maintenance - Polaris

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MAINTENANCEEngine OilOil and Filter ChangeAlways change the oil and filter at the intervals outlined in the Periodic Maintenance Chartbeginning on page 43. Always change the oil filter whenever changing oil.1. Position the vehicle on a level surface.2. Run the engine for two to three minutes until warm. Stop the engine.3. Clean the area around the drain plug.4. Place a drain pan beneath engine crankcase.CAUTION! Hot oil can cause burns to skin. Do not allow hot oil to contact skin.5. Remove the drain plug.6. Allow the oil to drain completely.7. Reinstall the sealing washer on the drain plug. The sealing surfaces on drain plug andcrankcase should be clean and free of burrs, nicks or scratches.8. Reinstall the drain plug. Torque to 20 ft. lbs. (27 Nm).9. Remove the seat and the underseat storage box.10. Place shop towels beneath the oil filter. Using an oil filter wrench, turn the filter counterclockwiseto remove it.11. Using a clean dry cloth, clean the filter sealing surface on the crankcase.12. Lubricate the o-ring on the new filter with a film of fresh engine oil. Check to make surethe o-ring is in good condition.13. Install the new filter and turn by hand until the filter gasket contacts the sealing surface,then turn and additional 1/2 turn.14. Remove the dipstick and fill the sump with two quarts (1.9 l) of recommended oil.15. Shift the transmission to neutral.16. Apply the brakes. Engage the park brake.17. Start the engine. Allow it to idle for one to two minutes.18. Stop the engine. Inspect for leaks.19. Check the oil level on the dipstick and add oil as necessary to bring the level to the uppermark on the dipstick.20. Reinstall the underseat storage box and the seat.21. Dispose of used filter and oil properly.48
GearcasesGearcase Specification ChartMAINTENANCERANGER 4X4 Gearcase SpecificationsGearcase Lubricant Capacity Fill Plug(s)TorqueMain Gearcase(Transmission)Front GearcaseAGL PLUSTransmission FluidDemand Drive PlusFluid34 oz.(1000 ml)9.3 oz.(275 ml)12 ft. lbs.(16.3 Nm)8-10 ft. lbs.(11-13.6 NmDrain Plug Torque12 ft. lbs.(16.3 Nm)11 ft. lbs.(15 Nm)RANGER 6x6 Gearcase SpecificationsGearcase Lubricant Capacity Fill Plug Torque Drain Plug TorqueMain Gearcase(Transmission)Front GearcaseMiddle GearcaseRear GearcaseAGL PLUSTransmission FluidDemand Drive PlusFluidPremium ATV AngleDrive FluidPremium ATV AngleDrive Fluid43.6 oz.(1290 ml)9.3 oz.(275 ml)6.75 oz.(200 ml)18 oz.(532 ml)12 ft. lbs.(16.3 Nm)8-10 ft. lbs.(11-13.6 Nm14 ft. lbs.(19.4 Nm)14 ft. lbs.(19.4 Nm)12 ft. lbs.(16.3 Nm)11 ft. lbs.(15 Nm)14 ft. lbs.(19.4 Nm)14 ft. lbs.(19.4 Nm)RANGER CREW Gearcase SpecificationsGearcase Lubricant Capacity Fill Plug(s)TorqueMain Gearcase(Transmission)Front GearcaseAGL PLUSTransmission FluidDemand Drive PlusFluid34 oz.(1000 ml)9.3 oz.(275 ml)12 ft. lbs.(16.3 Nm)8-10 ft. lbs.(11-13.6 NmDrain Plug Torque12 ft. lbs.(16.3 Nm)11 ft. lbs.(15 Nm)49
Page 1 and 2: RANGER® 800RANGER® 6X6 800RANGER
Page 3 and 4: The text is printed on 100% recycle
Page 5 and 6: WELCOMEThank you for purchasing a P
Page 7 and 8: TABLE OF CONTENTSIntroduction . . .
Page 9 and 10: INTRODUCTIONVehicle Identification
Page 11 and 12: Safety Labels and LocationsDiscreti
Page 13 and 14: Safe Riding GearAlways wear appropr
Page 15 and 16: SAFETYOperator Safety• Always fol
Page 17 and 18: Operator SafetySAFETYWARNINGFailure
Page 19 and 20: Operator SafetyTurning ImproperlySA
Page 21 and 22: ConsolePark BrakeLeverGear Selector
Page 23 and 24: FEATURES AND CONTROLSTrailer Hitch
Page 25 and 26: FEATURES AND CONTROLSCab NetsRiding
Page 27 and 28: FEATURES AND CONTROLSRollover Prote
Page 29 and 30: Instrument ClusterRider Information
Page 31 and 32: FEATURES AND CONTROLSInstrument Clu
Page 33 and 34: WARNINGOPERATIONFailure to operate
Page 35 and 36: OPERATIONStarting the Engine1. Alwa
Page 37 and 38: Driving on Slippery SurfacesWARNING
Page 39 and 40: OPERATIONDriving Through WaterYour
Page 41 and 42: Hauling CargoOPERATIONWARNINGHaulin
Page 43 and 44: Dumping the Cargo Box1. Select a le
Page 45 and 46: All Wheel Drive (AWD)Locking the Di
Page 47 and 48: MAINTENANCEPeriodic Maintenance Cha
Page 49 and 50: Periodic Maintenance ChartMAINTENAN
Page 51: MAINTENANCEEngine Intake Restrictor
Page 55 and 56: MAINTENANCEGearcasesTransmission (M
Page 57 and 58: MAINTENANCEGearcasesMiddle Gearcase
Page 59 and 60: MAINTENANCESpark PlugsSpark Plug Re
Page 61 and 62: MAINTENANCECooling SystemOverflow B
Page 63 and 64: MAINTENANCEPOLARIS Variable Transmi
Page 65 and 66: Spark ArresterWARNINGMAINTENANCEFai
Page 67 and 68: MAINTENANCEBrakesThe front and rear
Page 69 and 70: TiresWARNINGMAINTENANCEOperating yo
Page 71 and 72: MAINTENANCELightsPoor lighting can
Page 73 and 74: MAINTENANCEFusesIf the engine stops
Page 75 and 76: Swim and Survive deliveredvia class
Page 77 and 78: MAINTENANCEBatteryBattery Charging
Page 79 and 80: Cleaning and StorageStorage TipsMAI
Page 81 and 82: MAINTENANCERemoval from Storage1. C
Page 83 and 84: SPECIFICATIONSRANGER 4X4Driving Sys
Page 85 and 86: SPECIFICATIONSRANGER 6X6Driving Sys
Page 87 and 88: SPECIFICATIONSRANGER CREWDriving Sy
Page 89 and 90: Drive Belt Wear/BurnTROUBLESHOOTING
Page 91 and 92: Engine Runs Irregularly, Stalls or
Page 93 and 94: WARRANTYLIMITATIONS OF WARRANTIES A
Page 95 and 96: U.S.A. EPA Emissions Limited Warran
Page 97 and 98: Use the following chart to record p
Page 99 and 100: FFan, Cooling . . . . . . . . . . .

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