10 ranger 500 efi 4X4.fm

10 ranger 500 efi 4X4.fm
WARNING
Read, understand, and follow all of the instructions and safety precautions in
this manual and on all product labels.
Failure to follow the safety precautions could result in serious injury or death.
WARNING
The engine exhaust from this product contains chemicals known to the State
of California to cause cancer, birth defects or other reproductive harm.
The text is printed on 100% recycled
with 40% post-consumer waste (PCW).
WELCOME
Thank you for purchasing a Polaris vehicle, and welcome to our worldwide family of Polaris owners. We proudly produce an exciting line of
utility and recreational products.
• Snowmobiles
• All-terrain vehicles (ATVs)
• RANGER® utility vehicles
• Victory Motorcycles®
We believe Polaris sets a standard of excellence for all utility and recreational vehicles manufactured in the world today. Many years of experience have gone into the engineering, design, and development of your
Polaris vehicle, making it the finest machine we’ve ever produced.
For safe and enjoyable operation of your vehicle, be sure to follow the
instructions and recommendations in this owner’s manual. Your manual
contains instructions for minor maintenance, but information about
major repairs is outlined in the Polaris Service Manual and should be
performed only by a factory certified Master Service Dealer® (MSD)
technician.
Your Polaris dealer knows your vehicle best and is interested in your
total satisfaction. Be sure to return to your dealership for all of your service needs during, and after, the warranty period.
We also take great pride in our complete line of apparel, parts and accessories, available through our online store at www.purepolaris.com. Have
your accessories and clothing delivered right to your door!
1
POLARIS, POLARIS THE WAY OUT and RANGER are registered trademarks of
Polaris Industries Inc.
Copyright 2009 Polaris Sales Inc. All information contained within this publication is
based on the latest product information at the time of publication. Due to constant
improvements in the design and quality of production components, some minor discrepancies may result between the actual vehicle and the information presented in this publication. Depictions and/or procedures in this publication are intended for reference use
only. No liability can be accepted for omissions or inaccuracies. Any reprinting or reuse
of the depictions and/or procedures contained within, whether whole or in part, is
expressly prohibited.
Printed in U.S.A.
2010 RANGER 4X4 Owner’s Manual
P/N 9922518
2
TABLE OF CONTENTS
Vehicle Identification Numbers. . . . . . . . . . . . . 4
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Features and Controls . . . . . . . . . . . . . . . . . . . 18
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Emission Control Systems . . . . . . . . . . . . . . . 49
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . 100
Polaris Products. . . . . . . . . . . . . . . . . . . . . . . 102
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . 103
Declaration of Conformity . . . . . . . . . . . . . . . 107
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Maintenance Log . . . . . . . . . . . . . . . . . . . . . . 114
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
3
INTRODUCTION
The RANGER is an off-road vehicle. Familiarize yourself with all laws
and regulations concerning the operation of this vehicle in your area.
The following signal words and symbols appear throughout this manual
and on your vehicle. Your safety is involved when these words and symbols are used. Become familiar with their meanings before reading the
manual.
The safety alert symbol indicates a potential personal injury hazard.
WARNING
A WARNING indicates a hazardous situation which, if not avoided, may result in
death or serious injury.
CAUTION
A CAUTION indicates a hazardous situation which, if not avoided, may result in
minor or moderate injury.
NOTICE
A NOTICE indicates a situation that may result in property damage.
The Prohibition Safety Sign indicates an action NOT to take in order
to avoid a hazard.
The Mandatory Action Sign indicates an action that NEEDS to be
taken to avoid a hazard.
4
INTRODUCTION
WARNING
Failure to follow the warnings contained in this manual can result in severe
injury or death.
A Polaris RANGER is not a toy and can be hazardous to operate. This vehicle
handles differently than other vehicles, such as motorcycles and cars. A collision
or rollover can occur quickly, even during routine maneuvers like turning, or
driving on hills or over obstacles, if you fail to take proper precautions.
• Read this owner’s manual. Understand all safety warnings, precautions and
operating procedures before operating the vehicle. Keep this manual with the
vehicle.
• This vehicle is an ADULT VEHICLE ONLY. NEVER operate this vehicle if you
are under age 16 and NEVER operate without a valid driver’s license.
• No person under the age of 12 may ride as a passenger in this vehicle. Any
passenger must be able to comfortably reach the floor and hand holds.
• Never permit a guest to operate this vehicle unless the guest has read this
manual and all product labels.
5
INTRODUCTION
Vehicle Identification Numbers
Record your vehicle's identification numbers and key number in the
spaces provided. Remove the spare key and store it in a safe place. An
ignition key can be duplicated only by ordering a Polaris key blank
(using your key number) and mating it with one of your existing keys.
The ignition switch must be replaced if all keys are lost.
####
Key
Number
VIN
Vehicle Model Number: ___________________________________________________
Frame VIN: ____________________________________________________________
Engine Serial Number: ___________________________________________________
(label on side of engine)
Key Number ___________________________________________________________
6
SAFETY
Safety Labels and Locations
Warning labels have been placed on the vehicle for your protection.
Read and follow the instructions of the labels on the vehicle carefully. If
any of the labels depicted in this manual differ from the labels on your
vehicle, always read and follow the instructions of the labels on the
vehicle.
If any label becomes illegible or comes off, contact your Polaris dealer
to purchase a replacement. Replacement safety labels are provided by
Polaris at no charge. The part number is printed on the label.
Container/Passenger/Tire Pressure Warning
WARNING
Remove flammable material containers from
box before filling.
• Passengers can be thrown off. This can
cause serious injury or death.
• Never carry passengers in cargo box.
+
Maximum 4X4 Box Load 1000 lbs. (455 kg)
Maximum 6X6 Box Load 1250 lbs. (567 kg),
Storage Box Load 250 lbs. (113 kg)
IMPROPER TIRE PRESSURE OR
OVERLOADING can cause loss of control
resulting in SEVERE INJURY OR DEATH.
TIRE PRESSURE IN PSI (KPa):
RANGER - 4X4 FRONT 10 (69) REAR 10 (69)
RANGER - 6X6 FRONT 10 (69) CENTER 10 (69) REAR 10 (69)
MAXIMUM WEIGHT CAPACITY INCLUDES WEIGHT OF OPERATOR,
PASSENGER, CARGO, AND ACCESSORIES.
RANGER 4X4 is 1500 LBS. (682 KG)
RANGER 6X6 is 2000 LBS. (907 KG)
Reduce speed and allow greater distance for braking when carrying cargo.
Overloading or carrying tall, off-center, or unsecured loads will increase your risk
of losing control. Loads should be centered and carried as low as possible in
box. For stability on rough or hilly terrain, reduce speed and cargo. Be careful if
load extends over the side of the box.
Read Owner's Manual for more detailed loading information.
7176334
7
SAFETY
Safety Labels and Locations
Shift Caution
Discretionary
Warning
Age 16
Warning
Clutch Cover
Warning
Clutch Cover Warning
WARNING
NO STEP
• Moving parts hazard under belt-clutch guard. To prevent serious injury, do not
operate vehicle with guard removed.
• Do not modify engine or clutch. Doing so can cause part failure, possible
imbalance, and excessive engine RPM which can result in serious injury or
death.
7172563
Age 16 Warning
Operating this vehicle if you are under the age of 16 increases your chance of
severe injury or death.
NEVER operate this vehicle if you are under age 16 and NEVER operate this
vehicle without a valid driver’s license.
7175566
Shift Caution
CAUTION
To avoid transmission damage, shift only when vehicle is stationary and at idle.
7172674
8
SAFETY
Safety Labels and Locations
Discretionary Warning
WARNING
Improper vehicle use can result in Severe Injury or Death.
NEVER Operate:
• At speeds too fast for your skills or the conditions.
• After or while using Alcohol or Drugs.
• On hills steeper than 15 degrees
15°.
• On public roads, a collision can occur with a another vehicle.
• With more than two passengers, or passengers under age twelve or who
cannot comfortably reach the floor and hand holds.
• On paved surfaces - pavement may seriously affect handling and control.
• With non-Polaris approved accessories - they may seriously affect stability.
ALWAYS:
• Wear your seat belt. Vehicle rollover could cause severe injury or death.
• Wear a helmet and eye protection and keep hands and feet in vehicle at all
times.
• Reduce speed and use extra caution when carrying passengers.
• Avoid sharp turns or turns while applying heavy throttle.
• Operate slowly in reverse - avoid sharp turns or sudden braking.
• Make sure passenger reads and understands all safety labels.
• Watch for branches or other hazards that could enter vehicle.
LOCATE AND READ OWNER’S MANUAL. FOLLOW ALL INSTRUCTIONS
AND WARNINGS.
7176128
9
SAFETY
Operator Safety
WARNING
Serious injury or death can result if you do not follow these instructions and
procedures, which are outlined in further detail within your owner's manual.
• Read this manual and all labels carefully. Follow the operating
procedures described.
• Never allow anyone under age 16 to operate this vehicle and never
allow anyone without a valid driver's license to operate this vehicle.
• Do not carry a passenger until you have at least two hours of driving
experience with this vehicle.
• No person under the age of 12 may ride as a passenger in this vehicle.
Any passenger must be able to comfortably reach the floor and hand
holds.
• The driver and any passenger must wear helmet, eye protection and
seat belt at all times.
• Always keep arms and legs inside the cab frame while the vehicle is
in motion.
• Always keep both hands on the steering wheel and both feet on the
floorboards of the vehicle during operation.
• Never permit a guest to operate this vehicle unless the guest has read
this manual and all product labels.
• To reduce tipover risk, be especially careful when encountering
obstacles and slopes and when braking on hills or during turns.
• This vehicle is for off road use only. Never operate on public roads.
Always avoid paved surfaces.
• Never consume alcohol or drugs before or while operating this
vehicle.
• Never operate at excessive speeds. Always travel at a speed proper
for the terrain, visibility and operating conditions, and your
experience.
• Never attempt jumps or other stunts.
10
SAFETY
Operator Safety
• Always inspect your vehicle each time you use it to make sure it's in
safe operating condition. Always follow the inspection and
maintenance procedures and schedules described in this manual.
• Always travel slowly and use extra caution when operating on
unfamiliar terrain. Be alert to changing terrain.
• Never operate on excessively rough, slippery or loose terrain.
• Always follow proper procedures for turning. Practice turning at slow
speeds before attempting to turn at faster speeds. Never turn at excessive speeds.
• Always have this vehicle checked by an authorized Polaris dealer if it
has been involved in an accident.
• Never operate this vehicle on hills too steep for the vehicle or for your
abilities. Practice on smaller hills before attempting larger hills.
• Always follow proper procedures for climbing hills as described in
this manual. Check the terrain carefully before attempting to climb a
hill. Never climb hills with excessively slippery or loose surfaces.
Never open the throttle suddenly or make sudden gear changes. Never
go over the top of a hill at high speed.
• Always follow the proper procedures outlined in this manual for traveling downhill and for braking on hills. Check the terrain carefully
before descending a hill. Never travel downhill at high speed. Avoid
going downhill at an angle, which would cause the vehicle to lean
sharply to one side. Travel straight down the hill where possible.
• Always check for obstacles before operating in a new area. Never
attempt to operate over large obstacles such as rocks or fallen trees.
Always follow the proper procedures outlined in this manual when
operating over obstacles.
• Always be careful of skidding or sliding. On slippery surfaces such as
ice, travel slowly and exercise caution to reduce the chance of skidding or sliding out of control.
11
SAFETY
Operator Safety
• Never operate your vehicle in fast-flowing water or in water deeper
than that specified in this manual. Wet brakes may have reduced stopping ability. Test your brakes after leaving water. If necessary, apply
them lightly several times to let friction dry out the pads.
• Always be sure there are no obstacles or people behind your vehicle
when operating in reverse. When it's safe to proceed in reverse, move
slowly. Avoid turning at sharp angles in reverse.
• Always use the proper size and type of tires specified in this manual.
Always maintain proper tire pressure as specified on safety labels.
• Never modify this vehicle through improper installation or use of
accessories.
• Never exceed the stated load capacity for this vehicle. Cargo should
be properly distributed and securely attached. Reduce speed and follow the instructions in this manual for hauling cargo or pulling a
trailer. Allow a greater distance for braking.
• Always engage the park brake before getting out of the vehicle. See
page 25.
• Always apply the brakes before engaging or releasing the park brake.
• Always stop the engine before refueling. Remove flammable material
containers from the box before filling them with fuel. Make sure the
refueling area is well ventilated and free of any source of flame or
sparks. Gasoline is extremely flammable. See page 15 for fuel safety
warnings.
• Always remove the ignition key when the vehicle is not in use to prevent unauthorized use or accidental starting.
FOR MORE INFORMATION ABOUT SAFETY, call Polaris at 1-800342-3764.
12
SAFETY
Operator Safety
Equipment Modifications
We strongly recommend that consumers do not install on a Polaris
RANGER any equipment that may increase the speed or power of the
vehicle, or make any other modifications to the vehicle for these purposes. Any modifications to the original equipment of the vehicle create
a substantial safety hazard and increase the risk of bodily injury.
The warranty on your Polaris RANGER is terminated if any equipment
has been added to the vehicle, or if any modifications have been made to
the vehicle, that increase its speed or power.
The addition of certain accessories, including (but not limited to) mowers, blades, tires, sprayers, or large racks, may change the handling characteristics of the vehicle. Use only Polaris-approved accessories, and
familiarize yourself with their function and effect on the vehicle.
13
SAFETY
Operator Safety
WARNING
Failure to operate the RANGER properly can result in a collision, loss of control,
accident or overturn, which may result in serious injury or death. Heed all safety
warnings outlined in this section of the owner’s manual. See the OPERATION
section of the owner’s manual for proper operating procedures.
Age Restrictions
This vehicle is an ADULT VEHICLE ONLY.
NEVER operate this vehicle if you are under
age 16 and NEVER operate without a valid
driver’s license.
No person under the age of 12 may ride as a
passenger in this vehicle. Any passenger
must be able to comfortably reach the floor
and hand holds.
Operating Without Instruction
Operating this vehicle without proper
instruction increases the risk of an accident.
The operator must understand how to
operate the vehicle properly in different
situations and on different types of terrain.
All operators must read and understand the
Owner's Manual and all warning and
instruction labels before operating the
vehicle.
Seat Belts
Riding in this vehicle without wearing the seat belt increases the risk of serious
injury in the event of an accident or sudden stop. Riders must wear seat belts at
all times. Always make sure the seat belts are secured for both the operator and
all passengers before riding.
Using Alcohol or Drugs
Operating the vehicle after consuming alcohol
or drugs could adversely affect operator
judgment, reaction time, balance and
perception.
Never drink alcohol or use drugs or medications
before or while operating this vehicle.
14
SAFETY
Operator Safety
Failure to Inspect Before Operating
Failure to inspect and verify that the vehicle is in safe operating condition before
operating increases the risk of an accident.
Always inspect your RANGER before each use to make sure it's in safe
operating condition. Always follow all inspection and maintenance procedures
and schedules described in the owner's manual.
Handling Gasoline
Gasoline is highly flammable and explosive under certain conditions.
• Always exercise extreme caution whenever handling gasoline.
• Always stop the engine when refueling.
• Remove flammable material containers from the box before filling them with
fuel.
• Always refuel outdoors or in a well ventilated area.
• Do not smoke or allow open flames or sparks in or near the area where refueling is performed or where gasoline is stored.
• Do not overfill the tank. Do not fill the tank neck.
• If gasoline spills on your skin or clothing, immediately wash it off with soap
and water and change clothing.
Exposure to Exhaust
Engine exhaust fumes are poisonous and can cause loss of consciousness or
death in a short time. Never start the engine or let it run in an enclosed area.
The engine exhaust from this product contains chemicals known to cause
cancer, birth defects or other reproductive harm. Operate this vehicle only
outdoors or in well-ventilated areas.
Operating a Damaged Vehicle
Operating a damaged vehicle can result in an accident. After any overturn or
accident, have a qualified service dealer inspect the entire machine for possible
damage, including (but not limited to) brakes, throttle and steering systems.
Operating at Excessive Speeds
Operating this vehicle at excessive speeds increases the operator's risk of
losing control. Always operate at a speed that's appropriate for the terrain, the
visibility and operating conditions, and your experience.
15
SAFETY
Operator Safety
Operating on Pavement
This vehicle's tires are designed for off-road use only, not for use on pavement.
Operating this vehicle on paved surfaces (including sidewalks, paths, parking
lots and driveways) may adversely affect the handling of the vehicle and could
result in loss of control and accident or overturn.
Avoid operating the vehicle on pavement. If it's unavoidable, travel slowly and
avoid sudden turns or stops.
Operating on Public Roads
Operating this vehicle on public streets, roads or highways could result in a
collision with another vehicle.
Never operate this vehicle on any public street, road or highway, including dirt
and gravel roads. In some areas it's unlawful to operate this vehicle on public
streets, roads and highways.
Turning Improperly
Turning improperly could cause loss of traction, loss of control, accident or
overturn. Always follow proper procedures for turning. Never turn abruptly or at
sharp angles. Never turn at high speeds. Practice turning at slow speeds before
attempting to turn at faster speeds.
Jumps and Stunts
Attempting wheelies, jumps and other stunts increases the risk of an accident or
overturn. Never attempt wheelies, jumps, or other stunts. Avoid exhibition
driving.
Operating in Unfamiliar Terrain
Failure to use extra caution when operating on unfamiliar terrain could result in
an accident or overturn. Unfamiliar terrain may contain hidden rocks, bumps, or
holes that could cause loss of control or overturn.
Travel slowly and use extra caution when operating on unfamiliar terrain. Always
be alert to changing terrain conditions.
Operating on Slippery Terrain
Failure to use extra caution when operating on excessively rough, slippery or
loose terrain could cause loss of traction, loss of control, accident or overturn.
Do not operate on excessively slippery surfaces. Always reduce speed and use
additional caution when operating on slippery surfaces.
16
SAFETY
Operator Safety
Improper Hill Climbing
Climbing hills improperly can cause loss of control or vehicle overturn. Always
follow proper procedures for climbing hills as described in the owner's manual.
See page 36.
Stalling While Climbing a Hill
Stalling or rolling backwards while climbing a hill could cause an overturn.
Always maintain a steady speed when climbing a hill.
If all forward speed is lost:
• Apply the brakes.
• Place the transmission in reverse and slowly allow the vehicle to roll straight
downhill while applying light brake pressure to control speed.
If you begin rolling downhill:
• Never apply engine power.
• Apply the brakes gradually until the vehicle is fully stopped.
• Place the transmission in reverse and slowly allow the vehicle to roll straight
downhill while applying light brake pressure to control speed.
Improper Tire Maintenance
Operating this vehicle with improper tires or with improper or uneven tire
pressure could cause loss of control or accident.
Always use the size and type of tires specified for your vehicle. Always maintain
proper tire pressure as described in the owner's manual and on safety labels.
Operating on Frozen Bodies of Water
Severe injury or death can result if the vehicle and/or the operator fall through
the ice. Never operate the vehicle on a frozen body of water.
Unauthorized Use of the Vehicle
Leaving the keys in the ignition can lead to unauthorized use of the vehicle,
which could result in an accident or overturn. Always remove the ignition key
when the vehicle is not in use.
Hot Exhaust Systems
Exhaust system components are very hot during and after use of the vehicle.
Hot components can cause burns and fire. Do not touch hot exhaust system
components. Always keep combustible materials away from the exhaust
system. Use caution when traveling through tall grass, especially dry grass.
17
FEATURES AND CONTROLS
Component Locations
Not all models come with all features. Refer to the specifications section
beginning on page 100.
Cargo Box
Hip Bar
Console
Fuel Tank Cap
ROPS Cab
Frame
Headlights
Radiator
Front Bumper/Brush Guard
18
FEATURES AND CONTROLS
Component Locations
Tailgate
Tailgate
Latch Release
Receiver
Hitch
CV Boot/Rear Caliper
Muffler (Spark Arrestor)
Trailer Hitch Bracket
This vehicle is equipped with a receiver hitch bracket for a trailer hitch.
Trailer towing equipment is not supplied with this vehicle.
To avoid injury and property damage, always heed the warnings and
towing capacities outlined on pages 42-45.
19
FEATURES AND CONTROLS
Console
Park Brake
Lever
Cup
Holder
Gear Selector
(Shifter)
12V Auxiliary
Outlets
Fuel Gauge
Storage
Tray
Indicator
Lights
Storage
Compartment
Auxiliary Outlets
The 12-volt receptacles have spade connections on the back that may be
used to power an auxiliary light or other optional accessories or lights.
The connections are behind the console, under the hood.
Fuel Gauge/Hour Meter
Lighted bars in the upper display indicate fuel level. Hours of engine
operation since manufacture are indicated in the lower display.
20
FEATURES AND CONTROLS
Indicator Lights
The indicator light panel is located on the console.
Park Brake
Reverse
Gear
High
Temperature
Low Gear
(if equipped)
Neutral
Gear
High
Gear
Gear Selector
H: High Gear
H
L: Low Gear
N: Neutral
L
R: Reverse
N
Low gear is the primary driving range
for the RANGER. High gear is intended
for use on hard-packed surfaces with
R
light loads.
To change gears, stop the vehicle, and with the engine idling, move the
lever to the desired gear. Do not attempt to shift gears with engine speed
above idle or while the vehicle is moving.
Tip: Maintaining shift linkage adjustment is important to assure proper transmission function. See your dealer if you experience any shifting problems.
NOTICE: Do not attempt to shift the transmission while the vehicle is moving or
damage to the transmission could result. Always shift when the
vehicle is stationary and the engine is at idle.
21
FEATURES AND CONTROLS
Switches
Light Switch
AWD/Differential Switch
Ignition Switch
Ignition Switch
The ignition switch is a three-position, key-operated switch. The key
can be removed from the switch when it is in the OFF position.
OFF
The engine is off. Electrical circuits are off, except Acc, 12V.
ON
Electrical circuits are on. Electrical equipment can be used.
START
Turn the key to the START position to engage the electric starter.
The key returns to the ON position when released.
22
FEATURES AND CONTROLS
Switches
Light Switch
The ignition switch key must be in the ON/
RUN position to operate the headlights. Use the
light switch to turn the headlights on or off.
ON
AWD/Differential Lock Switch
The AWD/Differential Switch has three positions: All Wheel Drive (AWD), Differential
Lock/Two Wheel Drive (2WD) and Off (1WD/
Turf Mode).
Press the top of the rocker switch to engage All
Wheel Drive (AWD). See page 48 for AWD
operating instructions.
Move the rocker switch to the center position to
lock the differential and operate in two wheel
drive (2WD). See page 47 for Differential Lock
operating instructions.
Press the bottom of the switch to unlock the differential and allow the rear drive wheels to
operate independently (1WD). This mode of
operation is well suited to turf driving or when
active traction is not needed.
OFF
AWD
2WD
OFF
23
FEATURES AND CONTROLS
Adjustable Steering Wheel
The steering wheel can be tilted
upward or downward for rider preference.
Lift and hold the adjustment lever
toward you while tilting the steering
wheel upward or downward.
Release the lever when the steering
wheel is at the desired position.
Brake Pedal
Depress the brake pedal to slow or
stop the vehicle. Apply the brakes
while starting the engine.
Throttle Pedal
Push the pedal down to increase
engine speed. Spring pressure
returns the pedal to the rest position when released. Always check
that the throttle pedal returns normally before starting the engine.
Make sure there's adequate throttle pedal freeplay. See page 77 for
throttle pedal adjustment procedures.
24
Brake
Pedal
Throttle
Pedal
FEATURES AND CONTROLS
Park Brake Lever
To help prevent the vehicle from rolling, engage the park brake when
parking the vehicle. When the park brake is fully engaged and the park
brake indicator is illuminated, engine speed is limited to 1300 RPM in
all gears, except neutral. If throttle is applied, this limiting feature prevents operation, which protects the park brake pads from excessive
wear.
Tip: This feature will not operate properly if the park brake connector or switch
(under the hood) malfunctions or becomes disconnected, or if the switch
has moved. Check for disconnection, then see your dealer promptly if this
feature fails to operate properly.
Inspect and adjust park brake cable tension after the first 25 hours of
operation and every 100 hours thereafter to ensure proper cable tension.
See page 80.
Always apply the service brakes
before engaging or releasing the
park brake.
1. Apply the brakes.
2. Pull the park brake lever
downward as far as possible.
3. To release the park brake,
apply the brakes. Press the
park brake release inward and
move the lever upward as far
as possible.
WARNING! Operating the vehicle while the park brake is engaged could cause
loss of control and result in serious injury or death. Always disengage the park
brake before operating the vehicle.
25
FEATURES AND CONTROLS
Seat Belts
This Polaris vehicle is equipped with
three-point lap and diagonal seat belts on
all external seats.The center seat is
equipped with a lap-style seat belt. Always
make sure the seat belts are secured for all
riders before operating.
WARNING! Falling from a moving vehicle
could result in serious injury or death. Always
fasten your seat belt securely before operating
or riding in the RANGER.
Latch Plate
Buckle
To wear the seat belt properly, follow this
procedure:
1. For 3-point belts, pull the seat belt
latch downward and across your chest
toward the buckle at the inner edge of
the seat. The belt should fit snugly
across your hips and diagonally across
your chest. Make sure the belt is not
twisted. For lap style belts, place the
belt across your lap as low on your
hips as possible. Make sure that the
belt is not twisted.
2. Push the latch plate into the buckle until it clicks.
3. Release the strap, it will self tighten.
Tip: The center belt must be tightened manually by pulling on the strap.
4. To release the seat belt, press the square red button in the buckle's
center.
26
FEATURES AND CONTROLS
Seat Belts
Seat Belt Inspection
Inspect all seat belts for proper operation before each use of the vehicle.
1. Push the latch plate into the buckle until it clicks. The latch plate
must slide smoothly into the buckle. A click indicates that it's
securely latched.
2. Push the red release latch in the middle of the buckle to make sure it
releases freely.
3. Pull each seat belt completely out and inspect the full length for any
damage, including cuts, wear, fraying or stiffness. If any damage is
found, or if the seat belt does not operate properly, have the seat belt
system checked and/or replaced by an authorized Polaris dealer.
4. To clean dirt or debris from the seat belts, sponge the straps with
mild soap and water. Do not use bleach, dye or household detergents.
Seat Removal
Pull up on the front of the seat and slide it toward the front of the vehicle.
Install the seat by sliding the tabs into the rear of the seat base. Push
down firmly on the front of the seat until the pins are fully seated into
the grommets.
Fuel Cap
The fuel tank filler cap is
located on the right-hand side
of the vehicle near the passenger seat. When refueling,
always use either leaded or
unleaded gasoline with a minimum pump octane number of
87 R+M/2 octane. Do not use
fuel with ethanol content
greater than 10 percent, such
as E-85 fuel.
27
FEATURES AND CONTROLS
Rollover Protective Structure (ROPS)
The Rollover Protective Structure (ROPS) on this vehicle meets OSHA
1928.53 rollover performance requirements. Always have your authorized Polaris dealer thoroughly inspect the ROPS if it ever becomes
damaged in any way.
No device can assure occupant protection in the event of a rollover.
Always follow all safe operating practices outlined in this manual to
avoid vehicle rollover.
WARNING! Vehicle rollover could cause severe injury or death. Always avoid
operating in a manner that could result in vehicle rollover.
ROPS
28
OPERATION
WARNING
Failure to operate the vehicle properly can result in a collision, loss of control,
accident or overturn, which may result in serious injury or death. Read and
understand all safety warnings outlined in the safety section of this owner’s
manual.
Break-In Period
The break-in period for your new Polaris RANGER is the first twenty
hours of operation, or the time it takes to use the first two tanks full of
gasoline. No single action on your part is as important as a proper breakin period. Careful treatment of a new engine will result in more efficient
performance and longer life for the engine. Perform the following procedures carefully.
NOTICE: Excessive heat build-up during the first three hours of operation will
damage close-fitted engine parts. Do not operate at full throttle or
high speeds for extended periods during the first three hours of use.
29
OPERATION
Break-In Period
Engine and Drivetrain Break-in
1. Fill the fuel tank with gasoline. Heed the gasoline warnings on page
15.
2. Check the oil level. See page 57. Add the recommended oil as
needed to maintain the oil level in the normal (safe) operating
range.
3. Drive slowly at first. Select an open area that allows room to familiarize yourself with vehicle operation and handling.
4. Vary throttle positions. Do not operate at sustained idle.
5. Perform regular checks on fluid levels, controls and areas outlined
on the daily pre-ride inspection checklist. See page 31.
6. Pull only light loads.
7. During the break-in period, change both the oil and the filter at 25
hours.
8. Inspect and adjust park brake cable tension after the first 25 hours of
operation and every 100 hours thereafter to ensure proper cable tension. See page 80.
PVT Break-in (Clutches/Belt)
A proper break-in of the clutches and drive belt will ensure a longer life
and better performance. Break in the clutches and belt by operating at
slower speeds during the break-in period as recommended. Pull only
light loads. Avoid aggressive acceleration and high speed operation during the break-in period.
30
OPERATION
Pre-Ride Inspection
Failure to inspect and verify that the vehicle is in safe operating condition before operating increases the risk of an accident. Always inspect
the vehicle before each use to make sure it's in safe operating condition.
Item
Remarks
Page
Brake system/pedal travel
Ensure proper operation
24
78
Brake fluid
Ensure proper level
78
Front suspension
Inspect, lubricate if necessary
55
Rear suspension
Inspect, lubricate if necessary
55
Steering
Ensure free operation
80
Tires
Inspect condition and pressure
7
82
Wheels/fasteners
Inspect, ensure fastener tightness
82
Frame nuts, bolts, fasteners
Inspect, ensure tightness
Fuel and oil
Ensure proper levels
27
57
-
Coolant level
Ensure proper level
67
68
Coolant hoses
Inspect for leaks
-
Throttle
Ensure proper operation
76
Indicator lights/switches
Ensure operation
21
Air filter, pre-filter
Inspect, clean
72
Air box sediment tube
Drain deposits whenever visible
72
Headlamp
Check operation, apply Polaris dielectric grease when lamp is replaced
84
Brake light/tail lamp
Check operation, apply Polaris dielectric grease when lamp is replaced
86
Seat Belts
Check length of belt for damage,
check latches for proper operation
27
31
OPERATION
Starting Engine
1.
2.
3.
4.
5.
Always start the engine outdoors or in a well-ventilated area.
Sit in the driver's seat and fasten the seat belt.
Apply the brakes. Engage the park brake.
Shift the transmission to neutral.
Do not press the throttle pedal while starting the engine. Turn the
ignition key past the ON/RUN position to START. Engage the
starter for a maximum of five seconds. Release the key when the
engine starts.
6. If the engine does not start within five seconds, release the ignition
switch and wait five seconds. Repeat steps 5 and 6 until the engine
starts.
7. Vary the engine RPM slightly with the throttle to aid in warm up
until the engine idles smoothly.
NOTICE: Operating the vehicle immediately after starting could cause engine
damage. Allow the engine to warm up for several minutes before
operating the vehicle.
32
OPERATION
Stopping the Engine
1.
2.
3.
4.
Release the throttle pedal completely and brake to a complete stop.
Turn the engine off.
Apply the brakes.
Engage the park brake.
WARNING! A rolling vehicle can cause serious injury. Always engage the park
brake after stopping the engine.
Braking
1. Release the throttle pedal completely.
2. Press on the brake pedal evenly and firmly.
3. Practice starting and stopping (using the brakes) until you're familiar with the controls.
Tip: When the throttle pedal is released completely and the engine speed drops
near an idle, the vehicle has no engine braking.
33
OPERATION
Driving Procedure
1.
2.
3.
4.
5.
6.
7.
Wear a helmet and eye protection.
Sit in the driver's seat and fasten the seat belt.
Start the engine and allow it to warm up.
Apply the service brakes and shift the transmission into gear.
Check your surroundings and determine your path of travel.
Release the park brake.
Keeping both hands on the steering wheel, slowly release the brakes
and depress the throttle with your right foot to begin driving.
8. Drive slowly. Practice maneuvering and using the throttle and
brakes on level surfaces.
9. Do not carry a passenger until you have at least two hours of driving
experience with this vehicle.
34
OPERATION
Driving On Slippery Surfaces
WARNING
Skidding or sliding can cause loss of control or overturn (if tires regain traction
unexpectedly). When operating on slippery surfaces such as ice or loose gravel,
reduce speed and use extra caution to reduce the chance of skidding or sliding
out of control. Do not operate on excessively slippery surfaces.
Whenever riding on slippery surfaces such as wet trails or loose gravel,
or during freezing weather, follow these precautions:
1. Do not operate on excessively rough, slippery or loose terrain.
2. Slow down before entering slippery areas.
3. Maintain a high level of alertness, reading the trail and avoiding
quick, sharp turns, which can cause skids.
4. Engage all-wheel drive before wheels begin to lose traction.
NOTICE: Severe damage to the drive train may occur if the AWD is engaged
while the wheels are spinning. Always allow the wheels to stop
spinning before engaging AWD.
5. Correct a skid by turning the steering wheel in the direction of the
skid. Never apply the brakes during a skid.
Sideways
skid
Turn in
direction of
skid
35
OPERATION
Driving Uphill
Whenever traveling
uphill, follow these precautions:
1. Always travel
straight uphill.
2. Avoid steep hills
(15° maximum).
3. Keep both feet on
the floor.
15° maximum
4. Always check the
terrain carefully
before ascending
any hill.
5. Never climb hills with excessively slippery or loose surfaces.
6. Proceed at a steady rate of speed and throttle opening. Never open
the throttle suddenly.
7. Never go over the crest of a hill at high speed. An obstacle, a sharp
drop, or another vehicle or person could be on the other side of the
hill.
36
OPERATION
Driving on a Sidehill (Sidehilling)
Driving on a sidehill is not recommended. Improper procedure could
cause loss of control or overturn. Avoid crossing the side of any hill
unless absolutely necessary.
If crossing a sidehill is unavoidable, follow these precautions:
1. Slow down.
2. Exercise extreme caution.
3. Avoid crossing the side of a steep hill (15° maximum).
Driving Downhill
When driving downhill,
follow these precautions:
1. Avoid steep hills (15°
maximum).
2. Drive straight downhill. Avoid descending
a hill at an angle,
which would cause the
vehicle to lean sharply
to one side. Travel
straight downhill when
possible.
3. Slow down.
4. Apply the brakes slightly to aid in slowing.
15° maximum
37
OPERATION
Driving Through Water
Your Polaris RANGER can operate through water up to a maximum recommended depth equal to the floorboards.
NOTICE: Immersion can result in major damage if the vehicle isn't serviced
correctly and promptly. After immersion, always take the vehicle to
your dealer service. Do not start the engine! If it's impossible to bring
the vehicle to your dealer before starting the engine, perform the
service outlined on page 71, and take the vehicle to your dealer at
the first opportunity.
Follow these procedures
when operating through
water:
1. Determine water
depths and current
before entering water.
2. Choose a crossing
where both banks
have gradual inclines.
3. Proceed slowly,
avoiding rocks and
obstacles.
4. Avoid operating
through deep or fastflowing water.
Floorboard
WARNING! The large tires
on your RANGER may cause the vehicle to float in deep or fast-flowing water,
which could result in loss of control and lead to serious injury or death. Never
cross deep or fast-flowing water with your RANGER.
5. After leaving water, always dry the brakes by applying light pressure to the pedal repeatedly until braking action is normal.
NOTICE: After running your vehicle in water, it's critical that you perform the
services outlined in the Periodic Maintenance Chart beginning on
page 50. Give special attention to engine oil, transmission oil, front
and rear gearcases (if equipped), and all grease fittings.
38
OPERATION
Driving Over Obstacles
Follow these precautions when operating over obstacles:
1. Always check for obstacles before operating in a new area.
2. Look ahead and learn to read the terrain. Be constantly alert for hazards such as logs, rocks and low hanging branches.
3. Travel slowly and use extra caution when operating on unfamiliar
terrain. Not all obstacles are immediately visible.
39
OPERATION
Driving in Reverse
Follow these precautions when operating in reverse:
1. Always check for obstacles or people behind the vehicle. Always
inspect left and right fields of vision before backing.
2. Always avoid backing downhill.
3. Back slowly.
4. Apply the brakes lightly for stopping.
5. Avoid turning at sharp angles.
6. Never open the throttle suddenly.
40
OPERATION
Parking on an Incline
15° maximum
Avoid parking on an incline if possible. If it's unavoidable, follow these
precautions:
1. Apply the brakes.
2. Place the transmission in gear.
3. Engage the park brake.
4. Turn the engine off.
5. Block the rear wheels on the downhill side.
41
OPERATION
Hauling Cargo
WARNING
Hauling cargo improperly can alter vehicle handling and may cause loss of
control or brake instability, which can result in serious injury or death. Always
follow these precautions when hauling cargo:
Never exceed the maximum weight capacity of the vehicle. When determining
the weight you are adding to the vehicle, include the weight of the operator,
passenger, accessories, loads in the rack or box and the load on the trailer
tongue. The combined weight of these items must not exceed the maximum
weight capacity.
REDUCE SPEED AND ALLOW GREATER DISTANCES FOR BRAKING
WHEN HAULING CARGO.
Always load the cargo box with the load as far forward and as low as possible.
When operating over rough or hilly terrain, reduce speed and cargo to maintain
stable driving conditions.
Always operate the vehicle with extreme care when hauling or towing loads.
Slow down and drive in the lowest gear available.
SECURE ALL LOADS BEFORE OPERATING. Unsecured loads can create
unstable operating conditions, which could result in loss of control of the vehicle.
OPERATE ONLY WITH STABLE AND SAFELY ARRANGED LOADS. When
handling off-centered loads that cannot be centered, securely fasten the load
and operate with extra caution. Always attach the tow load to the hitch point
designated for your vehicle.
HEAVY LOADS CAN CAUSE BRAKING AND CONTROL PROBLEMS. Use
extreme caution when applying brakes with a loaded vehicle. Avoid terrain or
situations that may require backing downhill.
USE EXTREME CAUTION when operating with loads that extend over the rack
sides. Stability and maneuverability may be adversely affected, causing the
vehicle to overturn.
DO NOT TRAVEL FASTER THAN THE RECOMMENDED SPEEDS. Vehicle
should never exceed 10 mph (16 kph) while towing a load on a level grass
surface. Vehicle speed should never exceed 5 mph (8 kph) when towing loads in
rough terrain, while cornering, or while ascending or descending a hill.
42
OPERATION
Hauling Cargo
The RANGER has been designed to carry or tow specific capacities.
Always read and understand the load distribution warnings listed on the
warning labels. The total load (operator, passenger, accessories, cargo
and weight on hitch) must not exceed the maximum weight capacity of
the vehicle. Never exceed the following capacities.
Model
RANGER 4X4
Maximum Capacities
(Level Ground)
Cargo Box
1500 lbs. (681 kg)
1000 lbs. (454 kg)
WARNING! Driving with
passengers in the cargo box
can result in severe injury or
death. Never allow passengers
to ride in the cargo box.
Passengers must always ride
in the cab with seat belts
fastened securely.
43
OPERATION
Dumping the Cargo Box
1. Select a level site to dump the
cargo box. Do not attempt to
dump or unload the vehicle while
parked on an incline.
2. Apply the brakes.
3. Engage the park brake.
4. Dismount the vehicle.
5. Ensure that the cargo is positioned evenly or toward the front
of the cargo box.
6. Release the tailgate by pulling up
on the tailgate latch.
Release Lever
WARNING! If the weight distribution on the box is located toward the rear of the
box when the release lever is pulled forward, the box may dump unexpectedly
and cause serious injury to the operator or bystanders. Never operate the dump
lever without ensuring that the load is positioned evenly or at the front of the
box.
7. Stand clear and pull up on the cargo box release lever.
8. Lift the front of the cargo box to dump the cargo.
9. Lower the cargo box and push down securely to latch.
WARNING! Operating the vehicle while the cargo box is raised could result in
severe injury. The box could close unexpectedly and cause injury to the driver or
passenger. The rear tires will also catch the rear of a raised box, damaging the
vehicle and creating hazardous driving conditions. Never operate this vehicle
with the cargo box in the raised position.
44
OPERATION
Towing Loads
Towing improperly can alter vehicle handling and may cause loss of
control or brake instability. Always follow these precautions when towing:
1. Never load more than 150 lbs. (68.1 kg) tongue weight on the towing bracket.
2. Do not operate the vehicle faster than 10 mph (16 km/h) when towing. See page 42. Towing a trailer increases braking distance.
3. Do not tow more than the recommended weight for the vehicle. See
the towing capacity chart below and the specifications charts beginning on page 100.
4. Attach a trailer to the trailer hitch bracket only. Do not attach a
trailer to any other location or you may lose control of the vehicle.
5. Never tow a trailer on a grade steeper than 15°.
Model
Total Towed
Load Weight
(Level Ground)
Total Towed
Load Weight
(15° grade)
Total Hitch
Vertical
Weight
Maximum
Towing
Speed
RANGER 4X4
1500 lbs.
(681 kg)
850 lbs.
(386 kg)
150 lbs.
(68.1 kg)
10 mph
(16 kph)
Belt Life
To extend belt life, use the lowest gear possible when hauling or towing
heavy cargo.
45
OPERATION
Parking the Vehicle
1. Apply the brakes. Stop the vehicle on a level surface.
2. When parking inside a garage or other structure, be sure that the
structure is well ventilated and that the vehicle is not close to any
source of flame or sparks, including any appliance with pilot lights.
3. Turn the engine off.
4. Engage the park brake.
5. Remove the ignition switch key to prevent unauthorized use.
46
OPERATION
Differential Operation Modes
The 4X4 rear axle is equipped with a lockable differential that allows
the operator to choose between an open differential or a closed differential.
AWD
Press the top of the rocker switch to
engage All Wheel Drive (AWD). When
in AWD, the rear wheels rotate at the
same speed. The front wheels also rotate
at the same speed. See page 48 for AWD
operating instructions.
2WD/Rear Differential Locked
Move the rocker switch to the center
position to lock the differential and operate in two wheel drive (2WD). Locking
the differential in slippery or low traction
conditions helps improve traction. When
the rear differential is locked, both rear
wheels rotate at the same speed.
OFF/Differential Unlocked
Press the bottom of the switch to unlock the differential and allow the
rear drive wheels to operate independently (1WD). When the rear differential is unlocked, the rear wheels can rotate at different speeds. Unlock
the differential to make maneuvering easier and minimize damage to
turf.
NOTICE: Damage to the differential can occur if it is engaged while the vehicle
is traveling at high speeds or while the rear wheels are spinning.
Slow the vehicle to nearly stopped before engaging the differential.
47
OPERATION
All Wheel Drive (AWD)
The illuminated amber AWD switch indicates
that the vehicle is in AWD.
When the AWD switch is on, the front gearcase
will automatically engage any time the rear
wheels lose traction. When the rear wheels regain
traction, the front gearcase will automatically
disengage.
There is no limit to the length of time the vehicle
may remain in AWD.
Initially, the vehicle's electronic system will not enable the AWD until
the engine RPM is below 3100. Once enabled, the AWD remains
enabled until the AWD switch is turned off. If the switch is turned off
while the front gearcase is moving, it will not disengage until the rear
wheels regain traction.
Engage the AWD before getting into conditions where front wheel drive
may be needed. If the rear wheels are spinning, release the throttle
before switching to AWD.
NOTICE: Switching to AWD while the rear wheels are spinning may cause
severe drive shaft and clutch damage. Always switch to AWD while
the rear wheels have traction or are at rest.
Disengaging AWD
Under certain conditions, it may be possible for the front gearcase to
remain locked unnecessarily. This condition causes increased steering
effort and some vehicle speed restriction. If the front gearcase remains
locked after following these instructions, return the vehicle to your
dealer for service.
1. Stop the vehicle.
2. Operate in reverse for at least 10 feet.
3. Stop completely.
4. Shift into low gear and drive forward.
48
EMISSION CONTROL SYSTEMS
Noise Emission Control System
Do not modify the engine, intake or exhaust components, as doing so
may affect compliance with U.S.A. EPA noise control requirements (40
CFR 205) and local noise level requirements.
Operation on Public Lands in the U.S.A.
Your Polaris vehicle has a spark arrestor that was tested and qualified to
be in accordance with the USFS standard 5100-1c. Federal law requires
that this spark arrestor be installed and functional when the vehicle is
operated on public lands.
Operation of off-road vehicles on public lands in the U.S.A. is regulated
by 43 CFR 420. Violations are subject to monetary penalties. Federal
regulations can be viewed online at www.gpoaccess.gov/ecfr/.
Crankcase Emission Control System
This engine is equipped with a closed crankcase system. Blow-by gases
are forced back to the combustion chamber by the intake system. All
exhaust gases exit through the exhaust system.
Exhaust Emission Control System
Exhaust emissions are controlled by engine design. An electronic fuel
injection (EFI) system controls fuel delivery. The engine and EFI components are set at the factory for optimal performance and are not
adjustable.
The emissions label is located on the frame under the seat.
Electromagnetic Interference
This spark ignition system complies with Canadian ICES-002.
This vehicle complies with the EMC requirements of European directives 97/24/EC and 2004/108/EC.
49
MAINTENANCE
Periodic Maintenance Chart
Careful periodic maintenance will help keep your vehicle in the safest,
most reliable condition. Inspection, adjustment and lubrication of
important components are explained in the periodic maintenance chart.
Inspect, clean, lubricate, adjust and replace parts as necessary. When
inspection reveals the need for replacement parts, use genuine Polaris
parts available from your Polaris dealer.
Record maintenance and service in the Maintenance Log beginning on
page 114.
Tip: Service and adjustments are important for proper vehicle operation. If
you're not familiar with safe service and adjustment procedures, have a
qualified dealer perform these operations.
Maintenance intervals in the following chart are based upon average
riding conditions and an average vehicle speed of approximately ten
(10) miles per hour. Vehicles subjected to severe use must be inspected
and serviced more frequently.
Severe Use Definition
•
•
•
•
•
Frequent immersion in mud, water or sand
Racing or race-style high RPM use
Prolonged low speed, heavy load operation
Extended idle
Short trip cold weather operation
Pay special attention to the oil level. A rise in oil level during cold
weather can indicate contaminants collecting in the oil sump or crankcase. Change oil immediately if the oil level begins to rise. Monitor the
oil level, and if it continues to rise, discontinue use and determine the
cause or see your dealer.
50
MAINTENANCE
Periodic Maintenance Chart
Maintenance Chart Key
X Perform these operations more often for vehicles subjected to
severe use.
E Emission Control System Service - 4 Cycle (California)
Q Have an authorized Polaris dealer perform these services.
WARNING! Improperly performing the procedures marked with a Q could result
in component failure and lead to serious injury or death. Have an authorized
Polaris dealer perform these services.
51
MAINTENANCE
Periodic Maintenance Chart
Perform all services at whichever maintenance interval is reached first.
Item
Maintenance Interval
(whichever comes first)
Hours Calendar
Miles
(Km)
Q Steering
-
Pre-Ride
-
X Front suspension
-
Pre-Ride
-
X Rear suspension
-
Pre-Ride
-
-
Pre-Ride
-
-
Pre-Ride
-
Brake system
-
Pre-Ride
-
Wheels/fasteners
-
Pre-Ride
-
Tires
X Brake fluid level
Remarks
Make adjustments as need
ed. See Pre-Ride Checklist
on page 31.
X Brake pedal travel
-
Pre-Ride
-
X Engine oil level
Frame fasteners
-
Pre-Ride
-
X Air filter, pre-filter
E
-
Daily
-
Inspect; clean often; replace
as needed
X Air box sediment
E tube
-
Daily
-
Drain deposits when visible
Coolant
(if applicable)
-
Daily
-
Check level daily, change
coolant every 2 years
Headlamp/tail
lamp
-
Daily
-
Check operation; apply
dielectric grease if replacing
X Air filter,
E main element
-
Weekly
-
Inspect; replace as needed
10 H
Monthly
-
Inspect periodically
X Brake pad wear
Q
20 H
Monthly
-
Check terminals; clean; test
X Front Gearcase Oil
(if equipped)
Battery
25 H
Monthly
-
Inspect level; change yearly
X Middle Gearcase
Oil (if equipped)
25 H
Monthly
-
Inspect level; change yearly
X Rear gearcase oil
(if equipped)
25 H
Monthly
-
Inspect level; change yearly
X Transmission oil
25 H
Monthly
-
Inspect level; change yearly
X Perform these procedures more often for vehicles subjected to severe use.
E Emission-Related Service.
Q Have an authorized Polaris dealer perform these services.
52
MAINTENANCE
Periodic Maintenance Chart
Item
Maintenance Interval
Remarks
(whichever comes first)
Hours Calendar
Miles
(Km)
X Engine breather
E filter (if equipped)
25 H
Monthly
-
Inspect; replace if necessary
X Engine oil change
(break-in)
25 H
1M
-
Perform a break-in oil change
at one month
25 H
1M
-
Check tension, adjust
50 H
3M
-
Lubricate all fittings, pivots,
cables, etc.
Park brake cable
tension
X General
lubrication
50 H
6M
-
Inspect, lubricate, adjust
Q Steering
Shift Linkage
50H
6M
-
Lubricate
X Front Suspension
50 H
6M
-
Lubricate
X Rear Suspension
50 H
6M
-
Lubricate
Q Throttle cable
50 H
6M
-
Inspect; adjust; lubricate;
replace if necessary
E Throttle body air
intake ducts/flange
50 H
6M
-
Inspect duct for proper sealing/air leaks
Drive belt
50 H
6M
-
Inspect; adjust; replace as
needed
Cooling system
(if applicable)
50 H
6M
-
Inspect coolant strength
seasonally; pressure test
system yearly
Park brake cable
tension
100 H
6M
-
Check tension, adjust
X Engine oil change
100 H
6M
-
Perform a break-in oil change
at one month
X Oil filter change
100 H
6M
-
Replace with oil change
E
X Perform these procedures more often for vehicles subjected to severe use.
E Emission-Related Service.
Q Have an authorized Polaris dealer perform these services.
53
MAINTENANCE
Periodic Maintenance Chart
Item
Maintenance Interval
Remarks
(whichever comes first)
Hours Calendar
Miles
(Km)
Q Fuel system
100 H
12 M
-
Check for leaks at tank cap,
lines, fuel valve, pump, throttle body; replace lines every 2
years
X Radiator
(in applicable)
100 H
12 M
-
Inspect; clean external
surfaces
X Cooling Hoses
100 H
12 M
-
Inspect for leaks
X Engine mounts
100 H
12 M
-
Inspect
100 H
12 M
-
Inspect
X Spark plug
E
100 H
12 M
-
Inspect; replace as needed
E
Exhaust muffler/
pipe
Q Ignition timing
100 H
12 M
-
Inspect
X Wiring
100 H
12 M
-
Inspect for wear, routing,
security; apply dielectric
grease to connectors
subjected to water, mud, etc.
Q Clutches (drive
100 H
12 M
-
Inspect; clean; replace worn
parts
Q Front wheel
100 H
12 M
-
Inspect; replace as needed
Q Brake fluid
200 H
24 M
-
Change every two years
300 H
36 M
-
and driven)
bearings
Spark arrestor
Idle speed
Clean out
-
Adjust as needed
Q Toe adjustment
-
Inspect periodically; adjust
when parts are replaced
Q Auxiliary brake (if
X equipped)
-
Inspect daily; adjust as
needed
Headlight aim
-
Adjust as needed
X Perform these procedures more often for vehicles subjected to severe use.
E Emission-Related Service.
Q Have an authorized Polaris dealer perform these services.
54
MAINTENANCE
Lubrication Recommendations
Check and lubricate all components at the intervals outlined in the Periodic Maintenance Chart beginning on page 50, or more often under
severe use, such as wet or dusty conditions. Items not listed in the chart
should be lubricated at the general lubrication interval.
Item
Lube
Method
Engine Oil
Polaris PS-4 PLUS Performance See page 57.
Synthetic 2W-50 4-cycle Oil
Brake Fluid
DOT 4
See page 78.
Main Gearcase Oil
(Transmission)
Premium AGL Synthetic
Gearcase Lube
See page 61.
Front Gearcase Oil
Premium Demand Drive Hub
Fluid
See page 62.
Front Prop Shaft Yoke
Polaris Premium U-Joint Lube
Locate fittings and grease
(3 pumps maximum).
55
MAINTENANCE
Engine Oil
Always check and change the engine oil at the intervals outlined in the
Periodic Maintenance Chart beginning on page 50. Always change the
oil filter whenever changing oil.
WARNING! Vehicle operation with insufficient, deteriorated, or contaminated
engine oil will cause accelerated wear and may result in engine seizure,
accident, and injury. Always perform the maintenance procedures as outlined in
the Periodic Maintenance Chart.
Oil Recommendations
Polaris recommends the use of Polaris PS-4 PLUS Performance Synthetic 2W-50 4-cycle oil or a similar oil. See page 102 for the part numbers of Polaris products.
NOTICE: Mixing brands or using a non-recommended oil may cause serious
engine damage. Always use the recommended oil. Never substitute
or mix oil brands.
56
MAINTENANCE
Engine Oil
Always check and change the oil at the intervals outlined in the Periodic
Maintenance Chart beginning on page 50. See page 56 for oil recommendations.
Oil Check
The oil tank is located under
the seat.
1. Position the vehicle on a
level surface.
2. Apply the brakes. Start the
engine and allow it to idle
for 20-30 seconds. Stop the
engine.
3. Remove the seat. See page
27.
4. Remove the dipstick. Wipe
it dry with a clean cloth.
5. Reinstall the dipstick.
Screw it in completely.
{
Tip: The dipstick must be screwed
in completely to keep the
angle and depth of the stick
consistent.
Safe Range
Add
Full
6. Remove the dipstick. Make sure that the oil level is between the full
and add marks. Add oil if necessary. Do not overfill.
Tip: A rising oil level between checks in cool weather driving can indicate moisture collecting in the oil reservoir. If the oil level is above the full mark,
change the oil.
57
MAINTENANCE
Engine Oil
Oil and Filter Change
Always change the oil and filter at the intervals outlined in the Periodic
Maintenance Chart beginning on page 50. 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.
Drain
3. Clean the area around the
Plug
drain plug.
4. Place a drain pan beneath oil
tank.
Screen
CAUTION! Hot oil can cause burns
to skin. Do not allow hot oil to contact
skin.
Sealing
Washer
Fitting
5. Remove the drain plug.
Allow the oil to drain completely.
6. Install a new sealing washer Orientation
Mark
on the drain plug. The sealing
surfaces on drain plug and oil
tank should be clean and free
of burrs, nicks or scratches.
7. Reinstall the drain plug. Torque to 14 ft. lbs. (19 Nm).
8. Disconnect the lower oil delivery hose and remove the screen fitting
from the oil tank. Clean the fitting.
Tip: The fitting threads must be sealed with LOCTITE PST 505 or PTFE seal
tape.
9. Reinstall the screen fitting and rotate the fitting clockwise a minimum of 2 1/2 turns into the tank threads. Continue to rotate the fitting until the nipple of the fitting aligns with the mark on the tank.
Tip: Do not over-tighten. Maximum torque for the screen fitting is 25 ft. lbs. (34
Nm).
58
MAINTENANCE
Engine Oil
Oil and Filter Change
10. Reattach the oil line.
11. Place shop towels beneath
the oil filter. Using an oil filter wrench, turn the filter
counterclockwise to remove
it.
12. Using a clean dry cloth,
clean the filter sealing surface on the crankcase.
13. Lubricate the gasket on the
new filter with a film of new
engine oil. Make sure the
gasket is in good condition.
Make sure the gasket from the old filter is not still on the engine.
14. Install the new filter and turn by hand until the filter gasket contacts
the sealing surface, then turn and additional 1/2 turn.
15. Approximately one cup of engine oil will remain in the crankcase.
To drain, remove the drain plug on the lower right side of the crankcase.
Tip: The sealing surfaces on the drain plug and crankcase should be clean and
free of burrs, nicks or scratches.
16. Reinstall the drain plug. Torque to 14 ft. lbs. (19 Nm).
17. Remove the dipstick and fill the tank with two quarts (1.9 l) of the
recommended oil.
18. Place the gear selector in neutral and engage the parking brake.
19. Prime the oil pump using the procedure on page 60. Then stop
the engine and inspect for leaks.
20. Check the oil level on the dipstick. Add oil as necessary to bring the
level to the upper mark on the dipstick.
21. Dispose of used filter and oil properly.
59
MAINTENANCE
Engine Oil
Oil and Filter Change
Oil Pump Priming
This priming procedure must be
Tank
performed whenever the oil hose
2"
connection between the oil tank and
(5 cm)
pump inlet has been disconnected.
1. Clamp or pinch off the vent line
approximately 2" (5 cm) from
the oil tank, between the end of
Clamp
the oil tank vent fitting and the
vent line's pressure relief slit.
Pressure
Relief Slit
2. Start the engine. Allow it to idle
for 10-20 seconds.
3. Remove the vent line clamp. If the line is bled properly, you should
hear a rush of air, indicating that the line is properly primed and
ready for operation.
Tip: If you do not hear air, the line has not bled. Repeat the priming procedure.
Gearcases
Gearcase Specification Chart
Gearcase
Lubricant
Capacity
Fill Plug
Torque
Drain Plug
Torque
Main Gearcase
(Transmission)
Premium AGL
Synthetic
Gearcase Lube
34 oz.
(1000 ml)
12 ft. lbs.
(16.3 Nm)
12 ft. lbs.
(16.3 Nm)
Front Gearcase
Premium Demand
Drive Hub Fluid
9.3 oz.
(275 ml)
8-10 ft. lbs.
(11-13.6 Nm
11 ft. lbs.
(15 Nm)
60
MAINTENANCE
Gearcases
Transmission (Main Gearcase)
Always check and change the transmission oil at the intervals outlined
in the Periodic Maintenance Chart beginning on page 50. Maintain the
oil level even with the bottom of the fill plug hole threads.
Refer to the Gearcase Specifications Chart for recommended lubricants,
capacities and torque specifications. See page 102 for the part numbers
of Polaris products.
Oil Check
The fill plug is located on the side of the gearcase.
1. Position the vehicle on a level surface.
2. Remove the fill plug.
3. Check the oil level. Add the recommended oil as needed.
4. Reinstall the fill plug. Torque to specification.
Oil Change
The drain plug is located near the bottom of the gearcase.
1. Remove the fill plug.
2. Place a drain pan under the gearcase.
3. Remove the drain plug. Allow the oil to drain completely.
4. Clean and reinstall the drain plug. Torque to specification.
5. Add the recommended oil.
6. Reinstall the fill plug. Torque to specification.
7. Check for leaks. Dispose of used oil properly.
Fill Plug
Drain Plug
61
MAINTENANCE
Gearcases
Front Gearcase
Always check and change the front gearcase oil at the intervals outlined
in the Periodic Maintenance Chart beginning on page 50. Maintain the
oil level even with the bottom thread of the fill plug hole.
Refer to the Gearcase Specifications Chart on page 60 for recommended
lubricants, capacities and torque specifications. See page 102 for the
part numbers of Polaris products.
Oil Check
The front gearcase fill plug is located
on the right side of the front gearcase.
1. Position the vehicle on a level
surface.
2. Remove the fill plug. Check the
oil level.
3. Add the recommended oil as
needed.
4. Reinstall the fill plug. Torque to
Fill Plug
specification.
Drain Plug
62
MAINTENANCE
Gearcases
Front Gearcase
Oil Change
1. Support the vehicle securely with a jackstand.
2. Remove the front tire on the driver's side.
3. Remove the fill plug.
4. Place a drain pan under the drain plug on the bottom right-hand
side.
5. Remove the drain plug. Drain the oil.
6. Clean the drain plug. Reinstall the drain plug. Torque to specification.
7. Add the recommended oil.
8. Reinstall the fill plug. Torque to specification.
9. Check for leaks.
10. Discard used oil properly.
63
MAINTENANCE
Spark Plugs
Spark Plug Recommendations
Refer to the specifications section beginning on page 100 for the recommended spark plug type for your vehicle. Always torque spark plugs to
specification.
NOTICE: Using non-recommended spark plugs can result in serious engine
damage. Always use Polaris-recommended spark plugs.
Spark Plug Gap/Torque
Model
Electrode Gap
RANGER 4X4
.036" (.9 mm)
New Plug
Torque
9-11 ft. lbs.
(12-15 Nm)
Used Plug
Torque
9-11 ft. lbs.
(12-15 Nm)
Spark Plug Inspection
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 correct color. See page 64.
CAUTION! A hot exhaust system and engine can cause burns. Wear
protective gloves when removing a spark plug for inspection.
1. Remove the seat to access the engine compartment.
2. Remove the spark plug cap. Using the spark plug wrench provided
in the tool kit, remove the plug by rotating it counterclockwise.
3. Reverse the procedure for spark plug installation. Torque to specification.
64
MAINTENANCE
Spark Plugs
Spark Plug Inspection
Normal Plug
The 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.
Wet Fouled Plug
The 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.
65
MAINTENANCE
Cooling System
The engine coolant level is controlled or maintained by the recovery
system. The recovery system components are the overflow bottle, radiator filler neck, radiator pressure cap and connecting hose.
As coolant operating temperature increases, the expanding (heated)
excess coolant is forced out of the radiator, past the pressure cap, and
into the overflow bottle. As engine coolant temperature decreases, the
contracting (cooled) coolant is drawn back up from the tank, past the
pressure cap, and into the radiator.
Some coolant level drop on new vehicles is normal as the system is
purging itself of trapped air. Observe coolant levels and maintain as recommended by adding coolant to the overflow bottle.
Adding or Changing Coolant
To ensure that the coolant maintains its ability to protect the engine, we
recommend that the system be completely drained every two years and a
fresh mixture of antifreeze and water added. Polaris recommends the
use of Polaris Premium 60/40 anti-freeze/coolant or a 50/50 mixture of
high quality aluminum compatible anti-freeze/coolant and distilled
water. Polaris Premium 60/40 is already premixed and ready to use. Do
not dilute with water. See page 102 for the part numbers of Polaris products.
Always follow the manufacturer's mixing recommendations for the
freeze protection required in your area.
Any time the cooling system has been drained for maintenance or repair,
replace the coolant. If the recovery bottle has run dry, the level in the
radiator should be inspected. Add coolant as needed.
66
MAINTENANCE
Cooling System
Radiator and Cooling Fan
Always check and clean the screen and radiator fins at the intervals outlined in the Periodic Maintenance Chart beginning on page 50. Do not
obstruct or deflect air flow through the radiator by installing unauthorized accessories in front of the radiator or behind the cooling fan. Interference with the radiator air flow can lead to overheating and
consequent engine damage.
NOTICE: Washing the vehicle with a high-pressure hose could damage the
radiator fins and impair the radiator's effectiveness. Using a highpressure system is not recommended.
Overflow Bottle Coolant Level
Always check and change the coolant at the intervals outlined in the
Periodic Maintenance Chart beginning on page 50. Maintain the coolant
level between the minimum and maximum marks on the bottle (when
the fluid is cool).
The overflow bottle is located in front of the right front wheel.
1. Position the vehicle on a level surface.
2. View the coolant level in the overflow bottle.
3. If the coolant level is below the
safe operating range, lift the
hood and locate the overflow
bottle lid. Remove the cap and
use a funnel to add coolant
through the filler opening. Reinstall the cap.
Tip: If coolant must be added often, or if
the overflow bottle runs completely
dry, there may be a leak in the system. Have the cooling system
inspected by your Polaris dealer.
67
MAINTENANCE
Cooling System
Radiator Coolant Level
Always check and clean the screen and radiator fins at the intervals outlined in the Periodic Maintenance Chart beginning on page 50. Do not
obstruct or deflect air flow through the radiator by installing unauthorized accessories in front of the radiator or behind the cooling fan. Interference with the radiator air flow can lead to overheating and
consequentially, engine damage.
1. Lift the hood.
CAUTION! Escaping steam can cause
burns. Never remove the pressure cap
while the engine is warm or hot. Always
allow the engine to cool before removing
the pressure cap.
2. Slowly remove the radiator cap.
3. View the coolant level through
the opening.
4. Use a funnel and slowly add
coolant as needed.
Tip: This procedure is required only if
the cooling system has been
drained for maintenance and/or repair. But if the overflow bottle has run dry,
the level in the radiator should also be inspected.
5. Reinstall the pressure cap. Use of a non-standard pressure cap will
not allow the recovery system to function properly. See your dealer
for the correct replacement part.
68
MAINTENANCE
Polaris Variable Transmission (PVT) System
WARNING
Failure to comply with the instructions in this warning can result in severe injury
or death.
Do not modify any component of the PVT system. Doing so may reduce its
strength so that a failure may occur at a high speed. The PVT system has been
precision balanced. Any modification will cause the system to be out of balance,
creating vibration and additional loads on components.
The PVT system rotates at high speeds, creating large amounts of force on
clutch components. Extensive engineering and testing has been conducted to
ensure the safety of this product. However, as the owner, you have the following
responsibilities to make sure this system remains safe:
• Always follow all recommended maintenance procedures. See your dealer as
outlined in the owner's manual.
• This PVT system is intended for use on Polaris products only. Do not install it in
any other product.
• Always make sure the PVT housing is securely in place during operation.
When To Use Low Range vs. High Range
Belt slip is responsible for creating excessive heat that destroys belts,
wears clutch components and causes outer clutch covers to fail. Switch
to low range while operating at slower speeds to extend the life of the
PVT components (belt, cover, etc.).
Condition
Operating at speeds less than 7 MPH (11 km/h)
Range to Use
Low
Towing heavy loads
Low
Operating in rough terrain (swamps, mountains, etc.)
Low
Operating at speeds greater than 7 MPH (11 km/h)
High
69
MAINTENANCE
PVT System
PVT Drying
There may be some instances when water is ingested into the PVT system. Use the following instructions to dry it out before operating.
1. Position the vehicle on a level surface.
2. Remove the drain plug. Allow the water to drain completely. Reinstall the drain plug.
3. Apply the brakes. Start the engine.
4. Engage the park brake.
5. Shift the transmission to neutral.
6. Apply varying throttle for 10-15 seconds to expel the moisture and
air-dry the belt and clutches. Do not hold the throttle wide open for
more than 10 seconds.
7. Allow the engine RPM to settle to idle speed. Apply the brakes.
Release the park brake and shift the transmission to the lowest
available range.
8. Test for belt slippage. If the belt slips, repeat the process.
9. Take the vehicle to your dealer for service as soon as possible.
70
MAINTENANCE
Vehicle Immersion
NOTICE: If your vehicle becomes immersed, major engine damage can result
if the machine is not thoroughly inspected. Take the vehicle to your
dealer before starting the engine.
If it's impossible to take your RANGER to a dealer before starting it, follow the steps outlined below.
1. Move the vehicle to dry land or at the very least, to water below the
footrests.
2. Dry any water present in the air box. Filter replacement is required
if water is present.
3. Thoroughly dry the air pre-cleaner located under the hood.
4. Remove the spark plugs. Turn the engine over several times using
the electric start.
5. Dry the spark plugs and reinstall, or replace with new plugs.
6. Attempt to start the engine. If necessary, repeat the drying procedure.
7. Take the vehicle to your dealer for service as soon as possible,
whether you succeed in starting it or not.
8. If water has been ingested into the PVT follow the procedure on
page 70 for drying.
71
MAINTENANCE
Filter Systems
Air Filter
Always change the air filter at the intervals outlined in the Periodic
Maintenance Chart beginning on page 50. Service the air filter more frequently if the vehicle is operated in wet conditions or at high throttle
openings for extended periods.
1. Lift the cargo box to
access the air box.
2. Remove the air box
Air Filter
cover and inspect the
gasket. It should adhere
tightly to the cover and
seal all the way around.
3. Remove the air filter.
4. Do not attempt to clean
the main element.
Install a new air filter.
Tip: Apply a small amount of
general purpose grease to
the sealing edges of the
filter before installing.
5. Inspect the air box for
oil or water deposits. If present, drain them into a suitable container.
72
MAINTENANCE
Filter Systems
Breather Filter and Hoses
1. Lift the cargo box and
locate the air box.
2. Follow the right-hand
breather line out the side
of the air box and locate
the filter.
3. Remove and inspect the
filter for debris. Blow
gently through the filter
in the direction of the
arrow to check for clogging. Replace as needed.
4. Check hoses for cracks,
deterioration, abrasion, or
leaks. Replace as needed.
5. Reinstall the filter with
the arrow pointing toward
the engine. Secure the
clamps.
NOTICE: Operation of the vehicle without a breather filter can cause engine
damage. Always reinstall the breather filter after removing it for
service.
73
MAINTENANCE
Spark Arrestor
WARNING
Failure to heed the following warnings while servicing the spark arrestor could
result in serious injury or death.
Do not perform service on the spark arrestor while the system is hot. Exhaust
system temperatures can reach 1000° F. Allow components to cool sufficiently
before proceeding.
Remove any combustible materials from the area.
Wear eye protection and gloves.
Do not stand behind or in front of the vehicle while purging.
Never run the engine in an enclosed area. Exhaust contains poisonous carbon
monoxide gas that can cause loss of consciousness or death in a very short
time.
Never go under the vehicle while it's inclined.
74
MAINTENANCE
Spark Arrestor
Use the following procedure to periodically purge accumulated carbon
from the exhaust pipe.
1. Remove the arrestor clean-out
plugs located on the bottom of
the muffler.
2. Shift the transmission to neutral.
Apply the brakes. Start the
engine.
3. Purge accumulated carbon from
the system by momentarily revExhaust
Outlet
ving the engine several times.
Clean-Out
4. If carbon is expelled, cover or
Plugs
plug the exhaust outlet and rap
on the pipe around the clean-out
plugs while revving the engine several more times.
5. If particles are still suspected to be in the muffler, elevate the rear of
the vehicle one foot higher than the front. Block the wheels.
6. Repeat steps 3 and 4 until no more particles are expelled when the
engine is revved.
7. Stop the engine. Allow the arrestor to cool.
8. Reinstall the arrestor plugs and remove the outlet cover or plug.
75
MAINTENANCE
Throttle System
WARNING
Failure to check or maintain proper operation of the throttle system can result in
an accident and lead to serious injury or death if the throttle pedal sticks during
operation.
Always check the pedal for free movement and return before starting the engine
and occasionally during operation. Never start or operate this vehicle if it has a
sticking or improperly operating throttle pedal. Immediately contact your dealer
for service if throttle problems arise.
Throttle Freeplay
If the throttle pedal has excessive
play due to cable stretch or misadjustment, it will cause a delay
in throttle response, especially at
low engine speed. The throttle
may also not open fully. If the
throttle pedal has no freeplay, the
throttle may be hard to control,
and the idle speed may be erratic.
Check the throttle pedal freeplay
at the intervals outlined in the
Periodic Maintenance Chart
beginning on page 50. Adjust the
freeplay if necessary.
Throttle
Pedal
Throttle Freeplay Inspection
1. Apply the brakes. Engage the park brake. Shift the transmission to
neutral.
2. Start the engine. Allow it to warm up thoroughly.
3. Measure the distance the throttle pedal moves before the engine
begins to pick up speed. Freeplay should be 1/16 to 1/8 inches (1.63.2 mm).
76
MAINTENANCE
Throttle System
Throttle Body/Idle RPM
Idle RPM is preset by the manufacturer. If the engine idle speed is not
satisfactory, please see your Polaris dealer for adjustment.
Throttle Freeplay Adjustment
1. Remove the seat.
2. Locate the throttle cable
adjuster.
3. Squeeze the end of the rubber boot and slide it far
enough to expose the end
of the inline cable adjuster.
4. Loosen the adjuster lock
nut.
5. Rotate the boot to turn the
adjuster until 1/16" to 1/8"
(1.5-3 mm) of freeplay is
achieved at the throttle
pedal. See page 76.
Boot
Lock Nut
Adjuster
Tip: While adjusting, lightly flip the throttle pedal up and down.
6. Tighten the lock nut.
7. Squeeze the end of the rubber boot and slide it over the cable
adjuster to its original position.
Cylinder Head/Cylinder Base Fastener Torque
Have your dealer check the cylinder head and cylinder base fasteners for
proper torque at the first service or after 25 hours.
77
MAINTENANCE
Brakes
The front and rear brakes are hydraulic disc type brakes. Press down on
the brake pedal to engage the brakes. See page 24.
Brake Fluid
Inspect the brake system routinely. Inspect the level of the brake fluid
before each operation.
WARNING! After opening a bottle of brake fluid, always discard any unused
portion. Never store or use a partial bottle. Brake fluid is hygroscopic, meaning it
rapidly absorbs moisture from the air. The moisture causes the boiling
temperature of the brake fluid to drop, which can lead to early brake fade and
the possibility of accident or severe injury.
Change the brake fluid every two years and any time the fluid becomes
contaminated, the fluid level is below the minimum, or if the type and
brand of the fluid in the reservoir are unknown. See page 55 for fluid
recommendations.
1. Position the vehicle on a level
Maximum
Minimum
surface.
2. View the brake fluid level at the
reservoir in the driver’s side
wheel well. The level should be
between the upper (MAX) and
lower (MIN) level lines.
3. If the fluid level is lower than
the upper level line, add brake
fluid to the upper (MAX) line.
4. Apply the brake forcefully for a
few seconds and check for fluid
leakage around the fittings.
78
MAINTENANCE
Brakes
Brake Inspection
1. Check the brake system for
fluid leaks.
2. Check the brake pedal for
excessive travel or a spongy
feel.
3. Check the friction pads for
wear, damage and looseness.
4. Inspect the brake disc spline
and pad wear surface for
excessive wear.
5. Change pads when worn to
3/64" (1 mm).
Park Brake Inspection
1. Apply the brakes.
2. Pull the park brake lever
downward as far as possible.
3. Check the vehicle for
movement. The vehicle
should not roll while parked.
If the vehicle moves, adjust
the park brake.
3/64" (1mm)
Park Brake Release
79
MAINTENANCE
Brakes
Park Brake Adjustment
Inspect and adjust park brake cable tension after the first 25 hours of
operation and every 100 hours thereafter to ensure proper cable tension.
Loss of tension in the park brake cable may cause illumination of the
park brake light and activation of the limiting feature. If this occurs,
move the park brake lever to the forward-most position, then inspect and
adjust park brake cable tension.
Tip: If performing this service is difficult due to conditions or location, open the
hood and temporarily disconnect the park brake connector. This will inactivate the limiting function. Reconnect the connector as soon as possible,
and adjust the park brake cable to proper tension.
1. Position the vehicle on a level surface.
2. Shift the transmission to neutral.
3. Loosen or tighten the nuts on the lever end of the park brake cable
as needed.
Steering Wheel Inspection
Check the steering wheel for specified freeplay and smooth operation at
the intervals outlined in the Periodic Maintenance Chart beginning on
page 50.
1. Position the vehicle on a level surface.
2. Lightly turn the steering wheel left and right.
3. There should be 0.8"-1.0" (20-25 mm) of freeplay.
4. If there is excessive freeplay or strange noises, or the steering feels
rough or "catchy," have the steering system inspected by an authorized Polaris dealer.
80
MAINTENANCE
Suspension Adjustments
The front and rear suspensions can be adjusted to provide a stiffer suspension, if necessary.
1. Remove the top shock mounting bolts from the inside mounting
holes.
2. Reposition the shocks to the outside mounting holes.
3. Reinstall the shock mounting bolts. Torque to 30 ft. lbs. (40 Nm).
Spring Adjustment
Adjust the front and rear shock absorber springs by rotating the adjustment cam either clockwise or counterclockwise to increase or decrease
spring tension.
Outside Mounting Holes
Inside Mounting Holes
Cam
Rear Suspension Shown
Adjustment is similar for Front Suspension
81
MAINTENANCE
Tires
WARNING
Operating your vehicle with worn tires, improperly inflated tires, non-standard
tires or improperly installed tires will affect vehicle handling and could cause an
accident resulting in serious injury or death. Always follow all tire maintenance
procedures as outlined in this manual and on the labels on the vehicle. Always
use original equipment size and type when replacing tires.
Tire Tread Depth
Always replace tires
when tread depth is
worn to 1/8" (3 mm)
or less.
1/8" (3 mm)
Axle and Wheel Nut Torque Specifications
Inspect the following items occasionally for tightness, and if they've
been loosened for maintenance service.
Do not lubricate the stud or the lug nut.
Nut Type
Location
Nut Torque
Lug Nut
Front and Rear
90 ft. lbs. (122 Nm)
2-Piece Flange
Nut
Front and Rear
35 ft. lbs. (47 Nm)
Spindle Nut
Front
70 ft. lbs. (95 Nm)
Hub Retaining Nuts
Center and Rear
110 ft. lbs. (150 Nm)
82
MAINTENANCE
Tires
Wheel Removal
1.
2.
3.
4.
Apply the brakes. Engage the park brake.
Stop the engine. Place the transmission in gear.
Loosen the wheel nuts slightly.
Elevate the side of the vehicle by placing a suitable stand under the
frame.
5. Remove the wheel nuts and washers. Remove the wheel.
Wheel Installation
1. Place the transmission
in gear.
2. Apply the brakes.
Engage the park
brake.
3. Place the wheel in the
correct position on the
wheel hub. Be sure
the valve stem is
toward the outside
and rotation arrows
on the tire point
toward forward rotation.
WARNING! Improperly installed wheels can adversely affect tire wear and
vehicle handling, which can result in serious injury or death. Always ensure that
all nuts are torqued to specification. Do not service axle nuts that have a cotter
pin installed. See your Polaris dealer.
4. Attach the wheel nuts and washers and finger tighten.
5. Carefully lower the vehicle to the ground.
6. Torque the wheel nuts to specification. See page 82.
83
MAINTENANCE
Lights
Poor lighting can result in reduced visibility when driving. Headlight
and taillight lenses become dirty during normal operation. Clean lights
frequently and replace burned out lamps promptly. Always make sure
lights are adjusted properly for best visibility.
When servicing a halogen lamp, don't touch the lamp with bare fingers.
Oil from your skin leaves a residue, causing a hot spot that will shorten
the life of the lamp.
Headlight Lamp Replacement
1. Open the hood.
CAUTION! Hot components
can cause burns to skin. Allow
lamps to cool before servicing.
Wiring Harness
2. Unplug the headlamp
from the wiring harness.
Be sure to pull on the
connector, not on the
wiring.
3. Turn the lamp counterclockwise to remove it.
4. Install the new lamp.
Tip: Make sure the tab on the lamp locates properly in the housing.
5. Reinstall the harness assembly into the headlight assembly.
84
MAINTENANCE
Lights
Headlight Beam Adjustment
X
X
8" (20 cm)
25 ft.
(7.6 m)
1. Place the vehicle on a level surface with the headlight approximately 25 ft. (7.6 m) from a wall.
2. Measure the distance from the floor to the center of the headlight
and make a mark on the wall at the same height.
3. Apply the brakes. Start the engine. Turn on the headlights.
4. Observe the headlight aim. The most intense part of the headlight
beam should be aimed 8" (20 cm) below the mark placed on the
wall. Include the weight of a rider on the seat while performing this
step.
5. If a headlight needs adjustment, locate the adjustment screw at the
back of the headlight.
6. Loosen the screw, adjust the headlight, and tighten the screw.
7. Repeat steps 4-6 until the lamp is properly adjusted.
85
MAINTENANCE
Lights
Brake Lights
When the brake pedal is depressed, the console brake light comes on.
Check the brake light before each ride.
1. Turn the ignition switch to the ON position.
2. Depress the brake pedal. The brake light should come on after about
10mm (0.4 in.) of pedal travel. If the light doesn't come on, check
the bulb.
Indicator Lamp Replacement
1. Lift the hood.
Release
2. Reach in behind the console
Tab
panel and lift the release to
unplug the light from the
harness.
3. Using a flathead screwdriver,
press on the tab on the top of
the light to remove the indicator light assembly from the
console panel.
4. Locate the expired lamp. Using a screwdriver, rotate the lamp 1/4
turn counterclockwise.
5. Grip the lamp with a needle-nose pliers and remove it from the
assembly.
6. Install the new lamp. Using a screwdriver, rotate the lamp 1/4 turn
clockwise to seat it.
7. Snap the assembly back into the console panel. Reconnect the harness.
8. Close the hood.
86
MAINTENANCE
Battery
WARNING
Battery electrolyte is poisonous. It contains sulfuric acid. Serious burns can
result from contact with skin, eyes or clothing.
Antidote:
External: Flush with water.
Internal: Drink large quantities of water or milk. Follow with milk of magnesia,
beaten egg, or vegetable oil. Call physician immediately.
Eyes: Flush with water for 15 minutes and get prompt medical attention.
Batteries produce explosive gases. Keep sparks, flame, cigarettes, etc. away.
Ventilate when charging or using in an enclosed space. Always shield eyes
when working near batteries. KEEP OUT OF REACH OF CHILDREN.
Your vehicle may have either a sealed battery, which requires little
maintenance, or a conventional battery. A sealed battery can be identified by its flat covers on the top of the battery. A conventional battery
has six filler caps on the top of the battery.
Always keep battery terminals and connections free of corrosion. If
cleaning is necessary, remove the corrosion with a stiff wire brush.
Wash with a solution of one tablespoon baking soda and one cup water.
Rinse well with tap water and dry off with clean shop towels. Coat the
terminals with dielectric grease or petroleum jelly. Be careful not to
allow cleaning solution or tap water into the battery.
87
MAINTENANCE
Battery
Battery Removal
WARNING
Improperly connecting or disconnecting battery cables can result in an explosion
and cause serious injury or death. When removing the battery, always
disconnect the negative (black) cable first. When reinstalling the battery, always
connect the negative (black) cable last.
1. Open the hood.
2. On conventional batteries,
remove the battery vent tube.
3. Disconnect the black (-) battery
cable first.
4. Disconnect the red (+) battery
cable last.
5. Lift the battery out of the vehicle. Be careful not to tip a conventional battery sideways,
which could spill electrolyte.
NOTICE: If electrolyte spills, immediately wash it off with a solution of one
tablespoon baking soda and one cup water to prevent damage to the
vehicle.
88
MAINTENANCE
Battery
Battery Installation
Using a new battery that has not been fully charged can damage the battery and result in a shorter life. It can also hinder vehicle performance.
Follow the battery charging instructions on page 91 before installing the
battery.
1. Ensure that the battery is fully charged.
2. Place the battery in the battery holder. Make sure the positive terminal is toward the driver’s side of the vehicle.
3. With conventional batteries, install the battery vent tube (sealed batteries do not have a vent tube). The vent tube must be free of
obstructions and securely installed. Route the tube away from the
frame and vehicle body to prevent contact with electrolyte.
WARNING! Battery gases could accumulate in an improperly installed vent tube
and cause an explosion, resulting in serious injury or death. Always ensure that
the vent tube is free of obstructions and is securely installed as recommended.
4. On conventional batteries, coat the terminals with dielectric grease
or petroleum jelly.
5. Connect and tighten the red (+) cable first.
6. Connect and tighten the black (-) cable last.
7. Verify that cables are properly routed.
89
MAINTENANCE
Battery
Battery Storage
Whenever the vehicle is not used for a period of three months or more,
remove the battery from the vehicle, ensure that it's fully charged, and
store it out of the sun in a cool, dry place. Check battery voltage each
month during storage and recharge as needed to maintain a full charge.
See page 91.
Polaris recommends maintaining battery charge by using a Polaris Battery Tender charger or by charging about once a month to make up for
normal self-discharge. Battery Tender can be left connected during the
storage period, and will automatically charge the battery if the voltage
drops below a pre-determined point. See page 102 for the part numbers
of Polaris products.
Battery Fluid (Conventional Battery)
A poorly maintained battery will
deteriorate rapidly. Check the battery fluid level often. Maintain the
fluid level between the upper and
lower level marks.
Add only distilled water. Tap water
contains minerals that are harmful
to a battery.
90
Lower
Mark
Upper
Mark
MAINTENANCE
Battery
Battery Charging (Conventional Battery)
1. Remove the battery from the vehicle to prevent damage from leaking or spilled electrolyte during charging. See page 88.
2. Charge the battery with a charging output no larger than 1/10 of the
battery’s amp/hr rating. Charge as needed to raise the specific gravity to 1.270 or greater.
3. Reinstall the battery. See page 89. Make sure the positive terminal is
toward the driver’s side of the vehicle.
Battery Charging (Sealed Battery)
The following battery charging instructions apply only to the installation of a sealed battery. Read all instructions before proceeding with the
installation of this battery.
The sealed battery is already filled with electrolyte and has been sealed
and fully charged at the factory. Never pry the sealing strip off or add
any other fluid to this battery.
The single most important thing about maintaining a sealed battery is to
keep it fully charged. Since the battery is sealed and the sealing strip
cannot be removed, you must use a voltmeter or multimeter to measure
DC voltage.
WARNING! An overheated battery may explode, causing severe injury or
death. Always watch charging times carefully. Stop charging if the battery
becomes very warm to the touch. Allow it to cool before resuming charging.
For a refresh charge, follow all instructions carefully.
1. Check the battery voltage with a voltmeter or multimeter. A fully
charged battery will register 12.8 V or higher.
2. If the voltage is less than 12.8 volts, recharge the battery at 1.2 amps
or less until battery voltage is 12.8 or greater.
3. When using an automatic charger, refer to the charger manufacturer's instructions for recharging. When using a constant current
charger, use the guidelines on the next page for recharging.
91
MAINTENANCE
Battery
Battery Charging (Sealed Battery)
Always verify battery condition before and 1-2 hours after the end of
charging.
Charge Time
State of
Charge
Voltage
Action
(Using constant current
charger @ standard amps
specified on top of battery)
100%
12.8-13.0 volts
None required
75%-100%
12.5-12.8 volts
50%-75%
25%-50%
12.0-12.5 volts
11.5-12.0 volts
None, check at 3
mos. from date of
manufacture
May need slight
charge, if no
charge given,
check in 3 months
Needs charge
Needs charge
0%-25%
11.5 volts or less
92
Needs charge with
desulfating charger
3-6 hours
5-11 hours
At least 13 hours,
verify state of charge
At least 20 hours
MAINTENANCE
Fuses
Fuse
Feature Supported
15A
Accessories, 12V Power Receptacle
15A
Electronic Fuel Injection
15A
Lights
20A
Main Fuse - Ignition
If the engine stops or will not
start, or if you experience other
electrical failures, a fuse may
need replacement. Locate and
correct any short circuits that
may have caused the blown
fuse, then replace the fuse.
Spare fuses are provided in the
fuse box.
If you suspect that a fuse or
relay may not be working
properly, please see your
Polaris dealer.
93
MAINTENANCE
Cleaning and Storage
Washing the Vehicle
Keeping your Polaris vehicle clean will not only improve its appearance
but it can also extend the life of various components.
NOTICE: High water pressure may damage components. Polaris recommends
washing the vehicle by hand or with a garden hose, using mild soap.
NOTICE: Certain products, including insect repellents and chemicals, will
damage plastic surfaces. Do not allow these types of products to
contact the vehicle.
The best and safest way to clean your Polaris vehicle is with a garden
hose and a pail of mild soap and water.
1. Use a professional-type washing cloth, cleaning the upper body first
and the lower parts last.
2. Rinse with clean water frequently.
3. Dry surfaces with a chamois to prevent water spots.
Washing Tips
• Avoid the use of harsh cleaners, which can scratch the finish.
• Do not use a power washer to clean the vehicle.
• Do not use medium to heavy duty compounds on the finish.
• Always use clean cloths and pads for cleaning and polishing. Old or
reused cloths and pads may contain dirt particles that will scratch the
finish.
94
MAINTENANCE
Cleaning and Storage
Washing the Vehicle
If a high pressure water system is used for cleaning (not recommended),
exercise extreme caution. The water may damage components and could
remove paint and labels. Avoid directing the water stream at the following items:
• Wheel bearings
• Radiator
• Transmission seals
• Brakes
• Cab and body panels
• Labels and decals
• Switches and controls
• Electrical components and wiring
If an informational or graphic label becomes illegible or comes off, contact your Polaris dealer to purchase a replacement. Replacement safety
labels are provided by Polaris at no charge.
Grease all zerk fittings immediately after washing. Allow the engine to
run for a while to evaporate any water that may have entered the engine
or exhaust system.
Polishing the Vehicle
Polaris recommends the use of common household aerosol furniture
polish for polishing the finish on your Polaris vehicle. Follow the
instructions on the container.
Polishing Tips
• Avoid the use of automotive products, some of which can scratch the
finish of your vehicle.
• Always use clean cloths and pads for cleaning and polishing. Old or
reused cloths and pads may contain dirt particles that will scratch the
finish.
95
MAINTENANCE
Cleaning and Storage
Chrome Wheel Care (if equipped)
Proper maintenance will protect chrome wheels from corrosion, preserve wheel life and ensure a “like new” appearance for many years.
Chrome wheels exposed to road salt (or salt in the air in coastal areas)
are more susceptible to corrosion if not properly cleaned. Clean chrome
wheels more often if they're exposed to salt or other corrosive elements.
1. Wash chrome wheels frequently. Use a mild detergent. Never use
abrasive cleaners on plated or painted surfaces.
2. Rinse well with clear water. Soap, detergents, salt, dirt, mud and
other elements can cause corrosion.
3. Polish the clean chrome wheels periodically. Use an automotive
grade chrome polish.
4. Routinely and liberally apply a weather resistant wax to each polished chrome wheel. Choose a product suitable for chrome finishes.
Read and follow the product labels and instructions.
Removing Corrosion
If light rust is found on the chrome finish, use steel wool (#0000-OTT
grade) to remove it. Gently rub the affected areas with the steel wool
until the corrosion has been removed. Clean and polish the wheel as outlined above.
96
MAINTENANCE
Cleaning and Storage
Storage Tips
NOTICE: Starting the engine during the storage period will disturb the
protective film created by fogging and damage could occur. Never
start the engine during the storage period.
Clean the Exterior
Make any necessary repairs and clean the vehicle as recommended. See
page 94.
Stabilize the Fuel
1. Fill the fuel tank.
2. Add Polaris Carbon Clean Fuel Treatment or Polaris Fuel Stabilizer.
Follow the instructions on the container for the recommended
amount. Carbon Clean removes water from fuel systems, stabilizes
fuel and removes carbon deposits from pistons, rings, valves and
exhaust systems.
3. Allow the engine to run for 15-20 minutes to allow the stabilizer to
disperse through the entire fuel delivery system.
Oil and Filter
Change the oil and filter. See page 58.
Air Filter / Air Box
1. Inspect and clean or replace the pre-cleaner and air filter. See page
72.
2. Clean the air box.
3. Drain the sediment tube.
Inspect and Lubricate
Inspect all cables and lubricate all areas of the vehicle as recommended
in the Periodic Maintenance Chart beginning on page 50.
Battery Maintenance
See pages 90-92 for storage and charging procedures.
97
MAINTENANCE
Cleaning and Storage
Storage Tips
Fluid Levels
Inspect the fluid levels. Add or change fluids as recommended in the
Periodic Maintenance Chart beginning on page 50.
• Front and rear gearcase fluid (if equipped)
• Transmission fluid
• Brake fluid (change every two years and any time the fluid looks dark
or contaminated)
• Coolant (test strength/fill)
Fog the Engine
1. Treat the fuel system with Polaris Carbon Clean. Follow the instructions on the container. Start the engine. Allow it to idle for several
minutes so the Carbon Clean reaches the injectors. Stop the engine.
2. Remove the spark plugs and add 2-3 tablespoons of engine oil. To
access the plug holes, use a section of clear 1/4" hose and a small
plastic squeeze bottle filled with the pre-measured amount of oil.
Do this carefully! If you miss the plug holes, oil will drain from the
spark plug cavities into the hole at the front of the cylinder head,
and appear to be an oil leak.
3. Reinstall the spark plugs. Torque to specification. See page 64.
4. Apply dielectric grease to the inside of each spark plug cap and reinstall the caps onto the plugs.
5. Turn the engine over several times. Oil will be forced in and around
the piston rings and ring lands, coating the cylinder with a protective film of fresh oil.
6. If Polaris fuel system additive is not used, fuel tank, fuel lines, and
injectors should be completely drained of gasoline.
Storage Area/Covers
Be sure the storage area is well ventilated. Cover the vehicle with a genuine Polaris cover. Do not use plastic or coated materials. They do not
allow enough ventilation to prevent condensation, and may promote
corrosion and oxidation.
98
MAINTENANCE
Removal from Storage
1. Check the battery electrolyte level and charge the battery if necessary. Install it in the vehicle. Make sure the battery vent hose is
routed properly and that it's not pinched or restricted in any way.
2. Make sure the spark plug is tight.
3. Fill the fuel tank with fuel.
4. Check all the points listed in the Daily Pre-Ride Inspection section
on page 31. Tightness of the bolts, nuts and other fasteners should
be checked by an authorized Polaris dealer.
5. Lubricate at the intervals outlined in the Periodic Maintenance
Chart beginning on page 50.
Transporting the RANGER
Follow these procedures when transporting the vehicle.
1. Apply the brakes. Engage the park brake.
2. Stop the engine.
3. Place the transmission in gear.
4. Secure the fuel cap, oil cap and seat.
5. Always tie the frame of the RANGER to the transporting unit
securely with suitable straps or rope. Do not attach tie straps to the
front A-arm bolt pockets.
6. Remove the key to prevent loss during transporting.
99
SPECIFICATIONS
RANGER 4X4
Maximum Weight Capacity
Dry Weight
Fuel Capacity
Engine Oil Capacity
Coolant Capacity
Overall Length
Overall Width (box)
Overall Width (tires)
Overall Height
Wheelbase
Cargo Box (L x W x H)
Ground Clearance
Min. Turning Radius
Towing Capacity
Max. Cargo Box Load
Engine
Displacement
Bore x Stroke
Alternator Output
Compression Ratio
Starting System
Fuel System
Spark Plug
Front Suspension
Rear Suspension
100
1500 lbs. (681 kg) (includes weight of operator,
passenger, cargo, accessories)
1214 lbs. (551 kg)
8.8 gal. (33.3 l)
2 qts. (1.9 l)
3.25 qts. (3 l)
114 in. (289.6 cm)
60 in. (152.4 cm)
58 in. (147.3 cm)
76 in. (193 cm)
76 in. (193 cm)
58 x 42 x 10 in. (147 x 106.7 x 25.4 cm)
12 in. (30.5 cm)
158 in. (401 cm)
1500 lbs. (681 kg)
1000 lbs. (454 kg)
4 valve 4 stroke single cylinder with
counter balance
499 cc
92 x 75
350 W
10.2:1
Electric
Electronic Fuel Injection
NGK BKR5E
Dual A-arm w/9.6 in. (24.4 cm) of travel
Independent w/9 in. (23 cm) of travel
SPECIFICATIONS
RANGER 4X4
Lubrication System
Engine Oil
Driving System Type
Shift Type
Gear Reduction - Low
Gear Reduction - Reverse
Gear Reduction - High
Drive Ratio - Front:
Drive Ratio - Rear
Tire Size - Front
Tire Size - Rear
Tire Pressure - Front
Tire Pressure - Rear
Brakes, Front/Rear
Brake, Park
Hood Headlights
Taillights
Brake Light
Indicator Light
Dry Sump
0W/40
PVT
Single Lever (console)
7.7:1
7.0:1
4.12:1
3.818:1
3.105:1
25 x 10 - 12
25 x 11 - 12
8-12 psi (69 kPa)
8-12 psi (69 kPa)
Foot Activated, 4 wheel hydraulic disc
Hand activated, mechanical
2 single beam, 50W, quartz/halogen
10 L.E.D. (.28W)
10 L.E.D. (3.1W)
1.0 W
Clutching
See your Polaris dealer for clutching specifications.
101
POLARIS PRODUCTS
Part
Number
2870791
2876244
2876245
2873602
2873603
2871653
2872276
2870465
2871654
2872277
2871323
2871534
2871312
2871322
2871423
2871460
2871515
2871551
2871329
2872073
2872348
2871326
2872189
2871956
2871076
102
Description
Engine Lubricant
Fogging Oil (12 oz. Aerosol)
PS-4 PLUS Performance Synthetic 2W-50 4-Cycle Oil (qt.)
PS-4 PLUS Performance Synthetic 2W-50 4-Cycle Oil (gal.)
Gearcase / Transmission Lubricants
Premium AGL Synthetic Gearcase Lubricant (qt.)
Premium AGL Synthetic Gearcase Lube (gal.)
Premium ATV Angle Drive Fluid (8 oz.)
Premium ATV Angle Drive Fluid (2.5 gal.)
Pump for Gallon Jug
Premium Demand Drive Hub Fluid (8 oz.)
Premium Demand Drive Hub Fluid (2.5 gal.)
Coolant
60/40 Coolant (gal.)
60/40 Coolant (qt.)
Grease / Specialized Lubricants
Grease Gun Kit, Premium All Season (3 oz.)
Premium All Season Grease (3 oz. cartridge)
Premium All Season Grease (14 oz. cartridge)
Starter Drive Grease (2 oz.)
Premium U-Joint Lube (3 oz.)
Premium U-Joint Lube (14 oz.)
Dielectric Grease (NyogelTM)
Chain Lube, Aerosol (6.25 oz.)
Chain Lube, Aerosol (16 oz.)
Additives / Miscellaneous
Carbon Clean Plus (12 oz.)
DOT 4 Brake Fluid
LoctiteTM 565 Thread Sealant
Polaris Battery TenderTM Charger
TROUBLESHOOTING
Drive Belt Wear/Burn
Possible Cause
Driving onto a pickup or
tall trailer in high range
Starting out going up a
steep incline
Driving at low RPM or
ground speed (3-7 MPH)
Insufficient warm-up at
low ambient temperatures
Solution
Use low range during loading.
Use low range. See warnings on page 36.
Drive at a higher speed or use low range more frequently.
See page 69.
Warm the engine at least 5 minutes. With the transmission
in neutral, advance the throttle to about 1/8 throttle in
short bursts, 5 to 7 times. The belt will become more flexible and prevent belt burning.
Slow/easy clutch engage- Use the throttle quickly and effectively.
ment
Towing/pushing at low
Use low range only.
RPM/low ground speed
Utility use/plowing
Use low range only.
Stuck in mud or snow
Shift the transmission to low range and carefully use fast,
aggressive throttle application to engage clutch.
WARNING: Excessive throttle may cause loss of control
and vehicle overturn.
Climbing over large
Shift the transmission to low range and carefully use fast,
objects from a stopped
brief, aggressive throttle application to engage clutch.
position
WARNING: Excessive throttle may cause loss of control
and vehicle overturn.
Belt slippage from water Dry out the PVT. See page 70. Inspect clutch seals for
or snow ingestion into the damage if repeated leaking occurs.
PVT system
Clutch malfunction
See your Polaris dealer.
Poor engine performance Check for fouled plugs or foreign material in fuel tank or
fuel lines. See your dealer.
Slippage from failure to
Always warm up the belt by operating below 30 mph for
warm up belt
one mile (5 miles or more when temperature is below
freezing).
Wrong or missing belt
Install the recommended belt.
Improper break-in
Always break in a new belt and/or clutch. See pages 29
and 69.
103
TROUBLESHOOTING
Park Brake Engine Limiting Feature Fails to Disengage
Possible Cause
Solution
Park brake is not completely disengaged
Park brake connector malfunction or
switch movement or failure
Ensure lever is in forward-most position
Disconnect the connector if temporary
continued operation is necessary, see your
dealer promptly for service
Engine Doesn't Turn Over
Possible Cause
Low battery voltage
Loose battery connections
Loose solenoid connections
Loose electronic control box connections
Solution
Recharge the battery to 12.8 VDC
Check all connections and tighten
Check all connections and tighten
Inspect, clean, reinstall connectors
Engine Turns Over, Fails to Start
Possible Cause
Out of fuel
Water is present in fuel
Old or non-recommended fuel
Fouled or defective spark plugs
No spark to spark plug
Water or fuel in crankcase
Low battery voltage
Mechanical failure
Solution
Refuel
Drain the fuel system and refuel
Replace with fresh recommended fuel
Inspect plugs and replace if necessary
Inspect plugs and replace if necessary
Immediately see your Polaris dealer
Recharge the battery to 12.8 VDC
See your dealer
Engine Backfires
Possible Cause
Weak spark from spark plug
Incorrect spark plug gap or heat range
Old or non-recommended fuel
Incorrectly installed spark plug wires
Incorrect ignition timing
Mechanical failure
Loose ignition connections
Water present in fuel
104
Solution
Inspect, clean and/or replace spark plugs
Set gap to specs or replace plugs
Replace with fresh recommended fuel
See your dealer
See your dealer
See your dealer
Check all connections and tighten
Replace with fresh recommended fuel
TROUBLESHOOTING
Engine Pings or Knocks
Possible Cause
Poor quality or low octane fuel
Incorrect ignition timing
Incorrect spark plug gap or heat range
Solution
Replace with recommended fuel
See your dealer
Set gap to specs or replace plugs
Engine Runs Irregularly, Stalls or Misfires
Possible Cause
Fouled or defective spark plugs
Worn or defective spark plug wires
Incorrect spark plug gap or heat range
Loose ignition connections
Water present in fuel
Low battery voltage
Kinked or plugged fuel tank vent line
Incorrect fuel
Clogged air filter
Other mechanical failure
Possible Lean Fuel Cause
Low or contaminated fuel
Low octane fuel
Possible Rich Fuel Cause
Fuel is very high octane
Solution
Inspect, clean and/or replace spark plugs
See your dealer
Set gap to specs or replace plugs
Check all connections and tighten
Replace with new fuel
Recharge battery to 12.8 VDC
Inspect and replace
Replace with recommended fuel
Inspect and clean or replace
See your dealer
Solution
Add or change fuel, clean the fuel system
Replace with recommended fuel
Solution
Replace with lower octane fuel
105
TROUBLESHOOTING
Engine Stops or Loses Power
Possible Cause
Out of fuel
Kinked or plugged fuel vent line
Water is present in fuel
Fouled or defective spark plugs
Worn or defective spark plug wires
Incorrect spark plug gap or heat range
Loose ignition connections
Low battery voltage
Incorrect fuel
Clogged air filter
Other mechanical failure
Overheated engine
106
Solution
Refuel
Inspect and replace
Replace with new fuel
Inspect, clean and/or replace spark plug
See your dealer
Set gap to specs or replace plug
Check all connections and tighten
Recharge the battery to 12.8 VDC
Replace with fresh recommended fuel
Inspect and clean or replace
See your dealer
Clean radiator screen and core, clean
engine exterior, see your dealer
DECLARATION OF CONFORMITY
Polaris Industries Inc.,
2100 Hwy 55, Medina, MN 55340 U.S.A.
Telephone 763-542-0500
We, Polaris Industries Inc., declare that the vehicles listed below conform to the
essential health and safety requirements applicable to off-road all-terrain vehicles.
APPLICABLE EUROPEAN DIRECTIVES
98/37/EC as amended (Machinery Directive)
TEST / EVALUATION METHODS
EN 1050 hazard analysis
CD 77/311/EEC driver-perceived noise level
CISPR 12:2001
EN 55012:2002
CAN/CSA-C108.4-M92
EN 61000-6-2:2001
2004/108/EC as amended (EMC Directive)
PRODUCT IDENTIFICATION
VEHICLE SERIES
TRADE NAME
MODEL
YEARS
SOUND
PRESSURE
dB (A)
___KA05__
___KA09__
___FA09__
___VA17__
___PB20__
___BA32__
___CA32__
___BA50__
___GJ45__
___GJ52__, ___GP52__
___LH27__
___LH46__
___MN50__
___ZN55__ ___ZX55__
___TN55__, ___DN55__
___MN76__
___TN85__, ___DN85__
___CL76__
___ZN85__, ___ZX85__
___RH50__, ___HH50__
___HH76__
___WH76__
___HR__
___HY__
___VH76__
OUTLAW 50
OUTLAW 90
SPORTSMAN 90
RZR 170
PHOENIX 200
TRAIL BLAZER 330
TRAIL BOSS 330
SCRAMBLER 500
OUTLAW 450
OUTLAW 525
SPORTSMAN 300
SPORTSMAN 400
SPORTSMAN 500 EFI
SPORTSMAN 550 EFI
SPORTSMAN X2/TOURING 550
SPORTSMAN 800
SPORTSMAN X2/TOURING 850
SPORTSMAN 800 6X6
SPORTSMAN 850 EFI
RANGER 500 EFI 4X4
RANGER 800 EFI 4X4
RANGER 800 EFI CREW
RANGER 800 6X6
RANGER HD 800 4X4
RANGER RZR
2008, 2009, 2010
2008, 2009, 2010
2008, 2009, 2010
2009, 2010
2008, 2009, 2010
2008, 2009, 2010
2008, 2009, 2010
2008, 2009, 2010
2008, 2009, 2010
2008, 2009, 2010
2008, 2009, 2010
2008, 2009, 2010
2008, 2009, 2010
2009, 2010
2010
2008, 2009, 2010
2010
2009, 2010
2009, 2010
2009, 2010
2010
2010
2010
2010
2008, 2009, 2010
76.8
76.8
76.8
81.3
76.8
76.8
76.8
79.6
80.7
80.7
81.1
80.2
80.4
80.8
77.2
83.6
77.2
80.1
80.4
76.5
76.5
76.5
76.5
76.5
85.8
Authorized Signatory:
__________________________________
Alexander A. Kennedy, Product Compliance
Polaris Industries Inc., Engineering Operations
301 5th Avenue SW, Roseau, MN 56751
107
WARRANTY
LIMITED WARRANTY
Polaris Sales Inc., 2100 Highway 55, Medina, MN 55340, gives a SIX MONTH LIMITED WARRANTY on all components of the Polaris RANGER against defects in material or workmanship. Polaris also gives a one year limited warranty on the final drive
chain for failure due to defects. This warranty covers the parts and labor charges for
repair or replacement of defective parts which are covered by this warranty. This warranty begins on the date of purchase. This warranty is transferable to another consumer
during the warranty period through a Polaris dealer.
REGISTRATION
At the time of sale, the Warranty Registration Form must be completed by your dealer
and submitted to Polaris within ten days. Upon receipt of this registration, Polaris will
record the registration for warranty. No verification of registration will be sent to the
purchaser as the copy of the Warranty Registration Form will be the warranty entitlement. If you have not signed the original registration and received the customer copy,
please contact your dealer immediately. NO WARRANTY COVERAGE WILL BE
ALLOWED UNLESS YOUR VEHICLE IS REGISTERED WITH POLARIS.
Initial dealer preparation and set-up of your vehicle is very important in ensuring trouble-free operation. Purchasing a machine in the crate or without proper dealer set-up will
void your warranty coverage.
WARRANTY COVERAGE AND EXCLUSIONS:
LIMITATIONS OF WARRANTIES AND REMEDIES
The Polaris limited warranty excludes any failures that are not caused by a defect in
material or workmanship. This warranty does not cover accidental damage, normal wear
and tear, abuse or improper handling. This warranty also does not cover any vehicle that
has been altered structurally, modified, neglected, improperly maintained, used for racing, or used for purposes other than for which it was manufactured, or for any damages
which occur during trailer transit or as a result of unauthorized service or the use of
unauthorized parts. In addition, this warranty does not cover physical damage to paint or
finish, stress cracks, tearing or puncturing of upholstery material, corrosion, or defects in
parts, components or the vehicle due to fire, explosions or any other cause beyond
Polaris' control.
Warranty does not apply to parts exposed to friction surfaces, stresses, environmental
conditions and/or contamination for which they were not designed or not intended,
including but not limited to the following items:
•
•
•
•
•
•
•
•
Wheels and tires
Suspension components
Brake components
Seat components
Clutches and components
Steering components
Batteries
Light bulbs/Sealed beam lamps
108
•
•
•
•
•
•
•
Finished and unfinished surfaces
Carburetor/Throttle body components
Engine components
Drive belts
Hydraulic components
Circuit breakers/Fuses
Electronic components
WARRANTY
LIMITATIONS OF WARRANTIES AND REMEDIES
Warranty applies to the product only and does not allow for coverage of personal loss.
Some items are considered "consumable," meaning they are considered part of normal
maintenance or part of completing an effective repair. The following items are excluded
from warranty coverage in the event of a warranty claim:
•
•
•
•
•
•
•
•
Spark Plugs
Filters
Fuel
Sealants
Hotel fees
Towing charges
Mileage
Rentals/Loss of product use
•
•
•
•
•
•
•
•
Lubricants such as oil, grease, etc.
Batteries (unless defective)
Cosmetic damage/repair
Coolants
Meals
Shipping/ handling fees
Product pick-up/delivery
Loss of vacation/personal time
This warranty also excludes failures resulting from improper lubrication; improper
engine timing; improper fuel; surface imperfections caused by external stress, heat, cold
or contamination; operator error or abuse; improper component alignment, tension,
adjustment or altitude compensation; failure due to snow, water, dirt or other foreign
substance ingestion/contamination; improper maintenance; modified components; use
of aftermarket components resulting in failure; unauthorized repairs; repairs made after
the warranty period expires or by an unauthorized repair center; use of the product in
competition or for commercial purposes. Warranty will not apply to any product which
has been damaged by abuse, accident, fire or any other casualty not determined a defect
of materials or workmanship.
This warranty does not cover the use of unauthorized lubricants, chemicals, or fuels that
are not compatible with the vehicle. The exclusive remedy for breach of this warranty
shall be, at Polaris' exclusive option, repair or replacement of any defective materials, or
components or products. THE REMEDIES SET FORTH IN THIS WARRANTY ARE
THE ONLY REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF THIS
WARRANTY. POLARIS SHALL HAVE NO LIABILITY TO ANY PERSON FOR
INCIDENTAL, CONSEQUENTIAL OR SPECIAL DAMAGES OF ANY DESCRIPTION, WHETHER ARISING OUT OF EXPRESS OR IMPLIED WARRANTY OR
ANY OTHER CONTRACT, NEGLIGENCE, OR OTHER TORT OR OTHERWISE.
Some states do not permit the exclusion or limitation of incidental or consequential
damages or implied warranties, so the above limitations or exclusions may not apply to
you if inconsistent with controlling state law.
109
WARRANTY
LIMITATIONS OF WARRANTIES AND REMEDIES
ALL IMPLIED WARRANTIES (INCLUDING BUT NOT LIMITED TO THE
IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE) ARE LIMITED IN DURATION TO THE ABOVE SIX
MONTH WARRANTY PERIOD. POLARIS FURTHER DISCLAIMS ALL EXPRESS
WARRANTIES NOT STATED IN THIS WARRANTY. Some states do not allow limitations on how long an implied warranty lasts, so the above limitation may not apply to
you if inconsistent with controlling state law.
HOW TO OBTAIN WARRANTY SERVICE
If your vehicle requires warranty service, you must take it to a Polaris Servicing Dealer.
When requesting warranty service you must present your copy of the Warranty Registration form to the dealer. (THE COST OF TRANSPORTATION TO AND FROM THE
DEALER IS YOUR RESPONSIBILITY). Polaris suggests that you use your original
selling dealer; however, you may use any Polaris Servicing Dealer to perform warranty
service.
Please work with your dealer to resolve any warranty issues. Should your dealer require
any additional assistance they will contact the appropriate person at Polaris.
This warranty gives you specific legal rights, and you may also have other rights which
vary from state to state.
If any of the above terms are void because of state or federal law, all other warranty
terms will remain in effect.
Lubricants
1. Mixing oil brands or using non-recommended oil may cause engine damage. We recommend the use of Polaris engine oil.
2. Damage resulting from the use of non-recommended lubricants may not be covered
by warranty.
SPARK ARRESTOR
Polaris warrants that the spark arrestor in this vehicle will meet the efficiency requirements of USFS standard 5100-1c for at least 1000 hours when subjected to normal use
and when maintenance and installation are in accordance with Polaris recommendations.
110
WARRANTY
Exported Vehicles
EXCEPT WHERE SPECIFICALLY REQUIRED BY LAW, THERE IS NO WARRANTY OR SERVICE BULLETIN COVERAGE ON THIS VEHICLE IF IT IS SOLD
OUTSIDE THE COUNTRY OF THE SELLING DEALER'S AUTHORIZED LOCATION.
This policy does not apply to vehicles that have received authorization for export from
Polaris Industries. Dealers may not give authorization for export. You should consult an
authorized dealer to determine this vehicle's warranty or service bulletin coverage if you
have any questions.
This policy does not apply to vehicles registered to government officials or military personnel on assignment outside the country of the selling dealer's authorized location.
This policy does not apply to Safety Recalls.
How to Get Service
In the Country where your vehicle was purchased:
Warranty or Service Bulletin repairs must be done by an authorized Polaris dealer. If you
move or are traveling within the country where your vehicle was purchased, Warranty or
Service Bulletin repairs may be requested from any authorized Polaris dealer who sells
the same line as your vehicle.
Outside the Country where your vehicle was purchased:
If you are traveling temporarily outside the country where your vehicle was purchased,
you should take your vehicle to an authorized Polaris dealer. You must show the dealer
photo identification from the country of the selling dealer's authorized location as proof
of residence. Upon residence verification, the servicing dealer will be authorized to perform the warranty repair.
If You Move:
If you move to another country, be sure to contact Polaris Customer Assistance and the
customs department of the destination country before you move. Vehicles importation
rules vary considerably from country to country. You may be required to present documentation of your move to Polaris Industries in order to continue your warranty coverage. You may also be required to obtain documentation from Polaris Industries in order
to register your vehicle in your new country.
If Purchased From A Private Party:
If you purchase a Polaris product from a private citizen, to be kept and used outside of
the country in which the vehicle was originally purchased, all warranty coverage will be
denied.
Notice
If your vehicle is registered outside of the country where it was purchased, and you have
not followed the procedure set out above, your vehicle will no longer be eligible for warranty or service bulletin coverage of any kind. (Vehicles registered to Government officials or military personnel on assignment outside of the country where the vehicle was
purchased will continue to be covered by the basic warranty.)
For questions call Polaris Customer Assistance:
United States: 1-888-704-5290
Canada: 1-204-925-7100
111
WARRANTY
U.S.A. EPA Emissions Limited Warranty
This emissions limited warranty is in addition to the Polaris standard limited warranty
for your vehicle. Polaris Industries Inc. warrants that at the time it is first purchased, this
emissions-certified vehicle is designed, built and equipped so it conforms with applicable U.S. Environmental Protection Agency emission regulations. Polaris warrants that
the vehicle is free from defects in materials and workmanship that would cause it to fail
to meet these regulations.
The warranty period for this emissions-certified vehicle starts on the date the vehicle is
first purchased and continues for a period of 500 hours of engine operation, 5000 kilometers (3100 miles) of vehicle travel, or 30 calendar months from the date of purchase,
whichever comes first.
This emissions limited warranty covers components whose failure increases the vehicle’s regulated emissions, and it covers components of systems whose only purpose is to
control emissions. Repairing or replacing other components not covered by this warranty is the responsibility of the vehicle owner. This emissions limited warranty does not
cover components whose failure does not increase the vehicle’s regulated emissions.
For exhaust emissions, emission-related components include any engine parts related to
the following systems:
• Air-induction system
• Fuel system
• Ignition system
• Exhaust gas recirculation systems
The following parts are also considered emission-related components for exhaust emissions:
• Aftertreatment devices
• Crankcase ventilation valves
• Sensors
• Electronic control units
The following parts are considered emission-related components for evaporative emissions:
• Fuel Tank
• Vacuum Control Diaphragms*
• Fuel Cap
• Control Cables*
• Fuel Line
• Control Linkages*
• Fuel Line Fittings
• Purge Valves
• Clamps*
• Vapor Hoses
• Pressure Relief Valves*
• Liquid/Vapor Separator
• Control Valves*
• Carbon Canister
• Control Solenoids*
• Canister Mounting Brackets
• Electronic Controls*
• Carburetor Purge Port Connector
*As related to the evaporative emission control system.
112
WARRANTY
U.S.A. EPA Emissions Limited Warranty
The exclusive remedy for breach of this limited warranty shall be, at the exclusive
option of Polaris, repair or replacement of any defective materials, components or products. THE REMEDIES SET FORTH IN THIS LIMITED WARRANTY ARE THE
ONLY REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF THIS WARRANTY. POLARIS SHALL HAVE NO LIABILITY TO ANY PERSON FOR INCIDENTAL, CONSEQUENTIAL OR SPECIAL DAMAGES OF ANY
DESCRIPTION,WHETHER ARISING OUT OF EXPRESS OR IMPLIED WARRANTY OR ANY OTHER CONTRACT, NEGLIGENCE OR OTHER TORT OR
OTHERWISE.
ALL IMPLIED WARRANTIES (INCLUDING BUT NOT LIMITED TO ANY
IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE) ARE LIMITED IN DURATION TO THE WARRANTY
PERIOD DESCRIBED HEREIN. POLARIS DISCLAIMS ALL EXPRESS WARRANTIES NOT STATED IN THIS WARRANTY. Some states do not allow limitations on
how long an implied warranty lasts, so the above limitation may not apply if it is inconsistent with the controlling state law.
This limited warranty excludes failures not caused by a defect in material or workmanship.This limited warranty does not cover damage due to accidents, abuse or improper
handling, maintenance or use. This limited warranty also does not cover any engine that
has been structurally altered, or when the vehicle has been used in racing competition.
This limited warranty also does not cover physical damage, corrosion or defects caused
by fire, explosions or other similar causes beyond the control of Polaris.
Owners are responsible for performing the scheduled maintenance identified in the
owner's manual. Polaris may deny warranty claims for failures that have been caused by
the owner’s or operator’s improper maintenance or use, by accidents for which Polaris
has no responsibility, or by acts of God.
Any qualified repair shop or person may maintain, replace, or repair the emission control devices or systems on your vehicle. Polaris recommends that you contact an authorized Polaris dealer to perform any service that may be necessary for your vehicle.
Polaris also recommends that you use only Pure Polaris parts. It is a potential violation
of the Clean Air Act if a part supplied by an aftermarket parts manufacturer reduces the
effectiveness of the vehicle's emission controls. Tampering with emission controls is
prohibited by federal law.
If you have any questions regarding your warranty rights and responsibilities, please
contact the Polaris Warranty Department at 1-888-704-5290.
113
MAINTENANCE LOG
Use the following chart to record periodic maintenance.
DATE
114
MILES (KM)
OR HOURS
TECHNICIAN
SERVICE PERFORMED / COMMENTS
MAINTENANCE LOG
DATE
MILES (KM)
OR HOURS
TECHNICIAN
SERVICE PERFORMED / COMMENTS
115
MAINTENANCE LOG
DATE
116
MILES (KM)
OR HOURS
TECHNICIAN
SERVICE PERFORMED / COMMENTS
INDEX
A
Accessory Outlets . . . . . . . . . . . . . . .
Adjustment
Park Brake. . . . . . . . . . . . . . . . .
Shock Spring. . . . . . . . . . . . . . .
Suspension . . . . . . . . . . . . . . . .
Throttle Freeplay. . . . . . . . . . . .
Air Filter . . . . . . . . . . . . . . . . . . . . . .
All Wheel Drive
Disengaging AWD . . . . . . . . . .
Engaging AWD. . . . . . . . . . . . .
All Wheel Drive Switch . . . . . . . . . .
Auxiliary Outlets. . . . . . . . . . . . . . . .
Axle Nut Torque . . . . . . . . . . . . . . . .
C
20
80
81
81
77
72
48
48
23
20
82
B
Battery . . . . . . . . . . . . . . . . . . . . 87-92
Charging (Conventional) . . . . . 91
Charging (Sealed) . . . . . . . . 91-92
Fluid (Conventional). . . . . . . . . 90
Installation . . . . . . . . . . . . . . . . 89
Removal . . . . . . . . . . . . . . . . . . 88
Storage . . . . . . . . . . . . . . . . . . . 90
Warnings . . . . . . . . . . . . . . . . . . 87
Belt Burning . . . . . . . . . . . . . . . . . . 103
Belt Life . . . . . . . . . . . . . . . . . . . . . . 45
Belt Wear . . . . . . . . . . . . . . . . . . . . 103
Brake Adjustment, Park Brake . . . . . 80
Brake Fluid . . . . . . . . . . . . . . . . . . . . 78
Brake Inspection . . . . . . . . . . . . . . . . 79
Brake Lights . . . . . . . . . . . . . . . . . . . 86
Brake Pedal . . . . . . . . . . . . . . . . . . . . 24
Brake, Park . . . . . . . . . . . . . . . . . . . . 25
Brakes . . . . . . . . . . . . . . . . . . . . . 78-80
Braking . . . . . . . . . . . . . . . . . . . . . . . 33
Break-In Period. . . . . . . . . . . . . . 29-30
Breather Filter . . . . . . . . . . . . . . . . . . 73
Cab Frame, ROPS. . . . . . . . . . . . . . . 28
Cargo. . . . . . . . . . . . . . . . . . . . . . 42-43
Cargo Box, Dumping . . . . . . . . . . . . 44
Chart, Periodic Maintenance . . . 50-54
Chrome Wheel Care . . . . . . . . . . . . . 96
Cleaning and Storage . . . . . . . . . 94-98
Cleaning the Exhaust System . . . 74-75
Cleaning the Spark Arrestor . . . . 74-75
Clutching. . . . . . . . . . . . . . . . . . . . . 101
Component Locations . . . . . . . . . 18-19
Console . . . . . . . . . . . . . . . . . . . . . . . 20
Coolant Level, Overflow Bottle . . . . 67
Coolant Level, Radiator . . . . . . . . . . 68
Coolant, Adding or Changing. . . . . . 66
Cooling Fan . . . . . . . . . . . . . . . . . . . 67
Cooling System. . . . . . . . . . . . . . 66-68
Corrosion Removal, Chrome . . . . . . 96
Crankcase Emission Control System 49
Cylinder Head . . . . . . . . . . . . . . . . . . 77
D
Differential Lock Switch . . . . . . . . . 23
Differential Operation. . . . . . . . . . . . 47
Disengaging AWD . . . . . . . . . . . . . . 48
Drive Belt Wear . . . . . . . . . . . . . . . 103
Drivetrain Break-In. . . . . . . . . . . . . . 30
Driving Downhill . . . . . . . . . . . . . . . 37
Driving in Reverse . . . . . . . . . . . . . . 40
Driving on a Sidehill. . . . . . . . . . . . . 37
Driving on Slippery Surfaces . . . . . . 35
Driving Over Obstacles . . . . . . . . . . 39
Driving Procedure. . . . . . . . . . . . . . . 34
Driving Through Water . . . . . . . . . . 38
Driving Uphill. . . . . . . . . . . . . . . . . . 36
Driving, After Driving in Water . . . . 70
Drying the Transmission. . . . . . . . . . 70
Dumping the Cargo Box . . . . . . . . . . 44
117
INDEX
E
F
Emissions Limited Warranty . . 112-113
Engaging AWD . . . . . . . . . . . . . . . . 48
Engine Break-In. . . . . . . . . . . . . . . . 30
Engine Fogging . . . . . . . . . . . . . . . . 98
Engine Idle Speed . . . . . . . . . . . . . . 77
Engine Oil . . . . . . . . . . . . . . . . . . 56-60
Engine Starting . . . . . . . . . . . . . . . . 32
Engine Stopping. . . . . . . . . . . . . . . . 33
Equipment Modifications . . . . . . . . 13
Exhaust Cleaning . . . . . . . . . . . . . 74-75
Exhaust Emission Control System. . 49
Exhaust System Warning. . . . . . . . . 74
Freeplay Adjustment, Throttle. . . . . . 77
Freeplay, Throttle . . . . . . . . . . . . . . . 76
Front Gearcase. . . . . . . . . . . . . . . 62-63
Fuel Cap. . . . . . . . . . . . . . . . . . . . . . . 27
Fuel Gauge. . . . . . . . . . . . . . . . . . . . . 20
Fuel Safety. . . . . . . . . . . . . . . . . . . . . 15
Fuel Stabilizer . . . . . . . . . . . . . . . . . . 97
Fuel Tank Filler Cap . . . . . . . . . . . . . 27
Fuses . . . . . . . . . . . . . . . . . . . . . . . . . 93
F
Filter Systems . . . . . . . . . . . . . . . 72-73
Filter, Air . . . . . . . . . . . . . . . . . . . . . 72
Filter, Breather. . . . . . . . . . . . . . . . . 73
Fluid, Battery Fluid . . . . . . . . . . . . . 90
Fluid, Brake . . . . . . . . . . . . . . . . . . . 78
Fluid Change
Engine Oil . . . . . . . . . . . . . . 58-60
Front Gearcase . . . . . . . . . . . . . 63
Main Gearcase . . . . . . . . . . . . . 61
Transmission . . . . . . . . . . . . . . 61
Fluid Level
Coolant (Overflow Bottle). . . . 67
Coolant (Radiator) . . . . . . . . . . 68
Engine Oil . . . . . . . . . . . . . . . . 57
Front Gearcase . . . . . . . . . . . . . 62
Main Gearcase . . . . . . . . . . . . . 61
Transmission . . . . . . . . . . . . . . 61
Fluid Levels During Storage . . . . . . 98
Fluid Recommendation
Coolant. . . . . . . . . . . . . . . . . . . 66
Engine Oil . . . . . . . . . . . . . . . . 56
Gearcases . . . . . . . . . . . . . . . . . 60
Fogging the Engine . . . . . . . . . . . . . 98
Fouled Plugs . . . . . . . . . . . . . . . . . . 65
118
G
Gap, Spark Plug. . . . . . . . . . . . . . . . . 64
Gasoline Handling . . . . . . . . . . . . . . . 15
Gear Selector . . . . . . . . . . . . . . . . . . . 21
Gearcase Specification Chart. . . . . . . 60
Gearcase, Front . . . . . . . . . . . . . . 62-63
Gearcase, Main . . . . . . . . . . . . . . . . . 61
Gearcases . . . . . . . . . . . . . . . . . . . 60-63
Gears, Shifting . . . . . . . . . . . . . . . . . . 21
H
Hauling Cargo . . . . . . . . . . . . . . . 42-43
Headlight Beam Adjustment . . . . . . . 85
Headlight Lamp Replacement . . . . . . 84
Hitch Bracket. . . . . . . . . . . . . . . . . . . 19
Hitch Weight . . . . . . . . . . . . . . . . . . . 45
Hour Meter . . . . . . . . . . . . . . . . . . . . 20
I
Idle Speed . . . . . . . . . . . . . . . . . . . . . 77
Ignition Switch . . . . . . . . . . . . . . . . . 22
Immersion of Vehicle . . . . . . . . . . . . 71
Indicator Light Replacement . . . . . . . 86
Indicator Lights . . . . . . . . . . . . . . . . . 21
K
Key, Periodic Maintenance Chart . . . 51
INDEX
L
P
Lamp Replacement, Indicator Lights 86
Light Switch . . . . . . . . . . . . . . . . . . . 23
Lights . . . . . . . . . . . . . . . . . . . . . 84-86
Brake Lights . . . . . . . . . . . . . . . 86
Headlight Beam Adjustment. . . 85
Headlight Lamp Replacement . 84
Indicator Lamp Replacement . . 86
Indicator Lights. . . . . . . . . . . . . 21
Load Capacity . . . . . . . . . . . . . . . . . . 43
Lubricants, Gearcase. . . . . . . . . . . . . 60
Lubrication Recommendations . . . . . 55
Park Brake . . . . . . . . . . . . . . . . . . . . 25
Park Brake Adjustment. . . . . . . . . . . 80
Park Brake Inspection. . . . . . . . . . . . 79
Parking on an Incline . . . . . . . . . . . . 41
Parking the Vehicle. . . . . . . . . . . . . . 46
Periodic Maintenance Chart . . . . 50-54
Plug Gap . . . . . . . . . . . . . . . . . . . . . . 64
Plug Torque . . . . . . . . . . . . . . . . . . . 64
Plug, Accessory . . . . . . . . . . . . . . . . 20
Plugs, Fouled . . . . . . . . . . . . . . . . . . 65
Polaris Products . . . . . . . . . . . . . . . 102
Polishing the Vehicle . . . . . . . . . . . . 95
Pre-Ride Inspection . . . . . . . . . . . . . 31
PVT Break-In . . . . . . . . . . . . . . . . . . 30
PVT Drying . . . . . . . . . . . . . . . . . . . 70
PVT System . . . . . . . . . . . . . . . . . . . 70
PVT System Operation . . . . . . . . . . . 69
PVT Warning . . . . . . . . . . . . . . . . . . 69
M
Main Gearcase . . . . . . . . . . . . . . . . . 61
Maintenance Log . . . . . . . . . . 114-116
Maintenance, Periodic . . . . . . . . 50-54
Modifications . . . . . . . . . . . . . . . . . . 13
N
Noise Emission Control System . . . . 49
O
Obstacles . . . . . . . . . . . . . . . . . . . . . . 39
Oil, Engine . . . . . . . . . . . . . . . . . 56-60
Oil Change
Engine . . . . . . . . . . . . . . . . . 58-60
Front Gearcase . . . . . . . . . . . . . 63
Main Gearcase . . . . . . . . . . . . . 61
Transmission . . . . . . . . . . . . . . . 61
Oil Level
Engine . . . . . . . . . . . . . . . . . . . . 57
Front Gearcase . . . . . . . . . . . . . 62
Main Gearcase . . . . . . . . . . . . . 61
Transmission . . . . . . . . . . . . . . . 61
Oil Pump Priming . . . . . . . . . . . . . . . 60
Oil Recommendation
Engine Oil . . . . . . . . . . . . . . . . . 56
Gearcases . . . . . . . . . . . . . . . . . 60
Operation on Public Lands . . . . . . . . 49
Operator Safety . . . . . . . . . . . . . . 10-17
Outlets, Auxiliary . . . . . . . . . . . . . . . 20
R
Radiator. . . . . . . . . . . . . . . . . . . . . . .
Radiator Coolant Level. . . . . . . . . . .
Removing the Vehicle from Storage
Reverse Operation . . . . . . . . . . . . . .
Rollover Protective Structure . . . . . .
ROPS Cab Frame . . . . . . . . . . . . . . .
67
68
99
40
28
28
S
Safety Labels . . . . . . . . . . . . . . . . . 7-9
Safety Symbols . . . . . . . . . . . . . . . . . . 4
Seat Belt Inspection . . . . . . . . . . . . . 27
Seat Belts . . . . . . . . . . . . . . . . . . 26-27
Seat Removal . . . . . . . . . . . . . . . . . . 27
Severe Use Definition. . . . . . . . . . . . 50
Shifter . . . . . . . . . . . . . . . . . . . . . . . . 21
Shifting Gears . . . . . . . . . . . . . . . . . . 21
Shock Spring Adjustment . . . . . . . . . 81
Signal Words . . . . . . . . . . . . . . . . . . . 4
Spark Arrestor Warning . . . . . . . . . . 74
Spark Arrestor, Cleaning . . . . . . 74-75
Spark Plug Gap . . . . . . . . . . . . . . . . . 64
Spark Plug Inspection . . . . . . . . . 64-65
119
INDEX
S
T
Spark Plug Recommendations. . . . . 64
Spark Plug Torque . . . . . . . . . . . . . . 64
Spark Plugs . . . . . . . . . . . . . . . . . 64-65
Spark Plugs, Fouled . . . . . . . . . . . . . 65
Specifications. . . . . . . . . . . . . . 100-101
Specifications, Gearcase . . . . . . . . . 60
Starting the Engine . . . . . . . . . . . . . 32
Steering Wheel Inspection. . . . . . . . 80
Steering Wheel, Adjustment . . . . . . 24
Stopping the Engine. . . . . . . . . . . . . 33
Storage . . . . . . . . . . . . . . . . . . . . . 94-98
Storage Area . . . . . . . . . . . . . . . . . . 98
Storage Tips . . . . . . . . . . . . . . . . . . . 97
Storage, Battery . . . . . . . . . . . . . . . . 90
Storage, Covers . . . . . . . . . . . . . . . . 98
Storage, Removal from . . . . . . . . . . 99
Suspension Adjustment . . . . . . . . . . 81
Switches . . . . . . . . . . . . . . . . . . . 22-23
AWD Switch . . . . . . . . . . . . . . 23
Differential Lock Switch . . . . . 23
Ignition Switch . . . . . . . . . . . . 22
Light Switch . . . . . . . . . . . . . . 23
Towing Loads . . . . . . . . . . . . . . . . . . 45
Towing Speed . . . . . . . . . . . . . . . . . . 45
Trailer Hitch Bracket . . . . . . . . . . . . . 19
Transmission . . . . . . . . . . . . . . . . . . . 61
Transmission Operation. . . . . . . . . . . 69
Transmission System. . . . . . . . . . . . . 70
Transmission Warning. . . . . . . . . . . . 69
Transmission, Drying . . . . . . . . . . . . 70
Transporting the Vehicle . . . . . . . . . . 99
T
Throttle Freeplay . . . . . . . . . . . . . . . 76
Throttle Freeplay Adjustment . . . . . 77
Throttle Freeplay Inspection . . . . . . 76
Throttle Pedal. . . . . . . . . . . . . . . . . . 24
Throttle System . . . . . . . . . . . . . . 76-77
Tilt Steering . . . . . . . . . . . . . . . . . . . 24
Tires . . . . . . . . . . . . . . . . . . . . . . 82-83
Nut Torque. . . . . . . . . . . . . . . . 82
Tread Depth . . . . . . . . . . . . . . . 82
Wheel Installation . . . . . . . . . . 83
Wheel Removal . . . . . . . . . . . . 83
Torque, Spark Plug . . . . . . . . . . . . . 64
120
V
Vehicle Identification Numbers. . . . . . 6
Vehicle Immersion . . . . . . . . . . . . . . 71
Vehicle Transport . . . . . . . . . . . . . . . 99
W
Warning Symbols . . . . . . . . . . . . . . . . 4
Warning, Transmission Modification 69
Washing the Vehicle . . . . . . . . . . 94-95
Weight Capacity . . . . . . . . . . . . . . . . 43
Weight, Hitch. . . . . . . . . . . . . . . . . . . 45
Wheel Installation . . . . . . . . . . . . . . . 83
Wheel Nut Torque . . . . . . . . . . . . . . . 82
Wheel Removal . . . . . . . . . . . . . . . . . 83
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