Shock Spanner Wrench PN
26. attery that has not been fully charged can damage the battery and result in a shorter life It can also Battery Storage hinder vehicle performance Follow the battery charging procedure before installing the battery Whenever the vehicle is not used for a period of three months or more remove the battery from the vehicle 1 Ensure that the battery is fully charged ensure that it s fully charged and store it out of the sun in a cool dry place Check battery voltage each month during storage and recharge as needed to maintain a full charge 2 Place the battery in the battery holder 3 Install the battery vent tube and route it down in front of the shift cable into the front left wheel well NOTE Battery charge can be maintained by using a Polaris battery tender charger or by charging about gF once a month to make up for normal self discharge vent Tube Battery tenders can be left connected during the 7 7 4 storage period and will automatically charge the battery if the voltage drops below a pre determined point Shift Cable Battery Charging 1 Remove the battery from the vehicle to prevent damage from leaking or spilled electrolyte during charging 2 Charge the battery with a charging output no larger than 1 10 of the battery s amp hr rating Charge as needed to raise the specific gravity to 1 270 or greater 4 Route the vent tube through the triangular hole in the frame support from the back sid
27. ble ties IMPORTANT Ensure lines are not kinked or pinched 2 12 Fuel Pump Fuel Filters The RANGER 800 EFI engine uses a serviceable high volume high pressure fuel pump that includes a preliminary filter and an internal fine filter located before the pump regulator NOTE Neither filter is servicable individually Must replace the fuel pump as an assembly Fuel Pump Asm Located in Fuel Tank Fine Filter Preliminary Filter NOTE Refer to Chapter 4 for fuel pump replacement and all other information related to the EFI System Throttle Pedal Inspection If the throttle pedal has excessive play due to cable stretch or cable misadjustment it will cause a delay in throttle speed and the throttle may not open fully If the throttle pedal has no play it may be hard to control and the idle speed may be erratic Check the throttle pedal play periodically in accordance with the Periodic Maintenance Chart and adjust the play if necessary Throttle Freeplay Adjustment Inspection 1 Apply the parking brake 2 Put the gear shift lever in the N Neutral position 3 Start the engine and warm it up thoroughly 4 Measure the distance the throttle pedal moves before the engine begins to pick up speed Free play should be 1 16 1 8 1 5 3 mm 9923499 2011 2012 RANGER 800 Service Manual Copyright 2011 Polaris Sales Inc MAINTENANCE Adjustment 1 Remove the lower seat base
28. dd DOT 4 brake fluid only wear 1 Check the brake pads for wear damage or Brake fluid should be changed every two years The fluid 3 Pads should be changed when the friction material is should also be changed anytime the fluid becomes worn to 040 1 mm contaminated the fluid level is below the minimum level or if the type and brand of the fluid in the reservoir is unknown O O The brake master cylinder reservoir can be accessed through the front left wheel well 1 2 Position the vehicle on a level surface Place the transmission in Neutral N and set the Measure Pad Material e parking brake View the brake fluid level in the reservoir The level should be between the MAX and MIN level lines If the fluid level is lower than the MIN level line add 4 Check surface condition of the brake discs brake fluid until it reaches the MAX level line Thickness Service Limit 040 1 mm 5 Measure the thickness of the front and rear brake Install the reservoir cap and apply the brake pedal discs forcefully for a few seconds and check for fluid leakage around the master cylinder fittings and the 6 Thedisc s shouldbe replaced if thickness is less than brake caliper fittings the specified service limit see Chapter specifications Measure Brake Disc Thickness gt Master Cylinder 4 1 gt a Fi Brake Hose and Fitting Inspection Check brake system hoses and fittings for c
29. ded Lube Method Frequency Grease before long periods Front Propshaft Yoke Polaris Premium U Joint Grease Grease tunas of storage ana arrer pressure 3 pumps maximum washing or submerging the vehicle Front Propshafts CREW Grease Front Propshaft XP HD 6X6 9923499 2011 2012 RANGER 800 Service Manual Copyright 2011 Polaris Sales Inc MAINTENANCE SERVICE PRODUCTS AND LUBRICANTS Polaris Lubricants Maintenance and Service NOTE Each item can be purchased separately at Products your local Polaris dealer Part No Description Part No Description Additives Sealants Thread Locking Agents Misc Loctite Threadlock 242 6 ml 12 count Premium Carbon Clean 12 oz 12 count Engine Lubricant 2870791 Fogging Oil 12 oz Aerosol 2871950 PS 4 Plus Performance Synthetic did 4 Cycle Engine Oil Quart 2871326 PS 4 Plus Performance Synthetic E 4 Cycle Engine Oil Gallon 2870652 Fuel Stabilizer 16 oz 12 count 2872189 DOT 4 Brake Fluid 12 count 2871557 Crankcase Sealant 3 Bond 1215 5 oz 2876245 Gearcase Transmission Lubricants Demand Drive Plus 2877922 Quart A al NOTE The number count indicated by each part 2877923 Demand Drive Plus number in the table above indicates the number of 2 5 Gallon units that are shipped with each order 2878068 AGL Plus Gearcase Lubricant
30. e and place it behind 3 Reinstall th the panel einstall the battery Route through hole in frame tol Route behind IRH the panel IMPORTANT Route vent tube as shown to prevent electrolyte from damaging critical components i e wire harness brake lines throttle cable 5 Coat terminals with dielectric grease or petroleum jelly 6 Connect and tighten the red positive cable first 7 Connect and tighten the black negative cable last 2 33 9923499 2011 2012 RANGER 800 Service Manual Copyright 2011 Polaris Sales Inc MAINTENANCE Spark Plug Service 1 Remove both spark plug high tension leads A Clean plug area so no dirt and debris can fall into engine when plug is removed 2 Remove spark plugs with proper socket 3 Inspect electrodes for wear and carbon buildup Outer edge should be sharp with no rounding or erosion of the electrodes Inspect electrode for wear and buildup 4 Clean with electrical contact cleaner or a glass bead spark plug cleaner only CAUTION A wire brush or coated abrasive should not be used 5 Measure gap with a wire gauge Refer to specifications in picture below for proper spark plug type and gap Adjust gap if necessary by bending the side electrode carefully Spark Plug Gap oo G Gap 035 0 90 mm 6 If necessary replace spark plug with proper type CAUTION Severe engine damage may occur if the incorrect spark
31. ehicle moves adjustment is necessary 4 Adjust the parking brake cable where the cable attaches to the caliper mount bracket The mount bracket is located on the left hand side of the transmission behind the outer PVT cover 4x4 or on the rear gearcase 6x6 Adjustment Procedure Refer to Chapter 9 Brakes for complete adjustment procedure 2 40 Parking Brake Pad Inspection Measure the thickness of the rear caliper parking brake pads Replace assembly as needed See illustration below for proper readings 6x6 Shown n Inboard Pad Thickness New 304 7 72 mm Limit 0 24 6 1 mm i Inboard Outboard Installed Disc to Park Brake 0 375 0 953 cm New Rotor Disc Thickness 0 150 0 164 3 81 4 16 mm 9923499 2011 2012 RANGER 800 Service Manual Copyright 2011 Polaris Sales Inc MAINTENANCE MAINTENANCE LOG Service Date Hours Miles km Service Performed Comments Dealer Technician 9923499 2011 2012 RANGER 800 Service Manual Copyright 2011 Polaris Sales Inc 2 41 MAINTENANCE NOTES 2 42 9923499 2011 2012 RANGER 800 Service Manual Copyright 2011 Polaris Sales Inc
32. enance m CAUTION Due to the nature of these adjustments it is recommended this service be performed by an authorized Polaris dealer gt SEVERE USE ITEM See information provided above E Emission Control System Service California NOTE Inspection may reveal the need for replacement parts Always use genuine Polaris parts WARNING Improperly performing the procedures marked M could result in component failure and lead to serious injury or death Have an authorized Polaris dealer perform these services 2 3 9923499 2011 2012 RANGER 800 Service Manual Copyright 2011 Polaris Sales Inc MAINTENANCE Pre Ride 25 Hour Maintenance Interval Maintenance Interval whichever comes first Item Miles Remarks i Hours Calendar KM m Steering Pre Ride Front Suspension Pre Ride gt Rear Suspension Pre Ride Tires Pre Ride Brake Fluid Level Pre Ride Make adjustments as needed gt Brake Pedal Travel Pre Ride c See Pre Ride Checklist on Page 2 10 Brake Systems Pre Ride Wheels Fasteners Pre Ride Frame Fasteners Pre Ride M Engine Oil Level Pre Ride E k Air Filter Pre Filter Daily Inspect clean often la Air Box Sediment Tube E Daily E Drain deposits when visible Coolant Level p Daily Check level daily change coolant every 2 years g E Check operation apply dielectric
33. erformed by an authorized Polaris MSD certified technician when replacing worn or damaged steering parts Use only genuine Polaris replacement parts Tie Rod End Steering Inspection e To check for play in the tie rod end grasp the steering tie rod pull in all directions feeling for movement e Replace any worn steering components Steering should move freely through entire range of travel without binding e Elevate front end of machine so front wheels are off the ground Check for any looseness in front hub wheel assembly by grasping the tire firmly at top and bottom first and then at front and rear Try to move the wheel and hub by pushing inward and pulling outward If abnormal movement is detected inspect the hub and wheel assembly to determine the cause loose wheel nuts or loose front hub nut Refer to the Body Steering or Final Drive chapter for more information Wheel Toe Alignment Inspection 1 Place machine on a smooth level surface and set steering wheel in a straight ahead position Secure the steering wheel in this position 2 Place achalk mark on the center line of the front tires approximately 10 25 4 cm from the floor or as close to the hub axle center line as possible He Measure Here Mark A measure then roll forward A and measure B ff NOTE It is important the height of both marks be equally positioned to get an accurate measurement
34. he following chart are based upon average riding conditions and an average vehicle speed of approximately 10 miles per hour Vehicles subjected to severe use must be inspected and serviced more frequently Severe Use Definition e Frequent immersion in mud water or sand e Racing or race style high RPM use e Prolonged low speed heavy load operation Extended idle e Short trip cold weather operation Pay special attention to the oil level A rise in oil level during cold weather can indicate contaminants collecting in the oil sump or crankcase Change oil immediately if the oil level begins to rise Monitor the oil level and if it continues to rise discontinue use and determine the cause or see your dealer Break In Period The break in period consists of the first 25 hours of operation or the time it takes to use 14 gallons 53 liters of fuel Careful treatment of a new engine and drive components will result in more efficient performance and longer life for these components e Drive vehicle slowly at first while varying the throttle position Do not operate at sustained idle e Pull only light loads e Perform regular checks on fluid levels and other areas outlined on the daily pre ride inspection checklist e Change both the engine oil and filter after 25 hours or one month e See Owner s Manual for additional break in information Maintenance Chart Key The following symbols denote potential items to be aware of during maint
35. icant level Fill Plug 10 14 ft Ibs 14 19 Nm 5 Ifparticles are still suspected to be in the muffler drive the machine onto the incline so the front of the machine is one foot higher than the rear Set the parking brake block the wheels and repeat Steps 2 and 3 6 Repeat steps 2 through 5 until no more particles are expelled when the engine is revved Transmission lubricant 7 Stop the engine and allow the arrestor to cool flush with the bottom of thread area 8 Reinstall the clean out plugs 3 If lubricant level is not even with bottom threads add recommended lubricant as needed Do not overfill 4 Reinstall the fill plug and torque to specification T Drain Fill Plug 10 14 ft Ibs 14 19 Nm 2 19 9923499 2011 2012 RANGER 800 Service Manual Copyright 2011 Polaris Sales Inc MAINTENANCE Transmission Lubricant Change 2011 The drain plug is located on the right side of the transmission Access the drain plug from the rear right hand side of the vehicle 1 Remove the fill plug refer to Transmission Lubricant Level Check Place a drain pan under the transmission drain plug Remove the drain plug and allow lubricant to drain completely Fill Plug 10 14 ft Ibs 14 19 Nm Drain Plug 10 14 ft Ibs 14 19 Nm 4 Clean the drain plug magnetic surface Reinstall drain plug with a new O ring and torque to specification 5 Add the reco
36. id plate 1 Remove the fill plug refer to Transmission Lubricant Level Check 2 Place a drain pan under the transmission drain plug 3 Remove the drain plug and allow lubricant to drain completely Fill Plug 10 14 ft Ibs 14 19 Nm Drain Plug 10 14 ft Ibs 14 19 Nm 4 Clean the drain plug magnetic surface Reinstall drain plug with a new O ring and torque to specification 5 Add the recommended amount of lubricant through the fill plug hole Maintain the lubricant level at the bottom of the fill plug hole when filling the transmission Do not overfill Recommended Transmission Lubricant AGL Plus PN 2878068 Quart Capacity 43 6 oz 1290 ml 6 Reinstall fill plug with a new O ring and torque to specification 7T Drain Fill Plug 10 14 ft Ibs 14 19 Nm 7 Check for leaks Dispose of used lubricant properly 2 22 Front Gearcase Lubrication NOTE It is important to follow the front gearcase maintenance intervals described in the Periodic Maintenance Chart Regular fluid level inspections should be performed as well The front gearcase fluid level should be checked and changed in accordance with the maintenance schedule e Be sure vehicle is positioned on a level surface when checking or changing the fluid e Check vent hose to be sure it is routed properly and unobstructed Front Gearcase Fluid Level Check The fill plug is located on the
37. ional 1 2 turn 13 Remove the dipstick and fill the sump with 2 quarts 1 9 L of Polaris PS 4 Plus Synthetic Engine Oil PN 2876244 2 18 14 Place gear selector in neutral and set parking brake 15 Start the engine and let it idle for one to two minutes Stop the engine and inspect for leaks 16 Re check the oil level on the dipstick and add oil as necessary to bring the level to the upper mark on the dipstick 17 Dispose of used oil and oil filter properly Exhaust Pipe WARNING Do not perform clean out immediately after the engine has been run as the exhaust system becomes very hot Serious burns could result from contact with exhaust components To reduce fire hazard make sure that there are no combustible materials in the area when purging the spark arrestor Wear eye protection Do not stand behind or in front of the vehicle while purging the carbon from the spark arrestor Never run the engine in an enclosed area Exhaust contains poisonous carbon monoxide gas Do not go under the machine while it is inclined Set the hand brake and block the wheels to prevent roll back Failure to heed these warnings could result in serious personal injury or death The exhaust pipe must be periodically purged of accumulated carbon as follows 1 Remove the clean out plug s located on the bottom of the muffler as shown below Clean Out Plug 2 Set the parking brake and start the engi
38. ler perform these services 2 5 9923499 2011 2012 RANGER 800 Service Manual Copyright 2011 Polaris Sales Inc MAINTENANCE 100 500 Hour Maintenance Interval Maintenance Interval whichever comes first Item etl meas Me Remarks i Hours Calendar Km gt Cooling Hoses 100 H 12M 1000 1600 Inspect for leaks gt Engine Mounts 100 H 12M 1000 1600 Inspect Exhaust Silencer Pipe 100 H 12M 1000 1600 Inspect E Spark Plug 100 H 12M 1000 1600 Inspect replace as needed Inspect for wear routing security apply gt Wiring 100 H 12M 1000 1600 dielectric grease to connectors subjected to water mud etc m Clutches Drive and Driven 100 H 12M 1000 1600 Inspect clean replace worn parts m Front Wheel Bearings 100 H 12M 1000 1600 Inspect replace as needed Shocks 100 H Visually inspect shock seals m Brake Fluid 200 H 24M 2000 3200 Change every two years DOT 4 Spark Arrestor 300 H 36 M 3000 4800 Clean out Shocks Walker Evans 500 H 12M Change shock oil and replace seals m Toe Adjustment g Inspect periodically adjust when parts are replaced Headlight Aim Adjust as needed gt Perform these procedures more often for vehicles subjected to severe use E Emission Control System Service California m Have an authorized Polaris dealer perform these services Grease Lubrication Points Item Recommen
39. m nut with a wrench and tighten the inside jam nut clockwise until it is tight against the bracket 5 Repeat Step 3 and Step 4 until the proper adjustment is made to the shift cable 6 Use this procedure to loosen or tighten the shift linkage cable as needed 9923499 2011 2012 RANGER 800 Service Manual O Copyright 2011 Polaris Sales Inc MAINTENANCE Shift Cable Adjustment 6x6 NOTE The shift cable should be adjusted at the rear adjustment point located near the transmission If adjustment is needed beyond that remove the dash panel to access the shift cable adjustment point located underneath the shift lever 1 Place gear selector in neutral Make sure the transmission bell crank is engaged in the neutral position detents D AN Adjustment a Point E y A ma H PP E i A f Y DAS jm Neutral Position am 2 Locate the shift cable adjustment point attached to the frame in front of the transmission 3 With two open end wrenches loosen the outside jam nut counterclockwise Turn the outside jam nut 1 1 2 turns Outside Jam Nut MY y y 2 KY Inside Jam Nut 4 After turning the outside jam nut 1 1 2 turns Hold the outside jam nut with a wrench and tighten the inside jam nut clockwise until it is tight against the bracket 5 Repeat Step 3 and Step 4 until the proper adjustment is made for the transmission cable 6 Use this procedure to loose
40. mmended amount of lubricant through the fill plug hole Maintain the lubricant level at the bottom of the fill plug hole when filling the transmission Do not overfill Recommended Transmission Lubricant AGL Plus PN 2878068 Quart Capacity 33 8 oz 1000 ml 6 Reinstall fill plug with a new O ring and torque to specification E 1 Drain Fill Plug 10 14 ft Ibs 14 19 Nm 7 Check for leaks Dispose of used lubricant properly 2 20 2012 Transmission Lubrication XP HD CREW NOTE It is important to follow the transmission maintenance intervals described in the Periodic Maintenance Chart Regular fluid level inspections should be performed as well The transmission lubricant level should be checked and changed in accordance with the maintenance schedule e Be sure vehicle is positioned on a level surface when checking or changing the lubricant e Check vent hose to be sure it is routed properly and unobstructed Transmission Lubricant Level Check 2012 The fill plug is located at the rear of the transmission The check plug is located on the right side of the transmission Maintain the fluid level even with the bottom threads of the check plug hole 1 Position vehicle on a level surface 2 Remove the check plug and check the lubricant level Fill Plug 10 14 ft Ibs 14 19 Nm Check Plug 10 14 ft Ibs 14 19 Nm Transmission lubricant flush with the bottom of
41. n enclosed space Always shield eyes when working near batteries KEEP OUT OF REACH OF CHILDREN NOTE Batteries must be fully charged before use or battery life will be reduced by 10 30 of full potential Charge battery for 3 5 hours at a current equivalent of 1 10 of the battery s rated amp hour capacity Do not use the alternator to charge a new battery 2 32 Battery Fluid Level Conventional Battery A poorly maintained battery will deteriorate rapidly Check the battery fluid level often Maintain the fluid level between the upper and lower level marks Upper Level Lower Level Add only distilled water Tap water contains minerals that are harmful to a battery Battery Removal 1 Open the hood to access the battery EN Remove hold down strap and vent tube from battery Disconnect the black negative battery cable Disconnect the red positive battery cable OU 2 00 O Lift the battery out of the vehicle being careful not to tip it sideways and spill any electrolyte CAUTION To reduce the chance of sparks Whenever removing the battery disconnect the negative black cable first When reinstalling the battery install the negative cable last 9923499 2011 2012 RANGER 800 Service Manual Copyright 2011 Polaris Sales Inc MAINTENANCE Battery Installation 8 Verify that cables are properly routed and install the hold down strap Using a new b
42. n or tighten the shift linkage cable as needed 9923499 2011 2012 RANGER 800 Service Manual Copyright 2011 Polaris Sales Inc 2 11 MAINTENANCE FUEL SYSTEM AND AIR INTAKE Fuel System A WARNING Gasoline is extremely flammable and explosive under certain conditions Always stop the engine and refuel outdoors or in a well ventilated area Do not smoke or allow open flames or sparks in or near the area where refueling is performed or where gasoline is stored Do not overfill the tank Do not fill the tank neck If you get gasoline in your eyes or if you swallow gasoline seek medical attention immediately If you spill gasoline on your skin or clothing immediately wash it off with soap and water and change clothing Never start the engine or let it runin an enclosed area Engine exhaust fumes are poisonous and can result in loss of consciousness or death in a short time Never drain the fuel when the engine is hot Severe burns may result Fuel Lines 1 Check fuel lines for signs of wear deterioration damage or leakage Replace if necessary 2 Be sure fuel lines are routed properly and secured with cable ties CAUTION Make sure lines are not kinked or pinched 3 Replace all fuel lines every two years Vent Lines 1 Check fuel tank vent lines for signs of wear deterioration damage or leakage Replace every two years 2 Be sure vent lines are routed properly and secured with ca
43. ne Purge accumulated carbon from the system by momentarily revving the engine several times 9923499 2011 2012 RANGER 800 Service Manual Copyright 2011 Polaris Sales Inc MAINTENANCE 3 If some carbon is expelled cover the exhaust outlet TRANSMISSION AND GEARCASES and lightly tap on the pipe around the clean out plugs with a rubber mallet while revving the engine several 2011 Transmission Lubrication more umes XP HD CREW NOTE It is important to follow the transmission maintenance intervals described in the Periodic Maintenance Chart Regular fluid level inspections should be performed as well The transmission lubricant level should be checked and changed in accordance with the maintenance schedule e Be sure vehicle is positioned on a level surface when checking or changing the lubricant 4 If particles are still suspected to be in the muffler back Check vent hose to be sure it is routed properly the machine onto an incline so the rear of the machine and unobstructed is one foot higher than the front Set the parking brake block the wheels and repeat Steps 2 and 3 Transmission Lubricant Level Check 2011 The fill plug is located on the right side of the transmission Access the fill plug from the rear right hand side of the vehicle Maintain the fluid level even with the bottom threads of the fill plug hole 1 Position vehicle on a level surface 2 Remove the fill plug and check the lubr
44. oad Increase Preload Ut Le Factory Preload Setting 10 75 in 27 3 cm Front Shock ce CHES Increase 0 Preload Le Decrease E Preload 3 22 Factory Preload Setting 10 5 in 26 7 cm Rear Shock 2 38 Shock Spanner Wrench PN 2870803 Shock Compression Adjustment The compression damping adjustment is located on top of the remote shock reservoir on each shock Damping adjustments can be made without using any tools NOTE When the adjuster knob is turned counter clockwise until it stops the damping is in the fully open position Soft Turn the clicker clockwise to increase compression damping Turn the clicker counter clockwise to decrease compression damping NOTE The factory setting is 8 clicks clockwise from the softest position see Compression Adjustment Table Clicker Knob Increase Damping Compression Adjustment Table Setting Compression Damping Softest Full counter clockwise position Factory 8 clicks from softest position Firmest Full clockwise position 9923499 2011 2012 RANGER 800 Service Manual O Copyright 2011 Polaris Sales Inc MAINTENANCE BRAKE SYSTEM Brake Pad Disc Inspection Brake Fluid Inspection looseness Always check the brake pedal travel and inspect the brake fluid reservoir level before each operation If the fluid level 2 Inspect the brake pad wear surface for excessive is low a
45. oolant every 2 years Maintain fluid level between MAX and MIN lines on the master cylinder reservoir 3 Brake Fluid Polaris DOT 4 Brake Fluid Check level during pre ride inspection change fluid every two years More often under severe use such as operated in water or under severe loads 3 Brake Fluid Front LH wheel well 1 Engine Oil Under seat base Engine Oil Dipstick Master Cylinder 2 Engine Coolant A Recovery Je O Bottle lt 7 SN LA y NS Y Open front hood to add coolant View level through front RH wheel well Reservoir Radiator Cap 2 8 9923499 2011 2012 RANGER 800 Service Manual Copyright 2011 Polaris Sales Inc MAINTENANCE Component Quick Reference Continued Il Item Lube Rec Method Frequency 4 Front Gearcase Polaris Demand Drive Plus Add lubricant until it is visible Check level every 25 hours at the fill hole threads change according to intervals 5 Mid Gearcase Polaris ATV Angle Drive Add lubricant until it is visible Check level every 25 hours Fluid ADF at the fill hole threads change fluid yearly Rear Ge rcase Polaris ATV Angle Drive Add lubricant until it is visible Check level every 25 hours Fluid ADF at the fill hole threads change fluid yearly 7 Transmission Polaris AGL Plus Add lubricant until it is visible Check level every 25 hou
46. pressure 16 Remove the lower coolant hose and drain the coolant from the radiator and hose Allow the coolant to completely drain Properly dispose of the used coolant 10 Carefully lift up on the hood liner and lift it up far enough to allow radiator removal NOTE Turn coolant pressure cap to allow the hood liner to clear the cap 11 Remove the 2 screws retaining the upper portion of the radiator to the frame 17 Remove the upper coolant hose 18 Remove the recovery bottle return line from the radiator 19 Disconnect the fan motor electrical connector 20 Carefully lift the radiator fan motor from the vehicle as an assembly Take care not to damage the cooling fins 12 Remove the push rivets and front LH wheel well panel to access the lower coolant hose at the radiator 13 Place a suitable drain pan under the LH side of the radiator 2 29 9923499 2011 2012 RANGER 800 Service Manual Copyright 2011 Polaris Sales Inc MAINTENANCE 21 Remove the 4 bolts that retain the fan motor assembly and service radiator or fan as needed Fan Motor and Shroud 22 Reverse this procedure for installation 23 Upon installation be sure the lower radiator mounts are placed properly in the frame support Rubber Mounts 24 After the radiator is installed be sure the mounts have remained in place 25 After installation and reassembly remove the pressure cap and fill the
47. racks deterioration abrasion and leaks Tighten any loose fittings and replace any worn or damaged parts 9923499 2011 2012 RANGER 800 Service Manual Copyright 2011 Polaris Sales Inc 9 for 2 39 MAINTENANCE Parking Brake Cable Adjustment When the parking brake is fully engaged and the parking brake indicator is illuminated engine speed is limited to 1300 RPM in all gears including neutral If throttle is applied this limiting feature prevents operation which protects the parking brake pads from excessive wear NOTE Inspect the parking brake cable tension after the first 25 hours of operation and every 100 hours of operation afterwards to ensure proper cable tension Loss of tension in the parking brake cable will cause illumination of the parking brake indicator and activation of the limiting feature If this occurs inspect and adjust parking brake cable tension If performing this service is difficult due to conditions or location open the hood and temporarily disconnect the parking brake connector Reconnect the connector as soon as practicable and adjust the parking brake cable to proper tension 1 Pull back on the parking brake lever located in the dash 2 After 3 to 4 clicks BRAKE should display on the instrument cluster and the wheels of the vehicle should not rotate when turning by hand After 8 full clicks of lever travel the vehicle should not roll while parked 3 If the v
48. radiator and recovery bottle with coolant 26 Refer to the Cooling System Bleeding Procedure in Chapter 3 2 30 FINAL DRIVE WHEEL AND TIRE Wheel and Hub Torque Table Item Nut Type Specification pee Be 30 ft lbs 90 1 4 turn eee Fangs Nes hs 47 Nm Front Hub Nut 80 ft lbs 108 Nm nd 110 ft Ibs 150 Nm Steel Wheel Standard Models 35 ft Ibs 47 Nm Aluminum Wheel LE Models 30 ft Ibs 90 1 4 turn CV Shaft Boot Inspection Inspect the CV shaft boots in the front and rear of the RANGER for damage tears wear or leaking grease If the rubber boot exhibits any of these symptoms replace the boot Refer to Chapter 7 for CV boot replacement LT i Inspect Boots EES m Inspect Boots SSS 9923499 2011 2012 RANGER 800 Service Manual Copyright 2011 Polaris Sales Inc MAINTENANCE Wheel Removal Tire Inspection 1 Stop the engine place the transmission in gear and e Improper tire inflation may affect vehicle lock the parking brake maneuverability e When replacing a tire always use original equipment size and type 3 Elevate the side of the vehicle by placing a suitable The use of non standard size or type tires may stand under the footrest frame affect vehicle handling 2 Loosen the wheel nuts slightly 4 Remove the wheel nuts and washers and remove the wheel Tire Tread Depth i Replace tires when
49. rating temperature increases the expanding heated excess coolant is forced out of the radiator past the pressure cap and into the recovery bottle As engine coolant temperature decreases the contracting cooled coolant is drawn back up from the tank past the pressure cap and into the radiator NOTE Some coolant level drop on new machines is normal as the system is purging itself of trapped air Observe coolant levels often during the break in period Overheating of engine could occur if air is not fully purged from system Polaris Premium 60 40 coolant is already premixed and ready to use Do not dilute with water Coolant Level Inspection The recovery bottle and radiator pressure cap are located under the hood With the engine at operating temperature the coolant level should be between the MAX and MIN marks on the recovery bottle If not perform the following 1 Position the vehicle on a level surface 2 26 2 Check the coolant level in the recovery bottle located on the ride side of the machine The coolant level must be maintained between the MAX and MIN levels indicated on the recovery bottle ra 3 Ifthe coolant level is below the MIN mark open the hood to access the radiator pressure cap and recovery bottle cap NOTE If overheating is evident allow system to cool completely and check coolant level in the radiator and inspect for signs of trapped air in system
50. rs Gearcase Lubricant atthe check plug hole threads change lubricant yearly More often under severe use such as operated in water or under severe loads 4 Front Gearcase 7 Transmission XP HD CREW Front of vehicle Rear RH side of vehicle Models a o Check Fill Plug 5 Mid Gearcase 6x6 LH side of vehicle Fill Plug 6 Rear Gearcase 6x6 6X6 Rear of vehicle Models Check Fill Plug Check Fill Plug 2 9 9923499 2011 2012 RANGER 800 Service Manual Copyright 2011 Polaris Sales Inc MAINTENANCE GENERAL VEHICLE INSPECTION AND MAINTENANCE Pre Ride Daily Inspection Perform the following pre ride inspection daily and when servicing the vehicle at each scheduled maintenance Tires check condition and pressures Fuel tank fill tank to proper level All brakes check operation fluid level and adjustment includes parking brake Throttle check for free operation and closing Headlight Taillight Brakelight check operation of all indicator lights instrument cluster and switches Ignition switch check for proper function Wheels check for tightness of wheel nuts and axle nuts check to be sure axle nuts are secured by cotter pins Air cleaner element check for dirt clean or replace Steering check for free operation noting any unusual looseness in any area Loose parts visually inspect vehicle for any damaged or loose nut
51. s bolts or fasteners Engine coolant check for proper level at the recovery bottle Check all suspension components for wear or damage Frame Nuts Bolts and Fasteners Periodically inspect the torque of all fasteners in accordance with the maintenance schedule Check that all cotter pins are in place Refer to specific fastener torques listed in each chapter Shift Cable Inspection Shift cable adjustment is necessary when symptoms include e Noise on deceleration Inability to engage a gear Excessive gear clash noise e Gear selector is moving out of desired range Inspect shift cable clevis pins and pivot bushings and replace if worn or damaged 2 10 Shift Cable Adjustment XP HD CREW NOTE The shift cable should be adjusted at the rear adjustment point located near the transmission If adjustment is needed beyond that remove the dash panel to access the shift cable adjustment point located underneath the shift lever 1 Place gear selector in neutral Make sure the transmission bell crank is engaged in the neutral position detents x Neutral Position 2 Locate the shift cable adjustment point at the engine to transmission mount bracket 3 With two open end wrenches loosen the outside jam nut counterclockwise Turn the outside jam nut 1 1 2 turns Inside Jam Nut Mb y LA a Outside Jam Nut 4 After turning the outside jam nut 1 1 2 turns Hold the outside ja
52. schedule e Be sure vehicle is level with parking brake on before proceeding e Check vent hose to be sure it is routed properly and unobstructed Mid Gearcase Lubricant Level Check The fill plug is located on the left side of the mid gearcase Maintain the lubricant level even with the bottom threads of the fill plug hole 1 Position the vehicle on a level surface 2 Remove the fill plug and check the lubricant level see Side View 3 If lubricant level is not even with the bottom threads add the recommended lubricant as needed Do not overfill 4 Reinstall fill plug and torque to specification Fill Plug 14 ft Ibs 19 Nm Mid Gearcase Lubricant Change The drain plug is located on the bottom right side of the mid gearcase Access the drain plug through the skid plate 1 Remove the fill plug refer to Mid Gearcase Lubricant Level Check 2 Place a drain pan under the mid gearcase drain plug 3 Remove the drain plug and allow the lubricant to drain completely see Bottom View 4 Cleanand reinstall drain plug Torque to specification E T Drain Plug 14 ft Ibs 19 Nm 2 24 5 Add the recommended amount of lubricant through the fill hole Maintain the lubricant level even with the bottom threads of the fill plug hole N Recommended Mid Gearcase Lubricant ATV Angle Drive Fluid PN 2876160 Capacity 6 75 oz 200 ml 6 Reinstall fill
53. stick make certain to seat the lever lock 6 Remove dipstick and check to see that the oil level is in the SAFE range Add oil as indicated by the level on the dipstick Do not overfill see NOTE below MN Maintain Oil Level In SAFE Range DO NOT Overfill the Engine 9923499 2011 2012 RANGER 800 Service Manual O Copyright 2011 Polaris Sales Inc MAINTENANCE NOTE Due to the dipstick entry angle into the crankcase the oil level will read higher on the bottom side of the dipstick Proper level indication is determined on the upper surface of the dipstick as it is being removed regardless of the level marks being on top or on bottom see the next illustration Dipstick Always read top side of dipstick to properly check oil level in crankcase a NOTE A rising oil level between checks in cool weather driving can indicate contaminants such as gas or moisture collecting in the crankcase If the oil level is over the full mark change the oil immediately 7 Reinstall the dipstick and lock the lever Engine Oil and Filter Change gt 0 Recommended Engine Oil PS 4 Plus Synthetic 4 Cycle Engine Oil PN 2876244 Quart Capacity 2 Quarts 1 9 L 1 Place vehicle on a level surface and allow the engine to run for two to three minutes until warm Stop engine 2 Clean the area around the drain plug at the bottom of the crankcase Drain plug is accessible through the
54. system Straight water or antifreeze may cause the Shroud system to freeze corrode or overheat Radiator A 2 Carefully straighten any bent radiator fins Recommended Anti Freeze Coolant 3 Remove any obstructions with compressed air or low Polaris 60 40 Anti Freeze Coolant pressure water PN 2871534 Quart CAUTION Cooling System Hoses Washing the vehicle with a high pressure 1 Inspect all hoses for cracks deterioration abrasion washer could damage the radiator fins and or leaks Replace if necessary impair the radiators effectiveness Use of a high pressure washer is not recommended Clamp Hose E 7 to thermostat Coolant Drain SN Retainer 1 Remove the push rivets and front LH wheel well Boit panel to access the lower coolant hose at the ea radiator Y e L 2 Place a suitable drain pan under the LH side of the radiator 3 Allow the vehicle to cool down if recently operated Hose to waterpump A WARNING Never remove the pressure cap when the engine is warm or hot Escaping steam can Recovery A Bottle Radiator cause severe burns The engine must be cool before removing the pressure cap 2 Check tightness of all hose clamps 4 Open the hood and slowly open the radiator pressure A CAUTION cap to relieve system pressure 5 Remove the lower coolant hose and drain the coolant Do not over tighten hose clamps at radiator or from the radiator and
55. th of operation General beats 50 H 3M 500 800 AS all grease fittings pivots cables Shift Linkage 50 H 6M 500 800 Inspect lubricate adjust m Steering 50 H 6M 500 800 Lubricate if applicable Front Suspension 50 H 6M 500 800 Lubricate if applicable gt Re ce 50 H 6M 500 800 Lubricate if applicable gt Rear Suspension 50 H 6M 500 800 Lubricate if applicable m Throttle Cable Throttle 50H 6M 500 800 Inspect adjust lubricate replace if E Pedal necessary E O Hatake 50 H 6M 500 800 Inspect ducts for proper sealing air leaks Ducts Flange Drive Belt 50 H 6M 500 800 Inspect adjust replace as needed Inspect coolant strength seasonally Cooling System 50 H 6M 500 800 pressure test system yearly Parking Blake Gable 100 H 6M 1000 1600 Inspect adjust tension as needed m Adjustment gt Perform a break in oil change after the first E Engine Oil Change 100 H 6M 1000 1600 25 hours or one month of operation Oil Filter Change 100 H 6M 1000 1600 Replace with oil change ss Check for leaks at tank cap fuel lines fuel E Fuel System 100 H 12M 1000 1600 pump and fuel rail replace fuel lines every two years gt Radiator 100 H 12 M 1000 1600 Inspect clean external surfaces gt Perform these procedures more often for vehicles subjected to severe use E Emission Control System Service California m Have an authorized Polaris dea
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