The Ranger Crew 800, a versatile four-seater utility vehicle, was produced for the 2010, 2011, and 2012 model years. Engineered for recreational use, farming, hunting, and property management, this side-by-side (SxS) UTV boasts a robust ProStar 800 EFI engine and a durable chassis designed for demanding off-road conditions. Its 4-seater crew cab configuration, coupled with a practical cargo bed and towing capabilities, makes it a capable and reliable choice for various tasks and adventures. The manufacturer has consistently delivered vehicles known for their performance and innovation. This comprehensive service and repair manual provides in-depth information for the Ranger Crew 800. It covers all essential aspects of maintenance, diagnosis, and repair, including engine and powertrain systems, transmission and drivetrain, chassis and suspension, braking, and the electrical system. Detailed procedures for routine maintenance, component rebuilds, troubleshooting common issues, and specific technical specifications are included to assist owners and technicians. The manual is designed to facilitate the proper upkeep and repair of the vehicle, ensuring its continued optimal performance and longevity. 🏷️ Basic Information Identification Make: Polaris Model: Ranger Crew 800 Model Variant: Crew (4-seater) Product Type: Service & Repair Manual Product Format: PDF Download Codes Model Years Covered: 2010, 2011, 2012 Engine Code: ProStar 800 EFI 👋 Introduction Market Position Vehicle Type: Side-by-Side (SxS) Utility Vehicle / UTV Target Audience: Recreational users, farmers, hunters, property owners needing a versatile, multi-passenger off-road vehicle Competitive Analysis Key Competitors: John Deere Gator, Kawasaki Mule, Arctic Cat Prowler Key Features Passenger Capacity: 4-Seater Crew Cab configuration Powertrain: ProStar 800cc V-Twin engine, selectable 2WD/4WD Utility Focus: Cargo bed for hauling, towing capabilities, rugged construction for off-road use 📋 Manual Details Coverage Areas Comprehensive Coverage: Full factory service and repair Page Count Estimated Page Count: High (typical for factory manuals, precise count not stated but expected to be extensive for full service) Manual Type Manual Type: Workshop Manual / Service Manual Language Language: English Format Digital Format: PDF 📖 Manual Coverage Systems Covered Engine And Powertrain: Engine diagnosis, repair, overhaul, fuel system (EFI), cooling system, lubrication, ignition system, exhaust system Transmission And Drivetrain: CVT transmission service, belt inspection/replacement, drive shafts, differentials (front and rear), AWD system Chassis And Suspension: Frame inspection, suspension components (A-arms, shocks, springs), steering system, wheel bearings, bushings Brakes: Brake system diagnosis, hydraulic lines, calipers, master cylinder, brake pad/shoe replacement, bleeding procedures Electrical System: Battery, charging system (stator, regulator/rectifier), starter motor, lighting system, wiring diagrams, diagnostics, ECM/ECU troubleshooting Body And Interior: Body panel removal/installation, seats, seat belts, interior trim, cargo bed, body care and aesthetics Procedures Included Routine Maintenance: Oil changes, filter replacements, lubrication points, spark plug checks, air filter service, tire pressure checks Troubleshooting: Diagnostic charts, common problems and solutions, symptom-based troubleshooting guides Component Rebuilds: Detailed disassembly and reassembly instructions for major components (engine, transmission, differentials) Electrical Diagnostics: Wiring diagrams, voltage checks, component testing, PCM/ECM flashing and diagnostics Torque Specifications: Precise torque values for all critical fasteners Technical Depth Depth Of Information: Expert level, covering complete vehicle overhaul, advanced diagnostics, and component rebuilding 📊 Manual Specifications File Format File Format Details: PDF, typically high-resolution scans or digitally created documents with searchable text where available Print Quality Print Quality Notes: Designed for digital viewing and printing, with clear diagrams and text Binding Type Binding Type Digital: N/A (Digital Download) Paper Type Paper Type Digital: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Type: 4-Stroke, SOHC, V-Twin, 4-Valve Displacement: 760cc (approximate, often marketed as 800cc) Bore X Stroke: Refer to manual for specific dimensions (typically around 76mm x 74mm) Cooling System: Liquid-cooled Performance Horsepower Est: 50-55 HP (approximate, may vary slightly by year/tune) Torque Est: 45-50 lb-ft (approximate) Fuel System Fuel Delivery: Electronic Fuel Injection (EFI) Fuel Type: Unleaded gasoline, 87 octane (minimum) Lubrication Oil Type: SAE 0W-40 Synthetic (Polaris recommends) Oil Capacity: Refer to manual for exact capacity with filter change (typically around 2.0-2.5 liters) Ignition Spark Plug Type: Refer to manual for specific NGK or Champion part number, e.g., NGK CR7E Spark Plug Gap: Refer to manual for precise gap (typically 0.028-0.032 inches) 🔧 Transmission Standard Transmission Type: Automatic (CVT - Continuously Variable Transmission) Drive Modes: High, Low, Neutral, Reverse, Park Features Cv Belt Inspection Interval: Refer to manual (typically every 100-200 hours or annually) Gear Reduction Ratio: Refer to manual for specific ratios in low and high range Fluid Type Cv Transmission Fluid: Refer to manual for Polaris PVT Fluid or equivalent (e.g., AFT) 📐 Dimensions Exterior Overall Length: Approx. 129.2 inches (3282 mm) Overall Width: Approx. 60 inches (1524 mm) Overall Height: Approx. 74.7 inches (1897 mm) Wheelbase: Approx. 86.3 inches (2192 mm) Cargo Cargo Bed Dimensions: Refer to manual for specific dimensions Cargo Bed Capacity: Approx. 1000 lbs (453.6 kg) Weights Dry Weight: Approx. 1160 lbs (526 kg) Towing Capacity: Approx. 1500 lbs (680 kg) Payload Capacity: Approx. 1000 lbs...