CHAPTER 1 GENERAL INFORMATION - Alternative Support

1 GENERAL 1 GENERAL INFORMATION19923499 - 2011 / 2012 RANGER 800 Service Manual Copyright 2011 Polaris Sales INFORMATION .. IDENTIFICATION .. DESIGNATION NUMBER .. IDENTIFICATION .. AND ENGINE SERIAL NUMBER LOCATIONS .. INFORMATION .. NUMBERS .. KEYS .. TOOLS .. GENERAL SPECIFICATIONS .. : 2011 RANGER XP 800 / EPS .. : 2011 RANGER XP 800 / EPS .. : 2011 RANGER HD 800 .. : 2011 RANGER HD 800.. : 2011 RANGER CREW 800 / EPS .. : 2011 RANGER CREW 800 / EPS.. : 2011 RANGER 6X6 800 .. : 2011 RANGER 6X6 800 .. GENERAL SPECIFICATIONS .. : 2012 RANGER XP 800 / EPS .. : 2012 RANGER XP 800 / EPS .. : 2012 RANGER HD 800 .. : 2012 RANGER HD 800.. : 2012 RANGER CREW 800 / EPS .. : 2012 RANGER CREW 800 / EPS.. : 2012 RANGER 6X6 800 .. : 2012 RANGER 6X6 800 .. SPECIFICATIONS AND CHARTS .. TABLE .. BOLT TORQUE SPECIFICATION.. BOLT TORQUE SPECIFICATION.. TAP / DRILL SIZES .. TAP / DRILL SIZES.

2 EQUIVALENTS .. OF TERMS.. INFORMATION9923499 - 2011 / 2012 RANGER 800 Service Manual Copyright 2011 Polaris Sales INFORMATIONM odel IdentificationThe machine model number must be used with any correspondence regarding warranty or Designation Number1204172 RGR800-11, Cylinder, Liquid Cooled, 4-Cycle OHV, Electric Start 1204397 Cylinder, Liquid Cooled, 4-Cycle OHV, Electric Start 1204486 Cylinder, Liquid Cooled, 4-Cycle OHV, Electric StartVIN IdentificationVehicle and Engine Serial Number LocationsWhenever corresponding about a Polaris RANGER utility vehicle, be sure to refer to the vehicle identification number (VIN) and the engine model number and serial VIN can be found stamped on the lower frame rail on the front LH side of the vehicle (see Figure 1-1).The engine model and serial number can be found on a decal applied to the side of the engine s cylinder (see Figure 1-2).}Machine Model Number Identification}}Model Year Designation Basic Chassis Designation Engine Designation Emissions & Model Option R 1 2 T H 7 6 A G}4 X A T H 7 6 A * C P 0 0 0 0 0 0 }1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 World Mfg.

3 IDEngine Vehicle Description Vehicle Identifier Check Digit ModelYear Body Style Plant Serial No.* This could be either a number or a letterPowertrain Emissions Figure 1-1 VINF igure 1-2 EngineSerial INFORMATION19923499 - 2011 / 2012 RANGER 800 Service Manual Copyright 2011 Polaris Sales INFORMATIONP ublication Numbers(CA): California 50-State ModelsNOTE: When ordering service parts be sure to use the correct parts : Polaris factory publications can be found at or purchased from KeysReplacement keys can be made from the original key. To identify which series the key is, take the first two digits on the original key and refer to the chart to the right for the proper part TOOLSS pecial tools may be required while servicing this vehicle. Some of the tools listed or depicted are mandatory, while other tools may be substituted with a similar tool, if available. Polaris recommends the use of Polaris Special Tools when servicing any Polaris product.

4 Dealers may order special tools through Polaris official tool supplier, SPX Corporation, by phone at 1-800-328-6657 or on-line at s Manual PNParts Manual PN2011 RANGER XP 800 (CA)R11TH76AA, AB, AC, AF, AG, AH, AK, AO, AR, AZ (AAC, ABC, ACC, AFC, AGC, AHC, AKC, AOC, ARC, AZC)992312599231372011 RANGER XP 800 EPS (CA)R11TY76AB, AG, AR, AV, AZ (ABC, AGC, ARC, AVC, AZC)992312599231372011 RANGER HD 800R11TY76AN992312599231372011 RANGER CREW 800R11WH76AG, AR992312599231462011 RANGER CREW 800 EPSR11WY76AE, AH, AJ992312599231462011 RANGER 6X6 800R11HR76AG, AR992312599231262012 RANGER XP 800 (CA)R12TH76AA, AG, AH, AI, AM, AR, AW (AAC, AGC, AHC, AMC, ARC, AWC)992349799235152012 RANGER XP 800 EPS (CA)R12TH7 EAB, AG, AR, AZ (ABC, AGC, ARC, AZC)992349799235152012 RANGER HD 800R12TX7 EAN992349799235152012 RANGER CREW 800R12WH76AG, AR992349799235272012 RANGER CREW 800 EPSR12WH7 EAH, AV992349799235412012 RANGER 6X6 800R12HR76AG, AR99234979923498 Series#Part Number2040102782140102782240103212340103 2127401032128401032131411014132411014867 4010278684010278 Key SeriesNumberKEY COVERP/N INFORMATION9923499 - 2011 / 2012 RANGER 800 Service Manual Copyright 2011 Polaris Sales GENERAL SPECIFICATIONSMODEL: 2011 RANGER XP 800 / EPSMODEL NUMBER: R11TH76AA,AAC,AB,ABC,AC,ACC,AF,AFC,AG,AG C,AH,AHC,AK,AKC,AO,AOC,AR,ARC,AZ,AZC MODEL NUMBER: R11TY76AB,ABC,AG,AGC,AR,ARC,AV,AVC,AZ,AZ C ENGINE NUMBER: 1204172 CategoryDimension / CapacityLength114 in.

5 / cmWidth (cargo box)60 in. / cmWidth (tires)58 in. / cmHeight76 in. / 193 cmWheel Base76 in. / 193 cmGround Clearance12 in. / cmTurning Radius158 in. / cmDry WeightSTD: 1237 lbs. / 561 kgEPS: 1257 lbs. / 570 kgCargo Box Capacity49-State: 1000 lbs. / 454 kg50-State: 600 lbs. / 272 kgCargo Box Dimensions (inside dimensions) x 54 x in.(93 x 137 x 29 cm)Vehicle Payload (includes weight of operator, passenger, cargo and accessories)49-State: 1500 lbs. / 681 kg50-State: 1100 lbs. / 499 kgHitch Towing Capacity2000 lbs. / 907 kgHitch Tongue Capacity150 lbs. / 68 kg INFORMATION19923499 - 2011 / 2012 RANGER 800 Service Manual Copyright 2011 Polaris Sales : 2011 RANGER XP 800 / EPSXP 800 MODELS: R11TH76AA,AB,AC,AF,AG,AH,AK,AO,AR,AZXP 800 EPS MODELS: R11TY76AB,AG,AR,AV,AZENGINE NUMBER: 1204172 CLUTCH CHART(B) = Bushed Shift WeightEnginePlatformHigh Output Domestic Twin Cyl, Liquid Cooled, 4-StrokeEngine Number1204172 Engine Displacement760 cc of Cylinders2 Bore & Stroke (mm)80 x mmCompression :1 Compression Pressure165-185 psiEngine Idle Speed1250 100 RPML ubricationPressurized Wet SumpOil RequirementsPS-4 PlusOil Capacity2 qts.

6 ( L)Coolant qts. ( L)Overheat WarningInstrument Cluster IndicatorExhaust System2 to 1 Canister StyleFuel SystemFuel System TypeBosch M17 EFIFuel DeliveryElectronic Fuel Pump (in tank)Fuel Pressure45 +/- 2 psi (310 +/- 14 kPa)Fuel Capacity9 gal. (34 L)Fuel Requirement87 Octane (minimum)ElectricalAlternator Max Output500 Watts @ 3000 RPMH eadlights2 - Halogen: Low 55 W / High 60 WTail Watts / x 2 Brake Watts / x 2 Starting SystemElectric StartIgnition SystemBosch M17 (ECU Controlled)Ignition Timing (Variable)3 - 10 BTDC @ 1200 RPMS park plug / GapRC7YC3 / .035 in. ( mm)Battery / Model / Amp HrYuasa YB30L-B /30 Amp Hr. / 12 VoltInstrumentationMultifunction Instrument ClusterDC Outlets (2) - StandardRelaysChassis / ECM / Fan / Fuel Pump EPS / Rear DiffCircuit BreakerFan Motor: 20 AmpFusesLights: 20 AmpECM: 20 AmpDrive: 20 AmpEPS: 30 AmpAccessory: 20 AmpFuel Pump: 10 AmpDrivetrainTransmission TypePolaris Automatic PVTS hift TypeIn Line Shift - H / L / N / RTransmission Gear Ratio:HighLowReverseFront: :1 / Rear: :1 Front: :1 / Rear: :1 Front: :1 / Rear: :1 Front GearcaseLubricant RequirementsDemand Drive Plus9 oz.

7 (265 ml)TransmissionLubricant RequirementsAGL oz. (1000 ml)Clutch TypeStandard PVTD rive Belt3211133 Clutch Center (255 mm)Steering / SuspensionToe Out1/8 - 1/4 in. ( - mm)Front SuspensionDual A-armFront in. ( cm)Rear SuspensionIndependent (IRS)Rear Travel9 in. ( cm)Shock Preload AdjustmentCam AdjustmentWheels / BrakesFront Wheel Size / Type12 x 6 / Steel12 x 6 / Cast AluminumRear Wheel Size / Type12 x 8 / Steel12 x 8 / Cast AluminumFront TireMake / Model / SizeCarlisle / AT489 / 25 x 10 R12 Carlisle / PXT / 26 x 9 R12 Rear TireMake / Model / SizeCarlisle / AT489 / 25 x 11 R12 Carlisle / PXT / 26 x 11 R12 Tire Air Pressure8-12 psi (69 kPa)Brake System4 Wheel Hydraulic DiscBrake FluidDOT 4 Parking BrakeHand Actuated (in dash)AltitudeShift WeightDrive SpringDriven SpringMeters(Feet)0-1500(0-5000)23-62(56 32337)Black(7043594)Blk / Almd(7043167)1500-3700(5000 - 12000)23-58 (B)(1322911)Black(7043594)Blk / Almd(7043167) INFORMATION9923499 - 2011 / 2012 RANGER 800 Service Manual Copyright 2011 Polaris Sales : 2011 RANGER HD 800 MODEL NUMBER: R11TY76AN ENGINE NUMBER: 1204172 CategoryDimension / CapacityLength114 in.

8 / cmWidth (cargo box)60 in. / cmWidth (tires)58 in. / cmHeight76 in. / 193 cmWheel Base76 in. / 193 cmGround Clearance12 in. / cmTurning Radius158 in. / cmDry Weight1262 lbs. / 572 kgGross Vehicle Weight2912 lbs. / 1321 kgCargo Box Capacity1000 lbs. / 454 kgCargo Box Dimensions (inside dimensions) x 54 x in.(93 x 137 x 29 cm)Vehicle Payload (includes weight of operator, passenger, cargo and accessories)1500 lbs. / 681 kgHitch Towing Capacity2000 lbs. / 907 kgHitch Tongue Capacity150 lbs. / 68 kg INFORMATION19923499 - 2011 / 2012 RANGER 800 Service Manual Copyright 2011 Polaris Sales : 2011 RANGER HD 800HD 800 MODEL: R11TY76 ANENGINE NUMBER: 1204172 CLUTCH CHART(B) = Bushed Shift WeightEnginePlatformDomestic Twin Cylinder, Liquid Cooled, 4-StrokeEngine Number1204172 Engine Displacement760 cc of Cylinders2 Bore & Stroke (mm)80 x mmCompression :1 Compression Pressure165-185 psiEngine Idle Speed1250 100 RPML ubricationPressurized Wet SumpOil RequirementsPS-4 PlusOil Capacity2 qts.

9 ( L)Coolant qts. ( L)Overheat WarningInstrument Cluster IndicatorExhaust System2 to 1 Canister StyleFuel SystemFuel System TypeBosch M17 EFIFuel DeliveryElectronic Fuel Pump (in tank)Fuel Pressure45 +/- 2 psi (310 +/- 14 kPa)Fuel Capacity9 gal. (34 L)Fuel Requirement87 Octane (minimum)ElectricalAlternator Max Output500 Watts @ 3000 RPMH eadlights2 - Halogen: Low 55 W / High 60 WTail Watts / x 2 Brake Watts / x 2 Starting SystemElectric StartIgnition SystemBosch M17 (ECU Controlled)Ignition Timing (Variable)3 - 10 BTDC @ 1200 RPMS park plug / GapRC7YC3 / .035 in. ( mm)Battery / Model / Amp HrYuasa YB30L-B /30 Amp Hr. / 12 VoltInstrumentationMultifunction Instrument ClusterDC Outlets (2) - StandardRelaysChassis / ECM / Fan / Fuel Pump EPS / Rear DiffCircuit BreakerFan Motor: 20 AmpFusesLights: 20 AmpECM: 20 AmpDrive: 20 AmpEPS: 30 AmpAccessory: 20 AmpFuel Pump: 10 AmpDrivetrainTransmission TypePolaris Automatic PVTS hift TypeIn Line Shift - H / L / N / RTransmission Gear Ratio:HighLowReverseFront: :1 / Rear: :1 Front: :1 / Rear: :1 Front: :1 / Rear: :1 Front GearcaseLubricant RequirementsDemand Drive Plus9 oz.

10 (265 ml)TransmissionLubricant RequirementsAGL oz. (1000 ml)Clutch TypeStandard PVTD rive Belt3211133 Clutch Center (255 mm)Steering / SuspensionToe Out1/8 - 1/4 in. ( - mm)Front SuspensionDual A-armFront in. ( cm)Rear SuspensionSelf Leveling (IRS)Rear in. ( cm)Shock Preload AdjustmentCam Adjustment (front only)Wheels / BrakesFront Wheel Size / Type12 x 6 / Cast AluminumRear Wheel Size / Type12 x 8 / Cast AluminumFront TireMake / Model / SizeCarlisle / PXT / 26 x 9 R12 Rear TireMake / Model / SizeCarlisle / PXT / 26 x 11 R12 Tire Air Pressure8-12 psi (69 kPa)Brake System Type4 Wheel Hydraulic DiscBrake FluidDOT 4 Parking BrakeHand Actuated (in dash)AltitudeShift WeightDrive SpringDriven SpringMeters(Feet)0-1500(0-5000)23-62(56 32337)Black(7043594)Blk / Almd(7043167)1500-3700(5000 - 12000)23-58 (B)(1322911)Black(7043594)Blk / Almd(7043167) INFORMATION9923499 - 2011 / 2012 RANGER 800 Service Manual Copyright 2011 Polaris Sales : 2011 RANGER CREW 800 / EPSMODEL NUMBER: R11WH76AG, AR MODEL NUMBER: R11WY76AE, AH, AJ ENGINE NUMBER: 1204172 CategoryDimension / CapacityLength145 in.