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POLARIS OFF-ROAD VEHICLES

HELP CENTER

11/13/2020
RANGER 800 Spark Plug Replacement

Always wear safety glasses and nitrile gloves when servicing your Polaris RANGER. To change the spark plugs on your RANGER 800, RANGER 800 XP, RANGER 800 HD or RANGER CREW 800, follow these steps. As noted in the Periodic Maintenance Chart in your Owner's Manual, inspect the spark plugs and replace as needed every 100 hours, 12 months or 1,000 miles (1,600 km). Spark plug condition is indicative of engine operation. The spark plug firing end condition should be read after the engine is warmed up and the vehicle is driven at higher speeds. Immediately check the spark plug for the correct color. Caution: A hot exhaust system and engine can cause burns. Wear protective gloves when removing a spark plug for inspection.

1. Park the vehicle on a flat, level surface in a well-ventilated area.

2. Make sure the transmission is in PARK.

3. Remove the seat.

4. Using the spark plug wrench provided in the tool kit, remove the spark plug by rotating it counter-clockwise.

5. Inspect the spark plug. 

  • A normal insulator tip is gray, tan or light brown. There will be few combustion deposits. The electrodes are not burned or eroded. This indicates the proper type and heat range for the engine and the service.
  • The tip should not be white. A white insulator tip indicates overheating, caused by use of an improper spark plug or incorrect throttle body adjustments.
  • A wet fouled insulator tip is black. A damp oil film covers the firing end. There may be a carbon layer over the entire nose. Generally, the electrodes are not worn. General causes of fouling are excessive oil, use of non-recommended injection oil or incorrect throttle body adjustments.

6. Also inspect and adjust the spark plug gap if needed. Using a wire-type feeler gauge, measure the spark plug electrode gap. If necessary, correct the gap by carefully bending the side electrode. The electrode gap should be 0.035 inches (0.9 mm). 

7. If necessary, replace with the recommended spark plug. The spark plug is RC7YC3, which is part number 3021671.

8. Install or reinstall the spark plug into the engine using the spark plug wrench in the tool kit. Torque to 18 ft-lbs (24 Nm). 

9. Reinstall the seat.

10. Start the engine to ensure proper operation.

For more information, see your authorized Polaris Dealer. Find a dealer near you with the Dealer Locator.
More maintenance tips, procedures and specifications can be found in your Owner's Manual.
To find diagrams and replacement part numbers, use the online parts catalog.

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