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POLARIS RANGER CREW 800 ATV Full Service & Repair Manual 2010-2012

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🏷️ 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 (453.6 kg) 🛡️ Safety Features Ratings Rollover Protection: ROPS (Roll-Over Protective Structure) compliant for operator safety Active Features Braking System: Hydraulic disc brakes front and rear Selectable AWD: On-demand all-wheel drive system for enhanced traction Passive Features Seat Belts: 3-point seat belts for all occupants Doors: Full doors with integrated hand restraints (depending on trim/options) Lighting: Dual 50W headlights, LED taillights 💡 Technology Features Infotainment Instrument Cluster: Digital gauge cluster displaying speed, RPM, fuel level, engine temp, gear position, AWD status, etc. Driver Assistance Throttle Control: Electronic Throttle Control (ETC) for smooth acceleration Connectivity Accessory Ports: 12V accessory outlets for charging electronics (refer to manual for specific locations and ratings) 🔧 Maintenance Service Intervals Engine Oil Change: Every 100 hours or 12 months (whichever comes first) Air Filter Cleaning: Every 50 hours or 6 months; replacement as needed Spark Plug Inspection: Every 100 hours or 12 months Cv Belt Inspection: Every 100 hours or 12 months Brake Fluid Check: Every 50 hours or 6 months Fluid Specifications Engine...
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POLARIS RANGER CREW 800 ATV Full Service & Repair Manual 2010-2012
🏷️ 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 (453.6 kg)
🛡️ Safety Features
Ratings
Rollover Protection:
ROPS (Roll-Over Protective Structure) compliant for operator safety
Active Features
Braking System:
Hydraulic disc brakes front and rear
Selectable AWD:
On-demand all-wheel drive system for enhanced traction
Passive Features
Seat Belts:
3-point seat belts for all occupants
Doors:
Full doors with integrated hand restraints (depending on trim/options)
Lighting:
Dual 50W headlights, LED taillights
💡 Technology Features
Infotainment
Instrument Cluster:
Digital gauge cluster displaying speed, RPM, fuel level, engine temp, gear position, AWD status, etc.
Driver Assistance
Throttle Control:
Electronic Throttle Control (ETC) for smooth acceleration
Connectivity
Accessory Ports:
12V accessory outlets for charging electronics (refer to manual for specific locations and ratings)
🔧 Maintenance
Service Intervals
Engine Oil Change:
Every 100 hours or 12 months (whichever comes first)
Air Filter Cleaning:
Every 50 hours or 6 months; replacement as needed
Spark Plug Inspection:
Every 100 hours or 12 months
Cv Belt Inspection:
Every 100 hours or 12 months
Brake Fluid Check:
Every 50 hours or 6 months
Fluid Specifications
Engine Oil Specification:
SAE 0W-40 Synthetic, API CI-4 rated (Polaris APL 23676 or equivalent)
Coolant Type:
Ethylene glycol-based antifreeze (50/50 mix with distilled water) - Polaris branded coolant recommended
Brake Fluid Type:
DOT 4 Hydraulic Brake Fluid
Gearcase Lubricant:
SAE 80W-90 Hypoid Gear Lubricant (Polaris brand recommended)
Known Issues
Cv Belt Wear:
Premature wear can occur with aggressive riding, overloading, or incorrect belt tension. Manual provides inspection criteria.
Suspension Bushings:
Wear can lead to clunking noises and steering looseness. Manual details replacement procedures.
Fuel Pump Reliability:
Some units may experience issues with the fuel pump over time; manual aids in diagnosis.
Charging System Issues:
Stator or regulator/rectifier failure can lead to battery charging problems. Manual provides testing procedures.
📚 Vehicle History
Brand Heritage
Manufacturer:
Polaris Industries, a long-standing leader in powersports vehicles
Model Evolution
Ranger Lineup:
The Ranger line has been a cornerstone of Polaris' UTV offerings, evolving from basic utility models to feature-rich, multi-passenger vehicles like the Crew 800.
Production
Production Period For Model:
The 800cc engine platform was widely used by Polaris across various models, including the Ranger, during this timeframe. The Crew 800 specifically catered to the growing demand for 4-seater UTVs.
🏆 Awards & Recognition
Recognitions
Polaris Reputation:
Polaris is consistently recognized for innovation and performance in the powersports industry, with the Ranger line being a benchmark for utility and comfort.
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