PMS 419
RANGER XP® 900
RANGER CREW® 900
Owner's Manual
for Maintenance and Safety
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.
For videos and more information
about a safe riding experience with
your Polaris vehicle, scan this QR
code with your smartphone.
WELCOME
Thank you for purchasing a POLARIS vehicle, and welcome to our world-wide family of
POLARIS enthusiasts. Be sure to visit us online at www.polaris.com for the latest news, new
product introductions, upcoming events, career opportunities and more.
Here at POLARIS we proudly produce an exciting line of utility and recreational products.
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.
•
•
•
•
•
•
Snowmobiles
All-terrain vehicles (ATVs)
Low emission vehicles (LEVs)
RANGER® utility vehicles
BRUTUS® work vehicles
SLINGSHOT® three wheel motorcycles
•
•
•
•
•
•
RZR® sport vehicles
GEM® electric vehicles
VICTORY® motorcycles
INDIAN® motorcycles
POLARIS POWER® generators
POLARIS DEFENSE® combat vehicles
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 can be performed by a factory
certified Master Service Dealer® (MSD) Technician.
Your POLARIS dealer knows your vehicle best and is interested in your total satisfaction.
Your POLARIS dealership can provide for all of your service needs during, and after, the
warranty period.
1
POLARIS®, RANGER®, RANGER XP® and RANGER CREW® are trademarks of POLARIS Industries Inc.
Copyright 2015 POLARIS Industries 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.
The original instructions for this vehicle are in English. Other languages are provided as translations of the
original instructions.
Printed in U.S.A.
2016 RANGER XP 900 / RANGER CREW 900 Owner’s Manual
P/N 9926461
2
TABLE OF CONTENTS
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Features and Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Winch Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Emission Control Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
POLARIS Products. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
Maintenance Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
3
INTRODUCTION
WARNING
Failure to follow the warnings contained in this manual can result in severe injury or death.
Your POLARIS RANGER is not a toy and can be hazardous to operate. This vehicle handles differently
than other vehicles, such as cars, trucks or other off-road vehicles. 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 and review the safety DVD that came with your vehicle. A free extra copy
of the DVD can be obtained by contacting your local POLARIS dealer. Understand all safety
warnings, precautions and operating procedures before operating the vehicle. Keep this manual with
the vehicle.
• Review the safety DVD and take the free online Recreational Off-Highway Vehicle Association
(ROHVA) training course at www.rohva.org.
• This vehicle is an ADULT VEHICLE ONLY. You MUST be at least age 16 and have a valid driver’s
license to operate this vehicle.
• No person under the age of 12 may ride as a passenger in this vehicle. All riders must be able to sit
with backs against the seat, both feet flat on the floor and both hands on the steering wheel (if
driving) or on a passenger hand hold.
• Never permit a guest to operate this vehicle unless the guest has read this manual and all product
labels.
• Always use the cab nets (or doors) while riding in this vehicle. Always keep hands, feet and all other
body parts inside the vehicle at all times.
• Always wear a helmet, eye protection, gloves, long-sleeve shirt, long pants and over-the-ankle
boots.
• Never use this vehicle with drugs or alcohol, as these conditions impair judgment and reduce
operator reaction time.
4
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.
DANGER
A DANGER indicates a hazardous situation that, if not avoided, will result in death or serious injury.
WARNING
A WARNING indicates a hazardous situation that, if not avoided, could result in death or serious injury.
CAUTION
A CAUTION indicates a hazardous situation that, if not avoided, could result in minor or moderate
injury.
NOTICE
A NOTICE indicates a situation that could 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.
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
Engine Serial
Number
Vehicle Model Number: ________________________________________________________________________
Frame VIN: _________________________________________________________________________________
Engine Serial Number: ________________________________________________________________________
Key Number: ________________________________________________________________________________
6
INTRODUCTION
European Vibration and Noise
The driver-perceived noise and hand/arm and whole body vibration levels of this machinery
is measured per prEN 15997.
The operating conditions of the machinery during testing:
The vehicles were in like-new condition. The environment was controlled as indicated by the
test procedure(s).
The uncertainty of vibration exposure measurement is dependent on many factors, including:
• Instrument and calibration uncertainty
• Variations in the machine such as wear of components
• Variation of machine operators such as experience or physique
• Ability of the worker to reproduce typical work during measurements
• Environmental factors such as ambient noise or temperature
7
SAFETY
Safe Riding Gear
The driver and all passengers must wear helmet, eye protection, gloves, long-sleeve shirt,
long pants, over-the-ankle boots and seat belt at all times. Protective gear reduces the chance
of injury.
Helmet
Wearing a helmet can prevent a severe head injury. Whenever riding this POLARIS vehicle,
always wear a helmet that meets or exceeds established safety standards.
Approved helmets in the USA and Canada bear a U.S. Department of Transportation (DOT)
label.
Approved helmets in Europe, Asia and Oceania bear the ECE 22.05
label. The ECE mark consists of a circle surrounding the letter E,
E4
followed by the distinguishing number of the country which has granted
approval. The approval number and serial number will also be displayed
051039
0006.31
on the label.
Helmet
Eye Protection
Long
Sleeves
Gloves
Long Pants
Over-the-Ankle
Boots
8
SAFETY
Safe Riding Gear
Eye Protection
Do not depend on eyeglasses or sunglasses for eye protection. Whenever riding this
POLARIS vehicle, always wear shatterproof goggles or use a shatterproof helmet face
shield. POLARIS recommends wearing approved Personal Protective Equipment (PPE)
bearing markings such as VESC 8, V-8, Z87.1, or CE. Make sure protective eye wear is kept
clean.
Gloves
Wear gloves for comfort and for protection from sun, cold weather and other elements.
Boots
Wear sturdy over-the-ankle boots for support and protection. Never ride a POLARIS vehicle
with bare feet or sandals.
Clothing
Wear long sleeves and long pants to protect arms and legs.
Rider Comfort
Under certain operating conditions, heat generated by the engine and exhaust system can
elevate temperatures in the driver and passenger cab area. The condition occurs most
frequently when a vehicle is being operated in high ambient temperatures at low speeds and/
or high load conditions for an extended period of time. The use of certain windshield, roof
and/or cab systems may contribute to this condition by restricting airflow. Any discomfort
due to heat buildup in this area can be minimized by wearing proper riding apparel and by
varying speeds to increase airflow.
9
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.
Seat Belt/Drive Responsibly
Warning
Proper Use
Warning
Payload
Warning
Shift Caution
Proper Use Warning (XP 900)
Require Proper Use of Your Vehicle
Do your part to prevent injuries:
• Do not allow careless or reckless driving.
• Make sure operators are 16 or older with a valid driver’s license.
• Do not let people drive or ride after using alcohol or drugs.
• Do not allow operation on public roads (unless designated for off-highway vehicle access) - collisions
with cars and trucks can occur.
• Do not exceed seating capacity: 3 occupants.
7179979
Proper Use Warning (CREW)
Require Proper Use of Your Vehicle
Do your part to prevent injuries:
• Do not allow careless or reckless driving.
• Make sure operators are 16 or older with a valid driver’s license.
• Do not let people drive or ride after using alcohol or drugs.
• Do not allow operation on public roads (unless designated for off-highway vehicle access) - collisions
with cars and trucks can occur.
• Do not exceed CREW-5 seating capacity: 5 occupants.
• Do not exceed CREW-6 seating capacity: 6 occupants.
10
SAFETY
Safety Labels and Locations
Payload Warning/Shift Caution
WARNING
XP 900
Never exceed 40 MPH (64 km/h) if total payload is greater than 550 lbs. (250 kg)
Never exceed 25 MPH (40 km/h) if total payload is greater than 1050 lbs. (476 kg)
XP 900 CA
Never exceed 40 MPH (64 km/h) if total payload is greater than 550 lbs. (250 kg)
CREW 900
Never exceed 35 MPH (56 km/h) if total payload is greater than 1280 lbs. (582 kg)
CREW 900 CA
Never exceed 43 MPH (70 km/h) if total payload is greater than 1280 lbs. (582 kg)
CAUTION
To avoid transmission damage, shift only when vehicle is stationary and at idle. When vehicle is
stopped, place shift in parked position.
Seat Belt/Drive Responsibly Warning
WARNING
Improper vehicle use can result in SEVERE INJURY or DEATH
Be Prepared
• Fasten seat belts.
• Wear an approved helmet and protective gear.
• ALWAYS use cab nets and/or doors.
• Each rider must be able to sit with back against seat, feet flat on the floor, and
hands on steering wheel or hand holds. Stay completely inside the vehicle.
Drive Responsibly
Avoid loss of control and rollovers:
• Avoid abrupt maneuvers, sideways sliding, skidding or fishtailing,
and never do donuts.
• Slow down before entering a turn.
• Avoid hard acceleration when turning, even from a stop.
• Plan for hills, rough terrain, ruts and other changes in traction and
terrain. Avoid paved surfaces.
Rollovers have caused
• Avoid sidehilling (riding across slopes).
severe injuries and death,
Be Sure Riders Pay Attention and Plan Ahead
even on flat, open areas.
If you think or feel the vehicle may tip or roll, reduce your risk of injury:
• Keep a firm grip on the steering wheel or hand holds and brace yourself.
• Do not put any part of your body outside of the vehicle for any reason.
LOCATE AND READ OWNER’S MANUAL. FOLLOW ALL INSTRUCTIONS AND WARNINGS.
ALWAYS REVIEW SAFETY VIDEO AND TAKE ROHVA TRAINING (rohva.org).
7179983
11
SAFETY
Safety Labels and Locations
Load/Passenger/Tire Pressure Warning
WARNING
• Never carry passengers in cargo box.
• Passengers can be thrown off. This can cause serious
injury or death.
• If total payload is greater than 500 lbs., the vehicle must
be operated in LOW range.
Load/Passenger/Tire Pressure
Warning
IMPROPER TIRE PRESSURE OR OVERLOADING CAN
CAUSE LOSS OF CONTROL RESULTING IN SERIOUS
INJURY OR DEATH.
• 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.
RANGER XP
MAXIMUM CARGO BOX LOAD
TIRE PRESSURE IN PSI (KPa)
4x4
4x4 CA
CREW
CA CREW
1000 lbs.
600 lbs.
1000 lbs.
600 lbs.
(454 kg)
(272 kg)
(454 kg)
(272 kg)
FRONT 10 (69) FRONT 10 (69) FRONT 14 (96) FRONT 14 (96)
REAR 12 (83)
REAR 12 (83) REAR 16 (110) REAR 16 (110)
1500 lbs.
1100 lbs.
1750 lbs.
1350 lbs.
(682 kg)
(499 kg)
(795 kg)
(612 kg)
MAXIMUM WEIGHT CAPACITY
INCLUDES WEIGHT OF
OPERATOR, PASSENGERS,
CARGO AND ACCESSORIES
Read Operation and Maintenance Manual for more detailed loading information.
RANGER XP
MAXIMUM CARGO BOX LOAD
TIRE PRESSURE IN PSI (KPa)
4x4 Hunter/NorthStar
CA 4x4 Hunter/NorthStar
1000 lbs. (454 kg)
FRONT 12 (83)
REAR 12 (83)
1275 lbs. (578 kg)
600 lbs. (272 kg)
FRONT 12 (83)
REAR 12 (83)
875 lbs. (397 kg)
MAXIMUM WEIGHT CAPACITY
INCLUDES WEIGHT OF OPERATOR,
PASSENGER, CARGO AND NONFACTORY INSTALLED
ACCESSORIES
Read Operation and Maintenance Manual for more detailed loading information.
Clutch Cover Warning
WARNING
Improper service or maintenance of this PVT system can result
in vehicle damage, SEVERE INJURY or DEATH.
Always look for and remove debris inside and around clutch
and vent system when replacing belt.
Read owner’s manual or see authorized POLARIS dealer.
7177469
Clutch Cover
Warning
12
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 entire manual and all labels carefully. Follow the operating procedures
described.
• Never allow anyone under the age of 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. All riders must be
able to sit with backs against the seat, both feet flat on the floor and both hands on the
steering wheel (if driving) or on a passenger hand hold.
• The driver and all passengers must wear helmet, eye protection, gloves, long-sleeve shirt,
long pants, over-the-ankle boots and seat belt at all times.
• Always use the cab nets (or doors) while riding in this vehicle.
• Always keep hands and feet inside the vehicle at all times.
• 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 rollover 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 (unless marked for offroad use). 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.
• Always inspect the vehicle before each use to make sure it's in safe operating condition.
Always follow the inspection procedures described in this manual.
13
SAFETY
Operator Safety
• 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. See page
47. Check the terrain carefully before attempting to climb a hill. Never climb hills with
excessively slippery or loose surfaces. Never apply throttle suddenly. Never 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. See page 47. 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 large rocks or fallen trees. Always follow the proper procedures
outlined in this manual when operating over obstacles. See page 45.
• 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.
• Never operate your vehicle in fast-flowing water or in water deeper than that specified in
this manual. See page 48. 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.
14
SAFETY
Operator Safety
• 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 non-POLARIS
approved 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 place the transmission in PARK before getting out of the vehicle.
• 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 18 for fuel
safety warnings.
• Always remove the ignition key when the vehicle is not in use to prevent unauthorized use
by someone under the age of 16 or without a driver’s license and proper training, or
accidental starting.
FOR MORE INFORMATION ABOUT SAFETY, call
POLARIS at 1-800-342-3764.
Equipment Modifications
Do not install any non-POLARIS approved accessory or modify the vehicle for the purpose
of increasing speed or power. Any modifications or installation of non-POLARIS approved
accessories could create a substantial safety hazard and increase the risk of bodily injury.
The POLARIS limited warranty on your POLARIS vehicle will be terminated if any nonPOLARIS approved equipment and/or modifications have been added to the vehicle that
increase 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.
15
SAFETY
Operator Safety
WARNING
Failure to operate the RANGER properly can result in a collision, loss of control, accident or rollover,
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.
Never operate with a passenger under the age of 12. All riders must be
able to sit with backs against the seat, both feet flat on the floor and both
hands on the steering wheel (if driving) or on a passenger hand hold.
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.
All operators should review the safety DVD provided with this vehicle and
take a ROHVA training course (www.rohva.org).
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.
Seat Belts
Riding in this vehicle without wearing the seat belt increases the risk of
serious injury in the event of rollover, loss of control, other accident or
sudden stop. Seat belts may reduce the severity of injury in these
circumstances.
All riders must wear seat belts at all times.
Protective Apparel
Riding in this vehicle without wearing an approved helmet and protective eyewear increases the risk of
a serious injuries in the event of an accident.
Operator and all passengers must always wear an approved helmet that fits properly and eye
protection (goggles or face shield).
16
SAFETY
Operator Safety
Cab Nets and Doors
Riding in this vehicle without using the cab nets (or doors, if equipped) increases the risk of serious
injury or death in the event of an accident or rollover. Always use the cab nets (or doors) while riding in
this vehicle.
Always keep hands and feet inside the vehicle at all times.
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 perform the pre-ride inspection before each use of your RANGER to
make sure it's in safe operating condition. See page 42.
Always follow all inspection and maintenance procedures and schedules described in this owner's
manual. See page 67.
Operating With a Load on the Vehicle
The weight of both cargo and passengers impacts vehicle operation. For your safety and the safety of
others, carefully consider how your vehicle is loaded and how to safely operate the vehicle. Follow the
instructions in this manual for loading, tire pressure, gear selection and speed.
• Do not exceed vehicle weight capacities. The vehicle’s maximum weight capacity is listed in the
specifications section of this manual and on a label on the vehicle. When more passenger weight is
added, cargo weight may need to be reduced accordingly.
• The recommended tire pressures are listed in the specifications section of this manual and on a label
on the vehicle.
Always follow these guidelines:
Under ANY of these conditions:
Do ALL of these steps:
Passenger and/or cargo exceeds half the maximum weight capacity
1. Slow down.
2. Verify tire pressure.
3. Use extra caution when
operating.
Operating in rough terrain
Operating over obstacles
Climbing an incline
Towing
17
SAFETY
Operator Safety
Handling Gasoline
Gasoline is highly flammable and explosive under certain conditions.
• Always exercise extreme caution whenever handling gasoline.
• Always turn off the engine when refueling.
• Always refuel outdoors or in a well ventilated area free of any source of flame or sparks.
• Always use an approved gasoline container to store fuel and remove the container from the vehicle
before filling to avoid fuel ignition due to electrical static discharge.
• 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 rollover or other accident, have a
qualified service dealer inspect the entire machine for possible damage, including (but not limited to)
seat belts, rollover protection devices, 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, your skills
and experience and your passengers’ skills and experience.
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 may increase the risk of loss of control and accident or rollover. Avoid
operating the vehicle on pavement. If it's unavoidable, travel slowly, travel short distances and avoid
sudden turns or stops.
18
SAFETY
Operator Safety
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
(unless designated for off-highway use).
Turning Improperly
Turning improperly could cause loss of traction, loss of control, accident or rollover. Always follow
proper procedures for turning as described in this owner’s manual. Never turn abruptly or at sharp
angles. Never turn at high speeds. Practice turning at slow speeds before attempting to turn at faster
speeds.
Operating in Unfamiliar Terrain
Failure to use extra caution when operating on unfamiliar terrain could result in an accident or rollover.
Unfamiliar terrain may contain hidden rocks, bumps, or holes that could cause loss of control or
rollover. Travel slowly and use extra caution when operating on unfamiliar terrain. Always be alert to
changing terrain conditions.
Jumps and Stunts
Attempting wheelies, jumps and other stunts increases the risk of an accident or rollover. Never attempt
wheelies, jumps, or other stunts. Avoid exhibition driving.
Improper Hill Climbing
Climbing hills improperly can cause loss of control or vehicle rollover. Always follow proper procedures
for climbing hills as described in this owner's manual. See page 47.
Descending Hills Improperly
Improperly descending a hill could cause loss of control or rollover. Always follow proper procedures for
traveling down hills as described in this owner’s manual. See page 47.
Stalling While Climbing a Hill
Stalling or rolling backwards while climbing a hill could cause a rollover. 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.
19
SAFETY
Operator Safety
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 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 rollover. Do not operate on excessively slippery surfaces.
Always slow down and use additional caution when operating on slippery surfaces.
Skidding or sliding due to loss of traction can cause loss of control or rollover (if tires regain traction
unexpectedly). Always follow proper procedures for operating on slippery surfaces as described in this
owner's manual. See page 46.
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 unless you have first verified that the ice is sufficiently thick to
support the weight and moving force of the vehicle, you and your passengers, and your cargo, together
with any other vehicles in your party.
Always check with local authorities and residents to confirm ice conditions and thickness over your
entire route. Vehicle operators assume all risk associated with ice conditions on frozen bodies of water.
Unauthorized Use of the Vehicle
Leaving the keys in the ignition can lead to unauthorized use of the vehicle by someone under the age
of 16, without a drivers license, or without proper training. This could result in an accident or rollover.
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, to avoid debris build-up around the exhaust system.
20
FEATURES AND CONTROLS
Component Locations
Your vehicle is equipped with cab nets (or doors, if equipped) on both sides of the vehicle.
Cab nets must be used by both operator and passengers at all times. Any illustrations without
cab nets are only to allow component identification. Always use the cab nets (or doors).
Not all models (or doors) are equipped with all features. Refer to the specifications section
on page 98.
Console
Muffler (Spark Arrester)
Headlights
Radiator
Receiver
Hitch
CV Boot/Rear Caliper
Front Bumper/Brush Guard
Intake Screens
(both sides)
ROPS Cab
Frame
Cargo Box
Tailgate
Cab Net
Fuel Tank
Cap
21
FEATURES AND CONTROLS
Console
Gear Selector
Low gear is the primary driving range for the
RANGER. High gear is intended for use on
hard-packed surfaces with light loads. Using
high gear for heavy loads, hilly terrain or in
wet, muddy conditions will increase the
chance of drive belt burning. See the Drive
Belt Wear/Burn section on page 103.
H: High Gear
L: Low Gear
N: Neutral
R: Reverse
P: Park
To shift gears, brake to a complete stop. When
the engine is idling, move the lever to the desired gear.
Gear Selector
(Shifter)
NOTICE: Shifting gears with the engine speed above idle or while the vehicle is moving could cause
transmission damage. Always shift when the vehicle is stationary and the engine is at idle.
Tip: Maintaining shift linkage adjustment is important to assure proper transmission function. Your
POLARIS dealer can assist in resolving any shifting problems.
Using Low Range
Always shift into low gear for any of the following conditions.
• Operating in rough terrain or over obstacles
• Loading the vehicle onto a trailer
• Towing heavy loads
• Driving frequently at low RPM or at ground speeds below 7 MPH (11 km/h)
22
FEATURES AND CONTROLS
Switches
Refer to the illustrations below to identify the switches present on your model. Switch
operation is outlined on the following pages.
1
3
2
Base and Hunter Models
1
2
3
4
1
5
6
7
Hunter Deluxe Model
8
1
NorthStar Model
1.
2.
3.
4.
4
Light Switch
All Wheel Drive/Differential Lock Switch
Seat Heater Switch (Driver)
Seat Heater Switch (Passenger)
5
6
7
Trail Model
5.
6.
7.
8.
Drive Mode Indicator
AWD/ADC Drive Mode Switch
Winch Switch
Cab Heater Switches
23
FEATURES AND CONTROLS
Switches
Light Switch
The ignition switch key must be in the ON/RUN position to
operate the headlights. Press the top of the rocker switch
toward the dash to place the headlights on high beam. Move
the rocker switch to the center position to place the headlights
on low beam. Press the bottom of the rocker switch to turn off
the headlights.
HIGH
LOW
OFF
All Wheel Drive (AWD) Switches
Each model is equipped with an AWD switch that controls the All Wheel Drive System. The
type of AWD switch used depends on the type of All Wheel Drive system in your model.
AWD/Differential Lock Switch
The AWD/Differential Switch has three positions:
• All Wheel Drive (AWD)
• Differential Lock (2WD)
• Differential Unlock
See page 54 for operating instructions.
AWD
Differential Lock
Differential Unlock
AWD/ADC Drive Mode Switch and Indicator
The AWD/ADC Drive Mode switch controls AWD through
drive mode options. The selected drive mode displays at three
locations. See page 56.
Drive mode options include:
• ADC - All Wheel Drive (ADC 4X4)
• AWD - All Wheel Drive (AWD/4X4)
• 2WD - Two Wheel Drive (2X4)
• TURF - TURF Mode (1WD)
24
Drive Mode
Switch
FEATURES AND CONTROLS
Switches
Winch Switch
Press the top of the rocker switch to spool line out from
the winch. Press the bottom of the rocker switch to
spool line in to the winch. Move the rocker switch to the
center position to stop spooling.
OUT
OFF
IN
Remote Winch Switch
Pull the remote winch switch and cable out from the
dash storage area. Press and hold the left side of the
switch to spool line out from the winch. Press and hold
the right side of the switch to spool line in to the winch.
Release the switch and it returns to the center “OFF”
position to stop spooling.
IN
OFF
OUT
Seat Heater Switches
The driver and passenger seat heater switches (if
equipped) are located on the control panel. Seat heater
wiring is located under the seats.
Press and release a switch to cycle through the
available heat settings:
• Low
• Medium
• High
• Off
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.
Ignition Switch
25
FEATURES AND CONTROLS
Switches
Cab Heater Switches
To operate the cab heater, rotate the fan control
to the desired fan speed setting. The far left
setting turns the fan off.
Adjust the temperature by rotating the
temperature control to the desired heat setting.
Rotate the control clockwise to increase heat or
counter-clockwise to decrease heat.
Fan Control
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 dash.
26
12V Auxiliary
Outlets
Temperature
Control
FEATURES AND CONTROLS
Switches
Windshield Wiper and Washer (if equipped)
The windshield wiper and washer switches are located on the wiper motor centered above
the windshield. The windshield washer fluid reservoir is located under the hood.
Windshield Washer
Fluid Reservoir
Wiper
Switch
Washer
Switch
Wiper Switch
• Press the top of the wiper switch for a fast wiper speed.
• Move the rocker switch to the center position for a slow wiper
speed.
• Press the bottom of the switch to turn the wiper off.
FAST
SLOW
OFF
Washer Switch
• Press and hold the top of the washer switch to spray washer fluid
on the windshield.
• Release the switch to end the spray.
ON
OFF
27
FEATURES AND CONTROLS
Brake Pedal
Depress the brake pedal to slow or stop the vehicle. Apply
the brakes while starting the engine.
Brake
Pedal
Throttle
Pedal
Throttle Pedal
Push the throttle 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.
Tip: If the throttle pedal and brake pedal are applied simultaneously,
engine power may be limited.
Electronic Power Steering (EPS)
Electronic power steering (if equipped) engages when the ignition key is turned to the ON
position. EPS remains engaged whether the vehicle is moving or idle.
To conserve battery power, the EPS will shut down 5 minutes after the engine is stopped if
the key remains in the ON position. The EPS warning indicator will illuminate to indicate the
EPS has shut down. Turn the key off and on to reset the unit.
See page 36 for EPS warning indicator information.
Adjustable Steering Wheel
The steering wheel can be tilted upward or
downward for rider preference.
Lift and hold the adjustment lever toward
you while moving the steering wheel
upward or downward. Release the lever
when the steering wheel is at the desired
position.
Adjustment Lever
28
FEATURES AND CONTROLS
Seat and Storage Compartments
The electrical compartment is located under the center rear-most seat. Never use this area for
storage. Storage compartments are located under all other seats. Remove the storage bin
under the right rear-most passenger seat to access the battery.
If your model is equipped with a storage console and cup holders located between the front
seats, lift the console lid to access the storage compartment.
Pull the rear edge of a seat upward to release the latch pins from the grommets. Roll the seat
forward to access the under-seat area. To completely remove a seat, roll the seat forward and
lift the seat tabs from the seat base mounts.
Always make sure all seats are properly installed and securely latched before operating. Push
down firmly on the rear of each seat until the latch pins are fully seated into the grommets.
Electrical/Fuse Compartment
(Not For Storage)
Rear-Most Under-Seat Area
Storage
Compartment
(Under Seat)
Battery (Under Storage Bin)
Storage Compartment/Cup Holders (if equipped)
29
FEATURES AND CONTROLS
Fuel Cap
The fuel tank filler cap is located on the left
side of the vehicle near the driver’s seat. Use
only unleaded gasoline with a minimum pump
octane number of 87 R+M/2 octane. Unleaded
fuel blends with up to 10% ethanol can be
used.
NOTICE: Never use fuel blends with more than
10% ethanol. Engine damage could
occur.
Fuel Cap
Trailer Hitch Bracket
This vehicle is equipped with a receiver hitch bracket for a trailer hitch. To avoid injury and
property damage, always heed the warnings and towing capacities outlined on pages 51-52.
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.
ROPS
WARNING! Vehicle rollover could cause severe
injury or death. Always avoid operating in a
manner that could result in vehicle rollover.
Hood Latches
To remove the hood, rotate the hood latches
1/4-turn and lift the hood away from the
vehicle.
30
Hood Latches
FEATURES AND CONTROLS
Cab Nets/Doors
Riding in this vehicle without using the cab nets (or doors, if equipped) increases the risk of
serious injury or death in the event of an accident or rollover. Cab nets (or doors) must be
used by both operator and passengers at all times. Make sure all latches are secure before
operating the vehicle.
Always inspect cab nets and latches for tightness, wear and damage before each use of the
vehicle. Use the strap adjusters to tighten any loose straps. Promptly replace worn or
damaged cab nets and latches with new cab nets and latches. Please see your authorized
POLARIS dealer.
Securing a Cab Net
Latch
1. After entering the vehicle, insert the lower net rod
into the net mount on the floor. Make sure the ball
at the end of the rod is properly secured in the
mount.
2. Connect the latch at the top edge of the net to the
receiver latch mounted on the front frame.
Opening a Cab Net
1. To exit the vehicle, release the latch at the top front
edge of the cab net.
2. Rotate the net rearward and pull upward on the
lower net rod to remove it from the mount.
3. Allow the net to hang freely outside the vehicle
while dismounting.
Net Mount
Ball
Rod
31
FEATURES AND CONTROLS
Seat Belts
This POLARIS vehicle is equipped with three-point lap and diagonal seat belts on all seats.
Always make sure the seat belts are secured for all riders before operating.
The driver’s seat belt is equipped with a seat belt interlock. Vehicle speed will be limited to
15 MPH (24 km/h) if the seat belt is not secured.
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.
To wear the seat belt properly, follow this procedure:
1. 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.
2. Push the latch plate into the buckle until it
clicks.
3. Release the strap, it will self-tighten.
4. To release the seat belt, press the square red
button in the buckle’s center.
Seat Belt Inspection
Latch Plate
Buckle
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.
32
FEATURES AND CONTROLS
Windshield (if equipped)
If equipped, the windshield on your model may
be a fixed windshield or a tip-out windshield. The
tip-out windshield can be opened.
Tip-Out Windshield
The bottom edge of the tip-out windshield can be
tipped away from the vehicle to a vent position or
to a fully open position.
Vented Windshield
To vent air into the cab, firmly grasp the
windshield handle. Lift and push the handle
toward the windshield until the windshield opens
slightly. Align the rear handle ring (nearest the
hand grip) over the dash pin and press the handle
downward to secure the vented windshield.
Tip-Out Windshield Handle
Front Ring
(secures a closed windshield)
Open Windshield
NOTICE: Do not operate the vehicle with the
windshield in the fully open position.
Damage to the windshield could occur.
To open the windshield, firmly grasp the
windshield handle. Lift and push the handle
toward the windshield until the windshield opens
fully.
Closed Windshield
NOTICE: Grasping the glass to close the windshield
could result in damage to the windshield.
Always use the windshield handle.
To close the windshield, firmly grasp the
windshield handle. Pull the handle downward
until the windshield is fully closed.
Align the front handle ring (nearest the hinge)
over the dash pin and press the handle downward
to secure the closed windshield.
Rear Ring
(secures a vented windshield)
33
FEATURES AND CONTROLS
Rear Window Panel (if equipped)
Window Removal
1. Rotate the upper window latches
counter-clockwise to release the locks.
2. Tilt the upper edge of the window
slightly outward and free the lower
window brackets from the frame, then
carefully lift the window up and away
from the vehicle.
3. Secure the upper window latches.
4. To prevent damage to the window
during storage, store it in an upright
position in a secure area. Place the
lower frame of the window on wood or
another semi-soft surface.
Latches
Window Installation
Lower Brackets (2)
1. Rotate the upper window latches
counter-clockwise to release the locks.
2. From the rear of the cab, place the lower edge of the window into the window opening,
hooking the lower window brackets over the frame of the vehicle inside the cab.
3. Align the upper edge of the window to the window opening.
4. Secure the upper window latches.
34
FEATURES AND CONTROLS
Instrument Cluster
NOTICE: High water pressure may damage components. Wash the vehicle by hand or with a garden
hose using mild soap.
Certain products, including insect repellents and chemicals, will damage the speedometer
lens and other plastic surfaces. Do not use alcohol to clean the instrument cluster. Do not
allow insect sprays to contact the lens. Immediately clean off any gasoline that splashes on
the instrument cluster.
Speedometer
Indicator Lamps
MODE
Button
Rider Information
Center
Speedometer
The speedometer displays vehicle speed in either miles per hour (MPH) or kilometers per
hour (km/h). See page 38.
Mode Button
Use the MODE button to toggle through mode options. See page 38 for operation of the
modes.
35
FEATURES AND CONTROLS
Instrument Cluster
Indicator Lamps
Lamp
Indicates
Condition
When standard mode is selected, speed displays in miles per hour.
Vehicle Speed
When metric mode is selected, speed displays in kilometers per hour.
Over Temperature
This lamp illuminates to indicate an overheated engine. If the
indicator flashes, the overheating condition remains, and the system
will automatically reduce engine power.
EPS Warning (if
equipped)
This indicator illuminates briefly when the key is turned to the ON
position. If the light remains on, the EPS system is inoperative. Your
POLARIS dealer can assist.
Neutral
This lamp illuminates when the transmission is in neutral and the
ignition key is in the ON position.
High Beam
This lamp illuminates when the headlamp switch is set to high beam.
Helmet/Seat Belt
The lamp is a reminder to the operator to ensure all riders are
wearing helmets and seat belts before operating. The driver's seat
belt is equipped with a seat belt interlock. Vehicle speed will be limited
to 15 MPH (24 km/h) if the seat belt is not secured.
Check Engine
This indicator appears if an EFI-related fault occurs. Do not operate
the vehicle if this warning appears. Serious engine damage could
result. Your POLARIS dealer can assist.
Rider Information Center
The rider information center is
located in the instrument cluster.
All segments will light up for one
second at start-up.
If the instrument cluster fails to
illuminate, a battery over-voltage
may have occurred and the
instrument cluster may have shut
off to protect the electronic
speedometer. If this occurs, your
POLARIS dealer can provide
proper diagnosis.
The information center is set to
display standard units of
measurement and a 12-hour clock
at the factory. To change to metric
and/or a 24-hour clock, see page
38.
36
2
E
F
RPM
Trip 1
1
3
km
88:88
9
8 7
6
mi
4
5
FEATURES AND CONTROLS
Instrument Cluster
Rider Information Center
1. Gear Indicator - This indicator displays gear shifter position.
H = High Gear
L = Low Gear
N = Neutral
R = Reverse Gear
P = Park
-- = Gear Signal Error (or shifter between gears)
2. Fuel Gauge - The segments of the fuel gauge show the level of fuel in the fuel tank.
When the last segment clears, a low fuel warning is activated. All segments including
the fuel icon will flash. Refuel immediately.
Tip: If the fuel icon fails to display, an open or short circuit has occurred in the fuel sensor circuit. See
your dealer. Your POLARIS dealer can assist.
3. Information Display Area - This area displays odometer, trip meter, tachometer, engine
temperature meter, engine hour meter and programmable service hour interval.
4. Under / Over Voltage - This warning usually indicates that the vehicle is operating at an
RPM too low to keep the battery charged. It may also occur when the engine is at idle
and high electrical load (lights, cooling fan, accessories) is applied. Drive at a higher
RPM or recharge the battery to clear the warning.
5. Active Descent Control (ADC) Indicator (if equipped) - This indicator illuminates
when ADC mode is selected.
6. Clock - The clock displays time in a 12-hour or 24-hour format. See page 38 for
resetting instructions.
7. Service Indicator - A flashing wrench symbol alerts the operator that the preset service
interval has been reached. Your POLARIS dealer can provide scheduled maintenance.
See page 38 for resetting instructions.
8. 4X4 Indicator - This indicator illuminates when 4X4 is engaged.
9. Turf Mode Indicator - This indicator illuminates when the operator unlocks the
differential. See page 55.
37
FEATURES AND CONTROLS
Instrument Cluster
Rider Information Center
Use the MODE button to toggle through the information area
options.
Display Units (Standard/Metric)
The display can be changed to display either standard or metric
units of measurement.
MODE
Button
Tip: To exit the set-up mode at any time, wait 10 seconds.The display automatically exits and returns to
the odometer display.
Standard Display
Distance
Fuel
Temperature
Time
Miles
U.S. Gallons
Fahrenheit
12-Hour Clock
Metric Display
Kilometers
Liters, Imperial Gallons
Celsius
24-Hour Clock
1. Turn the key to the OFF position.
2. Press and hold the MODE button while turning the key to the ON position.
3. When the display flashes the distance setting, tap the MODE button to advance to the
desired setting.
4. Press and hold the MODE button to save the setting and advance to the next display
option.
5. Repeat the procedure to change remaining display settings.
Clock Mode
Tip: The clock must be reset any time the battery has been disconnected or discharged.
1. Turn the key to the ON position. Use the MODE button to toggle to the odometer
display.
2. Press and hold the MODE button until the hour segment flashes. Release the button.
3. With the segment flashing, tap the MODE button to advance to the desired setting.
4. Press and hold the MODE button until the next segment flashes. Release the button.
5. Repeat steps 3-4 twice to set the 10-minute and 1-minute segments. After completing the
1-minute segment, step 4 will save the new settings and exit the clock mode.
6. Turn the key to the OFF position.
38
FEATURES AND CONTROLS
Instrument Cluster
Rider Information Center
Odometer Mode
The odometer records and displays the distance traveled by the vehicle.
Trip Meter Mode
The trip meter records the distance traveled by the vehicle if reset before each trip. To reset,
select the trip meter mode. Press and hold the MODE button until the meter resets to zero. In
the Rider Information Center, the trip meter display contains a decimal point, but the
odometer displays without a decimal point.
Tachometer Mode
The engine RPM is displayed digitally.
Tip: Small fluctuations in the RPM from day to day may be normal because of changes in humidity,
temperature and elevation.
Engine Temperature Mode
This mode displays current temperature of the engine coolant.
Hour Meter Mode
This mode logs the total hours the engine has been in operation.
Programmable Service Interval
When the hours of engine operation equal the programmed service interval setting, the
wrench icon will flash for 5 seconds each time the engine is started. When this feature is
enabled, it provides a convenient reminder to perform routine maintenance. The service
interval is programmed at 50 hours at the factory. Use the following procedure to change the
service interval.
1. Press the MODE button until remaining service hours display.
2. Press and hold the MODE button.
3. When the service hours flash, press and release the MODE button to advance the hours
to the desired setting (including OFF). Press and hold the MODE button to set the new
service hour interval.
Diagnostic Display Mode
The EFI diagnostic display mode is for informational purposes only. Your POLARIS dealer
can provide for all major repairs.
The diagnostic mode is accessible only when the check engine warning indicator activates
after the key has been turned on. Leave the key on if you want to view the active code
(failure code).
The diagnostic mode becomes inaccessible if the key is turned off and on and the warning
indicator is no longer active. This allows the determination of persistent as well as
intermittent faults.
Inactive codes are stored in the history of the unit.
39
FEATURES AND CONTROLS
Instrument Cluster
Rider Information Center
Engine Error Codes
Suspect Parameter
Error Code
The error screen displays only when the
Number (SPN)
Number
(0-9)
CHECK ENGINE light is on or when it goes
on and off during one ignition cycle. Error
codes are not stored. When the key is turned
OFF, the code and message is lost, but will
reappear if the fault reoccurs after restarting the
engine.
If the CHECK ENGINE light illuminates,
retrieve the error codes from the display.
1. If the error codes are not displayed, use the
MODE button to toggle until “Ck ENG”
Failure Mode Indicator (FMI)
displays on the main line of the display.
2. Press and hold the MODE button to enter
the diagnostics code menu.
3. Record the three numbers displayed in the gear position, clock and odometer displays.
4. Press the MODE button to advance to the next error code.
5. Press and hold the MODE button to exit the diagnostics code menu.
6. Your authorized POLARIS dealer can provide code details and diagnosis.
40
OPERATION
WARNING
Failure to operate the vehicle properly can result in a collision, loss of control, accident or rollover,
which may result in serious injury or death. Read and understand all warnings outlined in the safety
section of this manual.
Break-In Period
The break-in period for your new RANGER is the first 25 hours of operation, or the time it
takes to use the first two tanks full of fuel. No single action on your part is as important as a
proper break-in 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.
Engine and Drivetrain Break-in
1. Fill the fuel tank with clean, fresh fuel. Review the fuel warnings on page 18.
2. Check the oil level. 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 42.
6. During the break-in period, change both the oil and the filter at 25 hours.
7. Check fluid levels of transmission and all gearcases after the first 25 hours of operation
and every 100 hours thereafter.
8. Pull only light loads.
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 breakin period as recommended. Pull only light loads. Avoid aggressive acceleration and high
speed operation during the break-in period.
If a belt fails, always clean any debris from the clutch air duct and from the engine
compartment. See page 78.
41
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
28
84
Brake fluid
Ensure proper level
84
Front suspension
Inspect, lubricate if necessary
70
Rear suspension
Inspect, lubricate if necessary
70
Steering
Ensure free operation
85
Tires
Inspect condition and pressure
87
Wheels/fasteners
Inspect, ensure fastener tightness
87
Frame nuts, bolts, fasteners
Inspect, ensure tightness
Fuel and oil
Ensure proper levels
37
71
Coolant level
Ensure proper level
77
Coolant hoses
Inspect for leaks
Throttle Pedal
Ensure proper operation
Indicator lights/switches
Ensure operation
-
23
Intake Screens (2)
Inspect, clean
82
Air filter
Inspect, clean
82
Headlamp
Verify proper operation
Brake light/tail lamp
Verify proper operation
Seat Belts
Check length of belt for damage, check latches for
proper operation
32
Cab Nets/Doors
Check for wear or damage, ensure proper installation
31
42
OPERATION
Starting the 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. Secure the cab nets (or doors).
Place the transmission in PARK.
Apply the brakes. 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.
Stopping the Engine
1.
2.
3.
4.
Release the throttle pedal completely and brake to a complete stop.
Place the transmission in PARK.
Turn the engine off.
Slowly release the brake pedal and make sure the transmission is in PARK before exiting
the vehicle.
WARNING! A rolling vehicle can cause serious injury. Always place the transmission in PARK when
stopping the engine.
Braking
1. Release the throttle pedal completely.
Tip: When the throttle pedal is released completely and the engine speed drops near an idle, the
vehicle has no engine braking.
2. Press on the brake pedal evenly and firmly.
Tip: If the throttle pedal and brake pedal are applied simultaneously, engine power may be limited.
3. Practice starting and stopping (using the brakes) until you’re familiar with the controls.
43
OPERATION
Driving Procedure
1. Wear a helmet, eye protection, gloves, long-sleeve shirt, long pants and over-the-ankle
boots.
2. Perform the pre-ride inspection. See page 42.
3. Sit in the driver's seat and fasten the seat belt.
4. Always use the cab nets (or doors) while riding in this vehicle.
5. Place the transmission in PARK.
6. Start the engine.
7. Apply the service brakes and shift the transmission into gear.
8. Check your surroundings and determine your path of travel.
9. Keeping both hands on the steering wheel, slowly release the brakes and slowly depress
the throttle with your right foot to begin driving.
10. Drive slowly. Practice maneuvering and using the throttle and brakes on level surfaces.
11. Do not carry a passenger until you have at least two hours of driving experience with this
vehicle.
44
OPERATION
Driving with a Passenger
1. Perform the pre-ride inspection. See page 42.
2. Make sure all passengers are at least 12 years of age and tall enough to comfortably and
safely sit in a passenger seat with the seat belt secured, put both feet on the floor and
grasp the hand hold.
3. Make sure all passengers are wearing helmet, eye protection, gloves, long-sleeve shirt,
long pants and over-the-ankle boots.
4. Make sure all passengers secure their seat belt.
5. Make sure all cab nets (or doors) are properly secured.
6. Do not carry more than the recommended number of passengers for your vehicle. See
page 10.
7. Allow a passenger to ride only in a passenger seat.
8. Slow down. Always travel at a speed appropriate for your skills, your passengers’ skills,
and operating conditions. Avoid unexpected or aggressive maneuvers that could cause
discomfort or injury to a passenger.
9. Vehicle handling may change with a passenger and/or cargo on board. Allow more time
and distance for braking.
10. Always follow all operating guidelines as outlined on safety labels and in this manual.
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.
4. Avoid operating over large obstacles such as large rocks and fallen trees. If unavoidable,
use extreme caution and operate slowly.
5. Always have all passengers dismount and move away from the vehicle before operating
over an obstacle that could cause a rollover.
45
OPERATION
Driving on Slippery Surfaces
WARNING
Skidding or sliding can cause loss of control or rollover (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
46
Turn in
direction of
skid
OPERATION
Driving Uphill
Whenever traveling uphill, follow these precautions:
1.
2.
3.
4.
Always travel straight uphill.
Avoid excessively steep hills.
Keep both feet on the floor.
Always check the terrain carefully before
ascending any hill. Never climb hills with
excessively slippery or loose surfaces.
5. Proceed at a steady rate of speed and throttle
pedal position. Never apply throttle suddenly.
6. 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.
Driving on a Sidehill (Sidehilling)
Driving on a sidehill is not recommended. Improper procedure could cause loss of control or
rollover. 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.
Driving Downhill
When driving downhill, follow these
precautions:
1. Avoid excessively steep hills.
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.
5. When transporting heavy loads and/or
when towing, always operate the vehicle in
low gear and have ADC activated (if
equipped).
47
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 for 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 81, 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.
WARNING! The large tires on your RANGER
may cause the vehicle to float in deep or fastflowing 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.
Floorboard
5. After leaving water, always dry the
brakes by applying light pressure to
the pedal repeatedly until braking action is normal. Avoid applying brake and throttle at
the same time.
NOTICE: If your vehicle becomes immersed or is operated in water that exceeds the floor level,
service is required before starting the engine. Your POLARIS dealer can provide this
service. If it's impossible to bring the vehicle in before starting the engine, perform the
service outlined on page 67, and take the vehicle in for service at the first opportunity.
48
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. Apply only light throttle. Never apply throttle suddenly.
49
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. Place the transmission in PARK.
4. Turn the engine off.
5. Slowly release the brake pedal and make sure the transmission is in PARK before exiting
the vehicle.
6. Remove the ignition switch key to prevent unauthorized use.
Parking on an Incline
Avoid parking on an incline if possible. If it's
unavoidable, follow these precautions:
1. Apply the brakes.
2. Place the transmission in PARK.
3. Turn the engine off.
4. Slowly release the brake pedal and make
sure the transmission is in PARK before
exiting the vehicle.
5. Block the rear wheels on the downhill
side.
50
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, passengers, non-factory installed 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. When transporting heavy loads and/or when towing,
always operate the vehicle in low gear and have ADC activated (if equipped).
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 a rollover.
DO NOT TRAVEL FASTER THAN THE RECOMMENDED SPEEDS. Vehicle should never exceed 10
MPH (16 km/h) while towing a load on a level grass surface. Vehicle speed should never exceed 5
MPH (8 km/h) when towing loads in rough terrain, while cornering, or while ascending or descending a
hill.
Load Capacity
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, passengers, non-factory installed accessories, cargo and weight on hitch) must not
exceed the maximum weight capacity of the vehicle. See page 12.
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.
51
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. When transporting heavy loads and/or when towing, always operate the vehicle in low
gear and have ADC activated (if equipped).
3. When towing a disabled RANGER vehicle, place the disabled vehicle’s transmission in
neutral. Do not operate the vehicle faster than 10 MPH (16 km/h) when towing.
4. Do not operate the vehicle faster than 10 MPH (16 km/h) when towing. See page 51.
Towing a trailer increases braking distance.
5. Do not tow more than the recommended weight for the vehicle. See the towing capacity
chart below and the specifications charts beginning on page 98.
6. 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.
7. 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 XP 900
2000 lbs.
(907 kg)
850 lbs.
(386 kg)
150 lbs.
(68.1 kg)
10 MPH
(16 km/h)
RANGER CREW 900
2000 lbs.
(907 kg)
850 lbs.
(386 kg)
150 lbs.
(68.1 kg)
10 MPH
(16 km/h)
Belt Life
To extend belt life, use the lowest gear possible when hauling or towing heavy cargo. Using
high gear for heavy loads, hilly terrain or in wet, muddy conditions will increase the chance
of drive belt burning. See the Drive Belt Wear/Burn section on page 103.
Towing a RANGER
Towing this vehicle is not recommended. Always transport the vehicle on a trailer or flatbed
with all four wheels off the ground. See page 97.
If towing a disabled vehicle is unavoidable, place the disabled vehicle’s transmission in
neutral. Tow the shortest distance possible. Do not operate faster than 10 MPH (16 km/h).
52
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. Place the
transmission in PARK.
3. Ensure that the cargo is positioned
evenly or toward the front of the cargo
box.
4. 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.
5. Stand clear and pull up on the cargo box release lever. Lift the front of the cargo box to
dump the cargo.
6. 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 could 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.
53
OPERATION
All Wheel Drive/Rear Differential System
If your model is equipped with a lockable differential, you can choose to operate with an
open differential or a closed differential.
For models equipped with Active Descent Control (ADC), refer to the All Wheel Drive/Active
Descent Control System section beginning on page 56.
Engaging AWD
Press the top of the switch to engage All Wheel
Drive (AWD). The 4X4 indicator illuminates in the
rider information center to indicate that the vehicle is
in AWD. See page 37.
When the AWD switch is on, the front wheels will
automatically engage any time the rear wheels lose
traction. When the rear wheels regain traction, the
front wheels will automatically disengage. There is
no limit to the length of time the vehicle may remain
in AWD.
Tip: The AWD switch may be turned on or off while the
vehicle is moving.
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
Move the AWD switch to the center or bottom position to disengage AWD. If the switch is
turned off while the front hubs are driving, they will not release until the rear wheels regain
traction.
In some situations, the front gearcase may remain locked after turning the AWD switch off.
If this occurs, you may notice increased steering effort and some vehicle speed restriction.
Perform the following procedure to unlock the front gearcase.
1. Stop the vehicle.
2. Operate in reverse for at least 10 feet (3 m).
3. Stop completely.
4. Shift into low gear and drive forward.
5. If the front gearcase remains locked after following these instructions, see your dealer
for service.
54
OPERATION
All Wheel Drive/Rear Differential System
Locking the Differential
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.
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.
Unlocking the Differential (TURF Mode)
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.
When operating in TURF mode, the inside rear wheel will rotate independently from the
outside wheel during turns. Operate in TURF mode only as needed to protect smooth, level
surfaces from tire damage. DO NOT operate in TURF mode when climbing or descending
hills, when sidehilling, or when operating on uneven, loose, or slippery terrain such as sand,
gravel, ice, snow, obstacles, and water crossings. Always operate in AWD on these types of
terrain.
WARNING! Operating in TURF mode (if equipped) when on sloped, uneven, or loose terrain could
cause loss of control and result in serious injury or death. One rear wheel may slip and lose traction or
may lift up and grab when it touches the ground again.
WARNING! Never operate in TURF mode (if equipped) while operating on a hill or other irregular
terrain. Always move the AWD switch to AWD before ascending or descending a hill.
55
OPERATION
All Wheel Drive/Active Descent Control System
ADC models are equipped with a drive mode switch that controls the AWD system. The
AWD/ADC Drive Mode switch controls AWD through drive mode options.
For models that are not equipped with ADC, refer to the All Wheel Drive section beginning
on page 54.
Drive Mode Operation
Drive mode options include:
• ADC - All Wheel Drive (ADC 4X4)
• AWD - All Wheel Drive (AWD/4X4)
• 2WD - Two Wheel Drive (2X4)
• TURF - TURF Mode (1WD)
The vehicle automatically engages 4X4 when operating in reverse
if the drive mode is set to either AWD (4X4) or ADC 4X4.
Drive Mode
Switch
• Always operate in low gear and engage ADC 4X4 when
transporting heavy loads and/or when towing.
• Always operate in low gear and engage ADC 4X4 before ascending or descending a hill.
See page 57 for Active Descent Control (ADC) System information.
WARNING! Operate in TURF mode only as needed to protect smooth, level surfaces from tire
damage. DO NOT operate in TURF mode when climbing or descending hills, when sidehilling, or when
operating on uneven, loose, or slippery terrain such as sand, gravel, ice, snow, obstacles, and water
crossings.
Drive Mode Switch
Press and release the top of the switch to toggle
through the drive mode options. The selected
drive mode displays at three locations on the
instrument cluster.
• Acronyms display in the information display
area of on the instrument cluster (for several
seconds)
• The corresponding icon illuminates in the
information center. See page 36.
• The indicator light for the selected drive mode
illuminates on the drive mode indicator.
Press and release the bottom of the switch to
toggle to a previous option.
When the switch is released, the drive mode
displayed is the active drive mode.
NOTICE: Switching to 4X4 or ADC 4X4 while the rear
wheels are spinning may cause severe
drive shaft and gearcase damage. Always
switch to 4X4 or ADC 4X4 while the rear
wheels have traction or are at rest.
km
88:88
mi
AWD System
Icons
ADC
AWD
2WD
TURF
Drive Mode
Indicator
Acronyms
56
OPERATION
Active Descent Control (ADC) System (if equipped)
The ADC system allows engine braking to all four wheels when the vehicle descends a hill
or incline.
• Always operate in low gear and engage ADC 4X4 when transporting heavy loads and/or
when towing.
• Always operate in low gear and engage ADC 4X4 before ascending or descending a hill.
Engaging Active Descent Control
The ADC system will automatically engage when both of the following conditions occur:
• The drive mode must be in the ADC 4X4 position
• The transmission must be in gear (high, low or reverse)
Disengaging Active Descent Control
The ADC system will automatically disengage if at least one of the following conditions
occur:
• The drive mode is changed from the ADC 4X4 position
• The transmission is shifted to neutral or park
57
WINCH GUIDE
These safety warnings and instructions apply if your vehicle came equipped with a winch or
if you choose to add an accessory winch to your vehicle.
WARNING
Improper winch use can result in SEVERE INJURY or DEATH. Always follow all winch instructions and
warnings in this manual.
Your winch may have a cable made of either wire rope or specially designed synthetic rope.
The term “winch cable” will be used for either unless noted otherwise.
Winch Safety Precautions
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
Read all sections of this manual.
Never use alcohol or drugs before or while operating the winch.
Never allow children under 16 years of age to operate the winch.
Always wear eye protection and heavy gloves when operating the winch.
Always keep body, hair, clothing and jewelry clear of the winch cable, fairlead and hook
when operating winch.
Never attempt to “jerk” a load attached to the winch with a moving vehicle. See the
Shock Loading section on page 64.
Always keep the area around the vehicle, winch, winch cable and load clear of people
(especially children) and distractions while operating the winch.
Always turn the vehicle ignition power OFF when it and the winch are not being used.
Always be sure that at least five (5) full turns of winch cable are wrapped around the
winch drum at all times. The friction provided by this wrapped cable allows the drum to
pull on the winch cable and move the load.
Always apply your vehicle’s park brake and/or park mechanism to hold the vehicle in
place during winching. Use wheel chocks if needed.
Always align the vehicle and winch with the load directly in front of the vehicle as much
as possible. Avoid winching with the winch cable at an angle to the winching vehicle’s
centerline whenever possible.
If winching at an angle is unavoidable, follow these precautions:
A.
B.
58
Look at the winch drum occasionally. Never let the winch cable “stack” or accumulate at one
end of the winch drum. Too much winch cable at one end of the winch drum can damage the
winch and the winch cable.
If stacking occurs, stop winching. Follow step 15 on page 63 to feed and rewind the cable
evenly before continuing the winch operation.
WINCH GUIDE
Winch Safety Precautions
13. Never winch up or down at sharp angles. This can destabilize the winching vehicle and
possibly cause it to move without warning.
14. Never attempt to winch loads that weigh more than the winch’s rated capacity.
15. The winch motor may become hot during winch use. If you winch for more than 45
seconds, or if the winch stalls during operation, stop winching and permit the winch to
cool down for 10 minutes before using it again.
16. Never touch, push, pull or straddle the winch cable while
winching a load.
17. Never let the winch cable run through your hands, even if
wearing heavy gloves.
18. Never release the clutch on the winch when the winch cable is
under load.
19. Never use the winch for lifting or transporting people.
20. Never use the winch to hoist or suspend a vertical load.
21. Never immerse or submerse your winch in water. Your dealer can provide service on
your winch if this occurs.
22. Always inspect your winch and winch cable before each use.
23. Never winch the hook fully into the winch. This can cause damage to winch
components.
24. Unplug the remote control from the vehicle when the winch is not in use to prevent
inadvertent activation and use by unauthorized persons.
25. Never grease or oil the winch cable. This will cause the winch cable to collect debris that
will shorten the life of the cable.
59
WINCH GUIDE
Winch Operation
Read the Winch Safety Precautions in the preceding pages before using your winch.
Tip: Consider practicing the operation and use of your winch before you actually need to use it in the
field.
WARNING
Improper winch use can result in SEVERE INJURY or DEATH. Always follow all winch instructions and
warnings in this manual.
Each winching situation is unique.
• Take your time to think through the winching you are about to do.
• Proceed slowly and deliberately.
• Never hurry or rush during winching.
• Always pay attention to your surroundings.
• You may need to change your winching strategy if it is not working.
• Always remember that your winch is very powerful.
• There are simply some situations that you and your winch will not be able to deal with. Do not be
afraid to ask others to help when this happens.
1. Always inspect the vehicle, winch, winch cable and winch controls for any signs of
damage or parts in need of repair or replacement before each use. Pay particular
attention to the first 3 feet (1 meter) of winch cable if the winch is being used (or has
been used) for lifting an accessory plow assembly. Promptly replace any worn or
damaged cable.
2. Never operate a winch or a vehicle in need of repair
or service.
3. Always apply your vehicle’s park brake and/or park
mechanism to hold the vehicle in place during
Hook Strap
winching. Use wheel chocks if needed.
60
WINCH GUIDE
Winch Operation
4. Always use the hook strap when handling the hook.
WARNING! Never put your fingers into the hook. This could lead
to SEVERE INJURY.
A. Attach the hook itself onto the load or use a tow strap or
chain to secure the load to the winch cable.
Tip: A “tow strap” is NOT intended to stretch. A “recovery strap”
NO
YES
is designed to stretch.
WARNING! Never use a recovery strap when winching due to
the excessive energy that can be released if the winch cable breaks. This can result in SEVERE
INJURY or DEATH. See the Shock Loading section on page 64.
B. Never hook the winch cable back onto itself. This will damage the winch cable and may result
in winch cable failure.
WARNING! Replace the winch cable at the first sign of damage to prevent SEVERE INJURY or
DEATH in the event of failure. For your safety, always replace POLARIS winch parts (including the
cable) with genuine POLARIS replacement parts available at your authorized POLARIS dealer.
C. If possible, keep the winch cable aligned with the centerline of the winching vehicle. This will
help the spooling of the winch cable and reduce the load on the fairlead.
D. If freeing a stuck vehicle by attaching to a tree, use an item such as a tow strap to avoid
damaging the tree during winch operation. Sharp cables and chains can damage and even kill
trees. Please remember to TreadLightly® (treadlightly.org).
E. Before operating the winch, be sure that the safety latch on
the winch cable hook is fully seated when the load is
attached.
F. Never operate your winch with a damaged hook or latch.
Always replace damaged parts before using the winch.
5. Never remove the hook strap from the hook.
NO
YES
6. Release the winch clutch and pull out the winch cable.
7. Pulling out as much cable as possible maximizes the
winch’s pulling capacity. Always be sure that at least five (5) full turns of winch cable
are wrapped around the winch drum at all times. The friction provided by this wrapped
cable allows the drum to pull on the winch cable and move the load.
61
WINCH GUIDE
Winch Operation
8. Read and adhere to the following information for winch damping to ensure safe winch
use.
A.
B.
C.
D.
In order to absorb energy that could be released by a winch cable failure, always place a
“damper” on the winch cable. A damper can be a heavy jacket, tarp, or other soft, dense
object. A damper can absorb much of the energy released if a winch cable breaks when
winching. Even a tree limb can help as a damper if no other items are available to you.
Lay the damper on top of the mid-point of the winch cable length that is spooled out.
On a long pull, it may be necessary to stop winching so that the damper can be repositioned
to the new mid-point of the winch cable. Always release the tension on the winch cable before
repositioning the damper.
Avoid being directly in line with the winch cable whenever possible. Also, never permit others
to stand near or in line with the winch cable during winch operation.
9. Never hook the winch cable back onto itself. This will damage the winch cable and may
result in winch cable failure.
10. Never use straps, chains or other rigging items that are damaged or worn.
11. The ONLY time a winch-equipped vehicle should be moving when using the winch is
when that vehicle itself is stuck. The winch-equipped vehicle should NEVER be in
motion to “shock” load the winch cable in an attempt to move a second stuck vehicle.
See the Shock Loading section on page 64. For your safety, always follow these
guidelines when winching a vehicle free:
A.
B.
C.
Release the winch clutch and spool out the necessary length of winch cable.
Align the winch cable as close as possible to the winching vehicle’s centerline.
Attach the winch cable hook to the anchor point or the stuck vehicle’s frame following
instructions in this manual.
D. Re-engage the clutch on the winch.
E. Slowly winch in the slack in the winch cable.
F. Select the proper vehicle gear to propel the stuck vehicle in the direction of winching.
G. Shift to the lowest gear available on the stuck vehicle.
H. Slowly and carefully apply vehicle throttle and winch together to free the vehicle.
I. Stop winching as soon as the stuck vehicle is able to propel itself without the help of the
winch.
J. Detach the winch cable hook.
K. Rewind the winch cable evenly back onto the winch drum following the instructions in this
manual.
12. Never attempt to winch another stuck vehicle by attaching the winch cable to a
suspension component, brush guard, bumper or cargo rack. Vehicle damage may result.
Instead, attach the winch to a strong portion of the vehicle frame or hitch.
13. Extensive winching will run down the battery on the winching vehicle. Let the winching
vehicle’s engine run while operating the winch to prevent the battery from running low if
winching for long periods.
62
WINCH GUIDE
Winch Operation
14. The winch motor may become hot during winch use. If you winch for more than 45
seconds, or if the winch stalls during operation, stop winching and permit the winch to
cool down for 10 minutes before using it again.
15. After winching is complete, especially if winching at an angle, it may be necessary to redistribute the winch cable across the winch drum. You will need an assistant to perform
this task.
A.
B.
C.
D.
E.
F.
Release the clutch on the winch.
Feed out the winch cable that is unevenly bunched up in one area.
Re-engage the winch clutch.
Have an assistant pull the winch cable tightly with about 100 lbs. (45 kg) of tension using the
hook strap.
Slowly winch the cable in while your assistant moves the end of the winch cable back and
forth horizontally to evenly distribute the winch cable on the drum.
Doing this reduces the chances of the winch cable “wedging” itself between lower layers of
winch cable.
Winch Cable Care
For your safety, always replace POLARIS winch parts (including the cable) with genuine
POLARIS replacement parts available at your authorized POLARIS dealer.
WARNING! Use of worn or damaged cable could lead to sudden failure and SEVERE INJURY.
1. Always inspect your winch before each use. Inspect for worn or loose parts including
mounting hardware. Never use the winch if any part needs repair or replacement.
2. Always inspect your winch cable before each use. Inspect for worn or kinked winch
cable.
A.
B.
C.
D.
A kinked winch cable made of wire rope is shown at
right. Even after being “straightened out,” this cable has
already been permanently and severely damaged.
Promptly discontinue use of a winch cable in this
condition.
A kinked winch cable made of wire rope that has been
“straightened out” is shown at right. Even though it may
look usable, the cable has been permanently and
severely damaged. It can no longer transmit the load
that it could prior to kinking. Promptly discontinue use
of a winch cable in this condition.
A winch cable made of synthetic rope should be
inspected for signs of fraying. Replace the cable if
fraying is observed (shown at right). Promptly
discontinue use of a winch cable in this condition.
Also replace the winch cable if there are fused or
melted fibers. Such an area of the synthetic rope will
be stiff and appear smooth or glazed. Promptly
discontinue use of a winch cable in this condition.
A
B
C
63
WINCH GUIDE
Shock Loading
WARNING! Your winch cable is very strong but it is NOT designed for dynamic, or “shock” loading.
Shock loading may tension a winch cable beyond its strength and cause the cable to break. The end of
a broken winch cable under such high loading can cause SEVERE INJURY or DEATH to you and other
bystanders.
Winch cables are designed to NOT absorb energy. This is true of both wire-rope and
synthetic-rope winch cables.
1. Never attempt to “jerk” a load with the winch. For example, never take up slack in the
winch cable by moving the winching vehicle in an attempt to move an object. This is a
dangerous practice. It generates high winch cable loads that may exceed the strength of
the cable. Even a slowly moving vehicle can create large shock loads in a winch cable.
WARNING! SEVERE INJURY or DEATH can result from a broken winch cable.
2. Never quickly turn the winch ON and OFF repeatedly (“jogging”). This puts extra load
on the winch, winch cable, and generates excessive heat from the motor. This is a form
of shock loading.
3. Never tow a vehicle or other object with your winch. Towing an object with a winch
produces shock loading of the cable even when towing at slow speeds. Towing from a
winch also positions the towing force high on the vehicle. This can cause instability of
the vehicle and possibly lead to an accident.
4. Never use recovery straps with your winch. Recovery straps are designed to stretch and
can store energy. This stored energy in the recovery strap is released if a winch cable
fails making the event even more hazardous. Similarly, never use elastic “bungie” cords
for winching.
5. Never use the winch to tie down a vehicle to a trailer or other transportation vehicle. This
type of use also causes shock loading that can cause damage to the winch, winch cable,
or vehicles used.
Your winch cable is designed and tested to withstand the loads produced by the winch
motor when operated from a stationary vehicle. Always remember that the winch and
winch cable are NOT designed for shock loading.
64
WINCH GUIDE
Winch Maintenance and Service Safety
WARNING! Improper or lack of winch maintenance and service could lead to SEVERE INJURY or
DEATH. Always follow all winch instructions and warnings in this manual.
1. Always inspect your winch before each use. Inspect for worn or kinked winch cable.
Also inspect for worn or loose parts including mounting hardware.
2. Permit your winch motor to cool down prior to servicing your winch.
3. Never work on your winch without first disconnecting the battery connections to prevent
accidental activation of the winch.
4. For your safety, always replace POLARIS winch parts (including the cable) with
genuine POLARIS replacement parts available at your authorized POLARIS dealer.
5. Some winch models use wire rope as the winch cable. Other winches use a specially
designed synthetic rope as the winch cable.
6. Never replace a synthetic-rope winch cable with a consumer-grade polymer rope such as
can be purchased in a hardware store. Although they may look similar, they are NOT
alike. A polymer rope not designed for winch use will stretch and store excessive energy
when winching.
WARNING! Failure of a stretched rope under winching conditions will release all of the stored energy.
This will increase the chances of SEVERE INJURY or DEATH.
65
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 arrester that was tested and qualified to be in accordance
with the USFS standard 5100-1c. Federal law requires that this spark arrester 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 an electronic fuel
injection (EFI) system. The engine and EFI components
are set at the factory for optimal performance and are
not adjustable.
The emissions label is located on the main frame under
the driver’s seat and storage compartment.
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.
Non-ionizing Radiation: This vehicle emits some electromagnetic energy. People with active
or non-active implantable medical devices (such as heart monitoring or controlling devices)
should review the limitations of their device and the applicable electromagnetic standards
and directives that apply to this vehicle.
66
MAINTENANCE
Periodic Maintenance Chart
Any qualified repair shop or person may maintain, replace or repair the emission control
devices or systems on your vehicle. An authorized POLARIS dealer can perform any service
that may be necessary for your vehicle. POLARIS also recommends POLARIS parts for
emissions-related service, however equivalent parts can be used.
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.
Owners are responsible for performing the scheduled maintenance identified in this owner’s
manual.
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, genuine POLARIS parts are available from your POLARIS
dealer. Equivalent parts may be used for emissions-related service.
Record maintenance and service in the Maintenance Log beginning on page 111.
Tip: Service and adjustments are important for proper vehicle operation. If you're not familiar with safe
service and adjustment procedures, a qualified dealer can perform these operations.
Vehicles subjected to heavy or severe use patterns must be inspected and serviced more
frequently.
Severe Use Definition
•
•
•
•
•
•
Frequent immersion in mud, water or sand
Frequent or prolonged operation in dusty environments
Racing or race-style high RPM use
Prolonged low speed, heavy load operation
Extended idle
Frequent short trip operation in cold weather (engine frequently does not operate long
enough to reach full operating temperature)
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.
Maintenance Chart Key
Ź Perform these operations more often for vehicles subjected to severe use.
D Have an authorized POLARIS dealer or other qualified person perform these services.
WARNING! Improperly performing the procedures marked with a “D” could result in component failure
and lead to serious injury or death. Have an authorized POLARIS dealer or other qualified person
perform these services.
67
MAINTENANCE
Periodic Maintenance Chart
Perform all services at whichever maintenance interval is reached first.
Item
Maintenance Interval
Remarks
(whichever comes first)
Hours Calendar
Miles (Km)
Steering
Front suspension
Rear suspension
Tires
Pre-Ride
Brake fluid level
Make adjustments as needed.
See Pre-Ride Checklist on page 42.
Brake pedal travel
Brake system
Wheels/fasteners
Frame fasteners
Engine oil level
Engine intake pre-filter (left side)
-
Daily
-
Inspect; clean screen often; replace
pre-filter as needed
PVT intake pre-filter (right side)
-
Daily
-
Inspect; clean screen often
Coolant
-
Daily
-
Check level
-
Daily
-
Inspect daily; clean often
-
Daily
-
Verify proper operation
Ź Power steering unit (if equipped)
Headlamp/tail lamp
Ź Air filter
-
Weekly
-
10 H
Monthly
100 (160)
Inspect periodically
Battery
25 H
Monthly
200 (320)
Check terminals; clean; test
Fuel System
25 H
Monthly
200 (320)
Inspect; cycle key to pressurize fuel
pump; check lines and fittings for leaks
and abrasion
Ź Demand drive fluid (extreme use)
25 H
1M
-
Change fluid every 25 hours if ADC is
subjected to extreme use. See page 74.
Ź Demand drive fluid (front
gearcase) (if equipped)
25 H
1M
-
Perform a break-in oil level check
Ź Transmission oil
25 H
1M
-
Ź Engine oil change (break-in)
25 H
-
500 (800)
Perform a break-in oil change
Ź General lubrication
50 H
3M
500 (800)
Lubricate all fittings, pivots, cables, etc.
50 H
6M
500 (800)
Inspect, lubricate, adjust
50 H
6M
500 (800)
Lubricate
Ź Brake pad wear
D
Shift Linkage
D Steering
Inspect; replace as needed
Perform a break-in oil level check
Ź Front Suspension
50 H
6M
500 (800)
Lubricate
Ź Rear Suspension
50 H
6M
500 (800)
Lubricate
Ź Perform these procedures more often for vehicles subjected to severe use.
D Have an authorized POLARIS dealer or other qualified person perform these services.
68
MAINTENANCE
Periodic Maintenance Chart
Item
Maintenance Interval
Hours Calendar
D Throttle pedal
Throttle body air intake ducts/
flange
Remarks
(whichever comes first)
Miles (Km)
50 H
6M
500 (800)
Inspect for free movement; replace
pedal as needed
50 H
6M
500 (800)
Inspect duct for proper sealing/air leaks
Drive belt
50 H
6M
500 (800)
Inspect; adjust; replace as needed
Cooling system (if applicable)
50 H
6M
500 (800)
Inspect coolant strength seasonally;
pressure test system yearly
Ź Radiator (if applicable)
50 H
6M
500 (800)
Inspect; clean external surfaces
Ź Oil lines, fasteners
50 H
6M
Ź Engine oil and filter change
100 H
6M
1000 (1600) Change the oil and filter
Ź Front gearcase oil
100 H
12 M
1000 (1600) Change fluid
Ź Transmission oil
100 H
12 M
1000 (1600) Change fluid
D Fuel system
100 H
12 M
1000 (1600) Cycle key to pressurize fuel pump;
check for leaks at fill cap, fuel lines/rail
and fuel pump; replace lines every two
years
Ź Cooling Hoses (if applicable)
100 H
12 M
1000 (1600) Inspect for leaks
Ź Engine mounts
100 H
12 M
1000 (1600) Inspect
Exhaust muffler/pipe
100 H
12 M
1000 (1600) Inspect
Drive shafts
100 H
12 M
1000 (1600) Remove and grease
D Spark plug
100 H
12 M
1000 (1600) Inspect; replace as needed
Ź Wiring
100 H
12 M
1000 (1600) Inspect for wear, routing, security; apply
dielectric grease to connectors subjected to water, mud, etc.
D Clutches (drive and driven)
Ź
100 H
12 M
1000 (1600) Inspect; clean; replace worn parts
1000 (1600) Inspect for leaks and loose fittings
D Front wheel bearings
100 H
12 M
1000 (1600) Inspect; replace as needed
D Brake fluid
200 H
24 M
2000 (3200) Change every two years
Suspension bushings
250 H
24 M
2000 (3200) Inspect; replace if necessary
Spark arrester
300 H
36 M
3000 (4800) Clean out
D Valve clearance
-
-
Ź Coolant
-
60 M
5000 (8000) Inspect; adjust as needed
-
Change coolant
D Toe adjustment
-
Inspect periodically; adjust when parts
are replaced
D Auxiliary brake (if equipped)
Ź
-
Inspect daily; adjust as needed
-
Adjust as needed
Headlight aim
Ź Perform these procedures more often for vehicles subjected to severe use.
D Have an authorized POLARIS dealer or other qualified person perform these services.
69
MAINTENANCE
Lubrication Recommendations
Check and lubricate all components at the intervals outlined in the Periodic Maintenance
Chart beginning on page 67, 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.
Engine Oil
Item
Lube
PS-4 5W-50 4-Cycle Oil
Brake Fluid
DOT 4 Brake Fluid
Main Gearcase Oil
(Transmission)
Front Gearcase Oil
Front Prop Shaft Yoke
AGL Gearcase Lubricant &
Transmission Fluid
Demand Drive Fluid
U-Joint Grease
Front Control Arm Pivot
Bushings
Rear Control Arm Pivot
Bushings
Rear Stabilizer Bar
Bushings
All Season Grease or grease
conforming to NLGI No. 2
Method
Add to proper level on dipstick. See page
71.
Maintain level between fill lines. See page
84.
See page 73.
See pages 73-74.
Locate fittings and grease (3 pumps
maximum).
Grease 3 fittings on each side of the
vehicle.
Grease 4 fittings on each side of the
vehicle.
Grease one fitting on each side of the
vehicle.
Engine Oil
Always check and change the engine oil at the intervals outlined in the Periodic Maintenance
Chart beginning on page 67. 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 5W-50 4-Cycle Oil or a similar oil. Refer
to the specifications section beginning on page 98 for capacities. 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.
Always check and change the oil at the intervals outlined in the Periodic Maintenance Chart
beginning on page 67. Always use the recommended engine oil.
70
MAINTENANCE
Engine Oil
Oil Check
Always check the oil when the engine is cold. If the engine is hot when the oil is checked, the
level will appear to be overfull.
CAUTION! Always remove all cargo from the cargo box before lifting the box to access engine
components.
Access the oil fill cap, dipstick and filter under
the cargo box.
1. Remove all cargo from the cargo box. See
page 53.
2. Position the vehicle on a level surface.
3. Place the transmission in PARK.
4. Stop the engine.
5. Stand clear and pull up on the cargo box
release lever. Lift the front of the cargo
box.
6. Remove the dipstick. Wipe it dry with a
clean cloth.
Oil Fill
Oil
Oil
7. Reinstall the dipstick completely. Remove
Cap
Filter
Dipstick
the dipstick and check the oil level.
8. Remove the oil fill cap to add the recommended oil as needed. Maintain the oil level
between the minimum and maximum marks on the dipstick. Do not overfill.
9. Reinstall the fill cap. Reinstall the dipstick.
10. Lower the cargo box and push down securely to latch.
Oil and Filter Change
Always change the oil and filter at the intervals outlined in the Periodic Maintenance Chart
beginning on page 67. Always change the oil filter whenever changing oil.
The crankcase drain plug is located on the bottom of the crankcase. Access the drain plug
through the access hole in the skid plate under the crankcase (see next page).
CAUTION! Always remove all cargo from the cargo box before lifting the box to access engine
components.
Access the oil fill cap, dipstick and filter under the cargo box.
1. Remove all cargo from the cargo box. See page 53.
2. Position the vehicle on a level surface.
71
MAINTENANCE
Engine Oil
Oil and Filter Change
3.
4.
5.
6.
Place the transmission in PARK.
Stand clear and pull up on the cargo box release lever. Lift the front of the cargo box.
Locate the crankcase drain plug access hole in the skid plate.
Clean the area around the crankcase drain plug.
Oil
CAUTION! Hot oil can cause burns to skin. Do not allow
hot oil to contact skin.
Oil Fill
Cap
Filter
Oil
Dipstick
7. Place a drain pan under the engine crankcase and
remove the drain plug. Allow the oil to drain
completely.
8. Using an oil filter wrench, turn the filter counterclockwise to remove it.
9. Using a clean dry cloth, clean the filter sealing
surface on the crankcase.
10. Lubricate the o-ring on the new filter with a film
of fresh engine oil. Check to make sure the o-ring
is in good condition.
Access
11. Install the new filter and turn by hand until the
Crankcase
Hole
Drain Plug
filter gasket contacts the sealing surface, then turn
an additional 1/2 turn.
12. Reinstall the drain plug. Torque the drain plug to
12 ft-lbs (16 Nm).
13. Remove the oil fill cap and add 2.5 quarts (2.4 l)
of recommended oil. Reinstall the fill cap.
14. Start the engine and check for leaks.
15. Stop the engine and wait 15 seconds before
removing the dipstick.
16. Remove the dipstick. Wipe it dry with a clean
Bottom View of Skid Plate
cloth.
17. Reinstall the dipstick completely. Remove the
dipstick and check the oil level.
18. Remove the oil fill cap and add oil as needed to bring the level to the upper mark on the
dipstick. Do not overfill.
19. Reinstall the fill cap. Reinstall the dipstick.
20. Lower the cargo box and push down securely to latch.
21. Dispose of used filter and oil properly.
72
MAINTENANCE
Gearcases
Gearcase Specification Chart
RANGER XP 900/RANGER CREW 900 Gearcase Specifications
Gearcase
Lubricant
Capacity
Fill Plug Torque Drain Plug Torque
Main Gearcase
(Transmission)
AGL Gearcase
Lubricant &
Transmission Fluid
40.6 oz.
(1200 ml)
12 ft-lbs
(16.3 Nm)
12 ft-lbs
(16.3 Nm)
Front Gearcase
Demand Drive Fluid
6.76-7.6 oz.
(200-225 ml)
8-10 ft-lbs
(11-13.6 Nm)
8-10 ft-lbs
(11-13.6 Nm)
Transmission (Main Gearcase)
Always check and change the transmission oil at the
intervals outlined in the Periodic Maintenance Chart
beginning on page 67. 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 level check/fill plug is located on the rear of the
gearcase. Maintain the oil level even with the
bottom of the level check/fill plug hole threads.
1. Position the vehicle on a level surface.
2. Place the transmission in PARK.
3. Remove the level check/fill plug. Check the oil
level.
4. Add the recommended oil as needed.
5. Reinstall the fill plug. Torque to specification.
Gearcase
Level
Check/Fill
Plug
Fill
Oil Change
Level
The drain plug is located near the bottom of the
gearcase.
1. Remove the level check/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.
Drain Plug
73
MAINTENANCE
Gearcases
Front Gearcase
Always check and change the front gearcase oil at the intervals outlined in the Periodic
Maintenance Chart beginning on page 67. Maintain the oil level even with the bottom thread
of the fill plug hole.
Refer to the Gearcase Specifications Chart on page 73 for recommended lubricants,
capacities and torque specifications. See page 102 for the part numbers of POLARIS
products.
ADC Models: Change the front gearcase fluid every 25 hours if the ADC unit is exposed to
extreme use. Extreme use includes any of the following:
• operation in ADC mode for prolonged periods
• constant ADC operation on hilly or mountainous terrain
• ADC is the primary mode of all-wheel-drive operation
Tip: If the front gearcase makes excessive noise during ADC operation, change the demand drive fluid.
If the noise continues, please see your POLARIS dealer or other qualified service person for
service.
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. Place the transmission in PARK.
3. Remove the fill plug. Check the oil level.
4. Add the recommended oil as needed.
5. Reinstall the fill plug. Torque to specification.
Oil Change
1. Support the vehicle securely with a jackstand.
2. Remove the fill plug.
3. Place a drain pan under the drain plug.
4. Remove the drain plug. Allow the oil to drain
completely.
5. Clean and reinstall the drain plug. Torque to
specification.
6. Add the recommended oil.
7. Reinstall the fill plug. Torque to specification.
8. Check for leaks. Dispose of used oil properly.
74
Fill
Plug
Fill
Level
Recessed
Drain Plug
MAINTENANCE
Spark Plugs
Spark Plug Recommendations
Refer to the specifications section beginning on page 98 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 or their equivalent.
Spark Plug Gap/Torque
Electrode Gap
New Plug Torque
Used Plug Torque
0.7-0.8 mm
10 ft-lbs (13.5 Nm)
10 ft-lbs (13.5 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.
CAUTION! Always remove all cargo from the cargo box before lifting the box to access engine
components.
1. Lift the cargo box. Remove the spark plug
cap.
Spark Plugs
CAUTION! A hot exhaust system and engine can
cause burns. Wear protective gloves when
removing a spark plug for inspection.
2. Using the spark plug wrench provided in
the tool kit, remove the plug by rotating it
counter-clockwise.
3. Reverse the procedure for spark plug
installation. Apply anti-seize compound
to the spark plug threads.
4. Torque to specification.
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: incorrect spark plug type or heat range, excessive engine oil consumption or
incorrect throttle body adjustments.
75
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
POLARIS recommends the use of POLARIS Antifreeze 50/50 Premix. This antifreeze is
already premixed and ready to use. Do not dilute with water. See page 102 for the part
numbers of POLARIS products.
To ensure that the coolant maintains its ability to protect the engine, we recommend that the
system be completely drained every five (5) years and fresh Antifreeze 50/50 Premix added.
Any time the cooling system has been drained for maintenance or repair, replace the coolant
with fresh Antifreeze 50/50 Premix. If the recovery bottle has run dry, the level in the
radiator should be inspected. Add coolant as needed.
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 67. 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 high-pressure system is not recommended.
76
MAINTENANCE
Cooling System
Overflow Bottle Coolant Level
Always check and change the coolant at the intervals outlined in the Periodic Maintenance
Chart beginning on page 67. Maintain the coolant level between the minimum and maximum
marks on the bottle (when the fluid is cool).
1. Position the vehicle on a level
Maximum
surface.
NLY
TO
Level
N
A
OL
2. Place the transmission in PARK.
CO
(Cold)
3. Remove the hood. See page 30.
4. View the coolant level in the
Minimum
overflow bottle.
Level
5. If the coolant level is below the
safe operating range, use a funnel
to add coolant through the filler
opening. Reinstall the cap.
LD
AX
M
Tip: If coolant must be added often, or if
the overflow bottle runs completely
dry, there may be a leak in the
system. Your POLARIS dealer can
inspect the cooling system.
CO
IN
M
Radiator
Cap
Radiator Coolant Level
1. Remove the hood. See page 30.
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. Your POLARIS dealer can provide the correct
replacement part.
77
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. As the
owner, you have the following responsibilities for your own safety and the safety of others:
• Always follow all recommended maintenance procedures. Always look for and remove debris inside
and around the clutch and vent system when replacing the belt.
• 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.
Belt Replacement/Debris Removal
If a belt fails, always clean any debris from the duct and from the clutch and engine
compartments when replacing the belt.
WARNING! Failure to remove ALL debris when replacing the belt could result in vehicle damage, loss
of control and severe injury or death.
1. Position the vehicle on a level surface. Block the
wheels to prevent vehicle movement. Place the
transmission in neutral.
2. Lift the cargo box.
3. Remove the clutch cover screws using an 8mm
socket with ratcheting wrench and extension.
4. Pull the bottom of the cover outward and over
the suspension to remove it.
Step 3
Step 4
78
MAINTENANCE
POLARIS Variable Transmission (PVT) System
Belt Replacement/Debris Removal
5. Make sure the cover gasket does not fall out of the groove when removing the cover.
6. Squeeze the belt together so that it submarines further into the driven clutch, creating
slack in the belt between the clutches.
7. Remove the belt by using the slack to pull part of the belt off the driven clutch.
Step 5
Step 6
Step 7
8. Rotate the driven clutch by hand until the belt is completely off.
Step 8
79
MAINTENANCE
POLARIS Variable Transmission (PVT) System
Belt Replacement/Debris Removal
9. Slide the front of the belt out from
between the drive clutch and inner clutch
cover to completely remove it.
10. Remove all debris wrapped in and
around the PVT system.
11. Remove all debris from the entire clutch
air duct passage.
12. Check for signs of damage to seals on the
transmission and engine. If any seals
appear to be damaged, your vehicle
requires prompt service. Your POLARIS
dealer can assist.
Step 9
Tip: 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.).
13. To install a belt, place one end of the belt
over the driving clutch. Route the belt
over the top of the driven clutch and
down into the groove of the clutch to
allow slack in the belt. Rotate the driven
clutch by hand until the belt falls into
place.
14. Reinstall the clutch cover in the reverse
order of removal, fitting the top of the
cover into place, then working the
bottom of the cover over the
suspension.
15. Install all clutch cover screws. Torque
to 4-5 ft. lbs. (5.5-6.5 Nm).
Remove ALL Debris
Step 13
80
MAINTENANCE
POLARIS Variable Transmission (PVT) System
PVT Drying
There may be some instances when water is accidently ingested into the PVT system. Use
the following instructions to dry it out before operating.
1. Position the vehicle on a level surface. Place the transmission in PARK. Stop the engine.
2. Remove the clutch cover drain plug. Allow the
water to drain completely. Reinstall the drain plug.
3. Start the engine.
4. Apply varying throttle for 10-15 seconds to expel
the moisture and air-dry the belt and clutches. Do
not apply heavy throttle for more than 10 seconds.
5. Allow the engine RPM to settle to idle speed.
Apply the brakes. Shift the transmission to the
lowest available range.
Drain Plug
6. Test for belt slippage. If the belt slips, repeat the
process.
7. Your vehicle requires service as soon as possible. Your POLARIS dealer can assist.
Vehicle Immersion
NOTICE: If your vehicle becomes immersed, major engine damage can result if the machine is not
thoroughly inspected. Take the vehicle in for service before starting the engine. Your
POLARIS dealer can provide this service.
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 floorboard.
2. Dry any water present in the air box. Filter replacement is required if water is present.
3. Dry any water present in the intake manifold.
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 in for service as soon as possible, whether you succeed in starting it or
not. Your POLARIS dealer can provide the required service.
8. If water has been ingested into the PVT, follow the PVT Drying procedure.
81
MAINTENANCE
Filter Systems
Air Filter
Always change the air filter at the
intervals outlined in the Periodic
Maintenance Chart beginning on
Air Box Latches
page 67. Service the air filter more
frequently if the vehicle is operated
Air
in wet conditions or at high throttle
Filter
for extended periods.
1. Lift the cargo box to access the
air box.
2. Release the five (5) air box
Right Side
cover latches and lower the
Left Side View
View
bottom to expose the air filter.
3. Remove the air filter.
4. Inspect the air box for oil or water deposits. Wipe away any deposits with a clean cloth.
5. Install a new filter if needed. Do not attempt to clean the air filter.
Intake Screens
An engine intake screen is located on the
driver’s side of the vehicle. A clutch
intake screen is located on the passenger
side of the vehicle.
Inspect the screens before each use of the
vehicle. Remove all dirt and debris from
the screens and clean them frequently
with warm soapy water.
82
Intake Screens
(both sides)
MAINTENANCE
Spark Arrester
WARNING
Failure to heed the following warnings while servicing the spark arrester could result in serious injury or
death.
• Do not perform clean-out immediately after the engine has been run, as the exhaust system
becomes very hot. Serious burns could result from contact with the exhaust components. Allow
components to cool sufficiently before proceeding.
• Wear eye protection and gloves.
• 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 operate without the spark arrester.
Periodically clean the spark arrester to remove accumulated carbon.
1. Place the transmission in PARK.
2. Remove the retaining screw and remove the
Retaining
arrester from the end of the muffler.
Screw
3. Use a non-synthetic brush to clean the
arrester screen. A synthetic brush may melt
if components are warm. If necessary, blow
Arrester
debris from the screen with compressed air.
4. Inspect the screen for wear and damage.
Replace a worn or damaged screen.
5. Reinstall the arrester.
6. Torque the bolts to 5-7 ft-lbs (7-9 Nm).
Screen
Muffler
83
MAINTENANCE
Brakes
The front and rear brakes are hydraulic disc type brakes activated by the brake pedal. See
page 28.
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.
1. Position the vehicle on a level surface.
Maximum
Minimum
2. Place the transmission in PARK.
3. View the brake fluid level at the reservoir in the driver’s
side wheel well.
4. The level should be between the upper (MAX) and
lower (MIN) level lines.
5. If the fluid level is lower than the upper level line, add
brake fluid to the upper (MAX) line.
6. Apply the brake forcefully for a few seconds and check
for fluid leakage around the fittings.
84
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. Check brake discs for signs of cracks, excessive
corrosion, warping or other damage. Clean any grease
using an approved brake cleaner or alcohol.
WARNING! Do not apply WD-40 or any petroleum product to
brake discs. These types of products are flammable and may also
reduce the friction between the brake pad and caliper.
0.030” (0.762 mm)
5. Inspect the brake disc spline and pad wear surface for excessive wear. Change pads when
worn to 0.030” (0.762 mm).
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 67.
1. Position the vehicle on a level surface.
2. Place the transmission in PARK.
3. Lightly turn the steering wheel left and right. 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.
85
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 positions.
2. Reposition the shocks to the outside mounting holes.
3. Reinstall the shock mounting bolts. Torque to 40 ft-lbs (54.2 Nm).
Outside Mounting Position
Inside Mounting
Position
Rear Suspension Shown
Adjustment is similar for Front Suspension
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.
86
Cam
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 POLARIS-approved size and type of tires for this vehicle 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
(Aluminum Wheels)
Front and Rear
120 ft-lbs (163 Nm)
Lug Nut (Tapered)
Front and Rear
60 ft-lbs (81 Nm)
Spindle Nut
Front
75 ft-lbs (102 Nm)
Hub Retaining Nuts
Rear
110 ft-lbs (150 Nm)
87
MAINTENANCE
Tires
Wheel Removal
1.
2.
3.
4.
5.
Position the vehicle on a level surface.
Place the transmission in PARK. Stop the engine.
Loosen the wheel nuts slightly.
Elevate the side of the vehicle by placing a suitable stand under the frame.
Remove the wheel nuts and washers. Remove the wheel.
Wheel Installation
1. Place the transmission in PARK.
2. 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. Your
POLARIS dealer can assist.
3. Attach the wheel nuts and washers and
finger tighten.
4. Carefully lower the vehicle to the ground.
5. Torque the wheel nuts to specification. See page 87.
Power Steering Unit
If your model is equipped with power steering,
frequently clean the areas around and on the power
steering unit to allow proper cooling. Clean these
areas thoroughly.
88
Clean Often
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. Do not operate this vehicle at night or in low light conditions until the headlight is
replaced. 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
Access a headlamp wiring harness through the front
wheel well.
CAUTION! Hot components can cause burns to skin.
Allow lamps to cool before servicing.
1. Unplug the headlamp from the wiring harness.
Be sure to pull on the connector, not on the
wiring.
2. Turn the lamp counter-clockwise to remove it.
3. Install the new lamp.
Connector
Tip: Make sure the tab on the lamp locates properly in the
housing.
4. Reinstall the harness assembly into the headlight
assembly.
Brake Lights
When the brake pedal is depressed, the 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 10 mm (0.4 in.) of
pedal travel.
89
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. Place the transmission in PARK.
3. Measure the distance from the floor to the center of the headlight and make a mark on
the wall at the same height.
4. Apply the brakes. Start the engine. Turn on the headlights.
5. 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.
6. If a headlight needs adjustment, locate the adjustment screw on the side of the headlight.
7. Loosen the screw. Adjust the headlight, then tighten the screw.
8. Repeat steps 5-7 until the lamp is properly adjusted.
90
MAINTENANCE
Fuses
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. Raise the passenger seat to access the fuses. Spare fuses are provided
in the fuse box. The power steering fuse (if equipped) is located on the power steering wiring
harness near the fuse box.
If you suspect that a fuse or relay may not be working properly, please see your POLARIS
dealer.
Fuse
Feature Supported
10A
Brake Lights
10A
Fuel Pump
10A
Drive System
20A
Accessories, 12V Power Receptacle
20A
Engine Control Module
20A
Lights
30A
Power Steering (if equipped)
Power Steering Fuse
(if equipped)
91
MAINTENANCE
Battery
Your vehicle has a sealed battery, which requires little maintenance. 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.
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.
2.
3.
4.
Remove the storage bin under the passenger seat to access the battery.
Disconnect the black (-) battery cable first. Disconnect the red (+) battery cable last.
Remove the battery hold-down strap.
Lift the battery out of the vehicle.
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 93 before installing the battery.
1. Ensure that the battery is fully charged.
2. Place the fully charged battery in the battery holder. Make sure the positive terminal is
toward the driver’s side of the vehicle.
3. Coat the terminals with dielectric grease or petroleum jelly.
4. Connect and tighten the red (+) cable first. Connect and tighten the black (-) cable last.
5. Install the hold-down strap.
6. Reinstall the storage bin and seat.
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 93.
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.
92
MAINTENANCE
Battery
Battery Charging
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 below for
recharging.
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
Needs charge with desulfating charger
3-6 hours
5-11 hours
At least 13 hours,
verify state of charge
At least 20 hours
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.
• 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.
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.
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.
• 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.
94
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 or equivalent
fuel treatments or stabilizers. 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 71.
Air Filter / Air Box
1. Replace the air filter. See page 82.
2. Clean the air box.
95
MAINTENANCE
Cleaning and Storage
Storage Tips
Inspect and Lubricate
Inspect all cables and lubricate all areas of the vehicle as recommended in the Periodic
Maintenance Chart beginning on page 67.
Battery Maintenance
See page 92 for storage and charging procedures.
Fluid Levels
Inspect the fluid levels. Add or change fluids as recommended in the Periodic Maintenance
Chart beginning on page 67.
• Front gearcase fluid
• 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 or other equivalent fuel treatment.
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 premeasured 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 75.
4. 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.
5. Apply dielectric grease to the inside of each spark plug cap and reinstall the caps onto
the plugs.
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.
96
MAINTENANCE
Removal from Storage
1.
2.
3.
4.
Charge the battery if necessary. Install it in the vehicle.
Make sure the spark plug is tight.
Fill the fuel tank with fuel.
Check all the points listed in the Daily Pre-Ride Inspection section on page 42. Tightness
of the bolts, nuts and other fasteners should be checked by an authorized POLARIS
dealer or other qualified service facility.
5. Lubricate at the intervals outlined in the Periodic Maintenance Chart beginning on page
67.
Transporting the RANGER
Follow these procedures when transporting the vehicle.
1. Place the transmission in PARK.
2. Stop the engine.
3. Slowly release the brake pedal and make sure the transmission is in PARK before exiting
the vehicle.
4. Secure the fuel cap, hood, doors (if equipped) and cargo box. Ensure that the seats are
attached correctly and are not loose.
WARNING! Cargo and other loose vehicle parts may fly off while transporting this vehicle. Secure or
remove all cargo, and inspect the unit for loose parts prior to transport.
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.
97
SPECIFICATIONS
RANGER XP 900
Maximum Weight Capacity
(including operator, passenger,
cargo, non-factory installed
accessories)
Dry Weight
Test GVW - Rollover Protection
System (ROPS)
Fuel Capacity
Engine Oil Capacity
Coolant Capacity
Towing Capacity
Hitch Tongue Capacity
Max. Cargo Box Load*
Overall Length
Overall Width
Overall Height
Wheelbase
Cargo Box Dimensions (Inside)
Ground Clearance
Min. Turning Radius
Engine
Displacement
Bore x Stroke
Alternator Output
Compression Ratio
Starting System
Fuel System
Ignition System
Spark Plug / Gap
Front Suspension
Rear Suspension
Lubrication System
98
1500 lbs. (681 kg) (4X4)
1100 lbs. (499 kg) (4X4 sold in California)
1275 lbs. (578 kg) (4X4 Hunter/NorthStar/Trail)
875 lbs. (397 kg) (4X4 Hunter/NorthStar/Trail sold in California)
1360 lbs. (617 kg)
1640 lbs. (744 kg) (Hunter)
1591 lbs. (722 kg) (NorthStar)
1530 lbs. (694 kg) (Trail)
3030 lbs. (1374 kg) per OSHA 29 CFR 1928.53
10 gal. (37.8 l)
2.5 qts. (2.4 l)
5 qts. (4.75 l)
2000 lbs. (907 kg)
150 lbs. (68 kg)
1000 lbs. (454 kg)
600 lbs. (272 kg) (Models sold in California)
116 in. (295 cm)
120 in. (305 cm) (Hunter)
60 in. (152.4 cm) (at box)
58 in. (147.3 cm) (at tires)
63.5 in. (161.3 cm) (Hunter, at rock guards/nerf bars)
63.5 in. (161.3 cm) (NorthStar, at doors)
63.5 in. (161.3 cm) (Trail)
76 in. (193 cm)
77 in. (195.6 cm) (Hunter/NorthStar/Trail)
81 in. (205.7 cm)
36.5 x 54 x 11.5 in. (93 x 137 x 29 cm)
12 in. (30.5 cm)
9.5 in. (24 cm) (Hunter, at rock guards/nerf bars)
161 in. (409 cm)
4-Stroke DOHC Twin Cylinder
875 cc
93mm x 64.4mm
660 W @ 3000 RPM
10.5:1
Electric
Electronic fuel injection
Electronic
MR7F / 0.7-0.8 mm
Dual A-arm w/10 in. (25.4 cm) of travel
Independent w/10 in. (25.4 cm) of travel
Wet Sump
SPECIFICATIONS
RANGER XP 900
Driving System Type
Shift Type
Transmission Gear Ratio - High
Transmission Gear Ratio - Low
Transmission Gear Ratio - Reverse
Front Drive Ratio
Tire Size - Front
Tire Size - Rear
Tire Pressure - Front
Tire Pressure - Rear
Brakes, Front/Rear
Hood Headlight
Taillights
Brake Light
PVT, 4-wheel independent shaft, lockable differential
Single Lever (H/L/N/R/P)
Front 3.48:1 / Rear 10.4:1
Front 8.56:1 / Rear 25.59:1
Front 7.67:1 / Rear 22.92:1
3.818:1 (Non-EPS)
3.077:1 (EPS)
25 x 10 - 12 (26 x 9 - 12 for select models)
25 x 11 - 12 (26 x 11 - 12 for select models)
10 psi (69 kPa)
12 psi (83 kPa) (Hunter/NorthStar/Trail)
12 psi (83 kPa)
Foot Activated, 4 wheel hydraulic disc
2 single beam, 50W, quartz/halogen
10 L.E.D. (.28W)
10 L.E.D. (3.1W)
Clutching
See your POLARIS dealer for clutching specifications.
99
SPECIFICATIONS
RANGER CREW 900
Maximum Weight Capacity
Dry Weight
Test GVW - Rollover Protection
System (ROPS)
Fuel Capacity
Engine Oil Capacity
Coolant Capacity
Towing Capacity
Hitch Tongue Capacity
Max. Cargo Box Load*
Overall Length
Overall Width (box)
Overall Width (tires)
Overall Height
Wheelbase
Cargo Box Dimensions (Inside)
Ground Clearance
Min. Turning Radius
Engine
Displacement
Bore x Stroke
Alternator Output
Compression Ratio
Starting System
Fuel System
Ignition System
Spark Plug / Gap
Front Suspension
Rear Suspension
Lubrication System
100
1750 lbs. (795 kg) (including operator, passengers, cargo, accessories)
1350 lbs. (612 kg) (Models sold in California)
1570 lbs. (712 kg)
3600 lbs. (1633 kg) per OSHA 29 CFR 1928.53
10 gal. (37.8 l)
2.5 qts. (2.4 l)
5 qts. (4.75 l)
2000 lbs. (907 kg)
150 lbs. (68 kg)
1000 lbs. (454 kg)
600 lbs. (272 kg) (Models sold in California)
148 in. (376 cm)
60 in. (152.4 cm)
58 in. (147.3 cm)
76 in. (193 cm)
113 in. (287 cm)
36.5 x 54 x 11.5 in. (93 x 137 x 29 cm)
12 in. (30.5 cm)
214 in. (543.5 cm)
4-Stroke DOHC Twin Cylinder
875 cc
93mm x 64.4mm
660 W @ 3000 RPM
10.5:1
Electric
Electronic fuel injection
Electronic
XG4YCX / 0.7-0.8 mm
Dual A-arm w/10 in. (25.4 cm) of travel
Independent w/10 in. (25.4 cm) of travel
Wet Sump
SPECIFICATIONS
RANGER CREW 900
Driving System Type
Shift Type
Transmission Gear Ratio - High
Transmission Gear Ratio - Low
Transmission Gear Ratio - Reverse
Front Drive Ratio
Tire Size - Front
Tire Size - Rear
Tire Pressure - Front
Tire Pressure - Rear
Brakes, Front/Rear
Hood Headlight
Taillights
Brake Light
PVT, 4-wheel independent shaft, lockable differential
Single Lever (H/L/N/R/P)
Front 4.03:1 / Rear 12.05:1
Front 8.56:1 / Rear 25.59:1
Front 7.67:1 / Rear 22.92:1
3.818:1 (Non-EPS)
3.077:1 (EPS)
26 x 9 - 12
26 x 11 - 12
14 psi (96 kPa)
16 psi (110 kPa)
Foot Activated, 4 wheel hydraulic disc
2 single beam, 50W, quartz/halogen
10 L.E.D. (.28W)
10 L.E.D. (3.1W)
Clutching
See your POLARIS dealer for clutching specifications.
101
POLARIS PRODUCTS
Part Number
Description
Engine Lubricant
2870791
Fogging Oil (12 oz./355 ml Aerosol)
2876244
PS-4 Full Synthetic 5W-50 4-Cycle Oil (qt./.95 l)
2876245
PS-4 Full Synthetic 5W-50 4-Cycle Oil (gal./3.8 l)
2878920
PS-4 Extreme Duty Synthetic 10W-50 4-Cycle Oil (qt./.95 l)
2878919
PS-4 Extreme Duty Synthetic 10W-50 4-Cycle Oil (gal./3.8 l)
2878068
AGL Full Synthetic Gearcase Lubricant & Transmission Fluid (qt./.95 l)
Gearcase / Transmission Lubricants
2878069
AGL Full Synthetic Gearcase Lubricant & Transmission Fluid (gal./3.8 l)
2877922
Demand Drive Fluid (qt./.95 l)
2877923
Demand Drive Fluid (gal./3.8 l)
2870465
Pump for Gallon (3.8 l) Jug
2880514
Antifreeze 50/50 Premix (qt./.95 l)
2880513
Antifreeze 50/50 Premix (gal./3.8 l)
Coolant
Grease / Specialized Lubricants
2871312
Grease Gun Kit, All Season Grease
2871322
All Season Grease (3 oz./89 ml cartridge)
2871423
All Season Grease (14 oz./414 ml cartridge)
2876160
ATV Angle Drive Fluid (qt./.95 l)
2872276
ATV Angle Drive Fluid (2.5 gal./9.5 l)
2871460
Premium Starter Grease
2871515
U-Joint Grease (3 oz./89 ml cartridge)
2871551
U-Joint Grease (14 oz./414 ml cartridge)
2871329
Dielectric Grease (Nyogel™)
Additives / Miscellaneous
2871326
Carbon Clean
2870652
Fuel Stabilizer
2872189
DOT 4 Brake Fluid
2871956
Loctite™ 565 Thread Sealant
2859044
POLARIS Battery Tender™ Charger
102
TROUBLESHOOTING
Drive Belt Wear/Burn
Possible Cause
Solution
Driving onto a pickup or tall
trailer in high range
Use low range during loading.
Starting out going up a steep
incline
Use low range. See warnings on page 47.
Driving at low RPM or ground
speed (3-7 MPH)
Drive at a higher speed or use low range more frequently.
Insufficient warm-up at low
ambient temperatures
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 engagement
Use the throttle quickly and effectively.
Towing/pushing at low RPM/low
ground speed
Use low range only.
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
rollover.
Climbing over large objects from
a stopped position
Shift the transmission to low range and carefully use fast, brief, aggressive
throttle application to engage clutch.
WARNING: Excessive throttle may cause loss of control and vehicle
rollover.
Belt slippage from water or snow
ingestion into the PVT system
Dry out the PVT. See page 81. Inspect clutch seals for damage if repeated
leaking occurs.
Clutch malfunction
Your POLARIS dealer can assist.
Poor engine performance
Check for fouled plugs or foreign material in gas tank or fuel lines. Your
POLARIS dealer can assist.
Slippage from failure to warm up
belt
Always warm up the belt by operating below 30 MPH for 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 41 and 78.
103
TROUBLESHOOTING
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
Your POLARIS dealer can assist.
Recharge the battery to 12.8 VDC
Your POLARIS dealer can assist.
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
Mechanical failure
Loose ignition connections
Water present in fuel
Solution
Inspect, clean and/or replace spark plugs
Set gap to specs or replace plugs
Replace with fresh recommended fuel
Your POLARIS dealer can assist.
Your POLARIS dealer can assist.
Check all connections and tighten
Replace with fresh recommended fuel
Engine Pings or Knocks
Possible Cause
Solution
Poor quality or low octane fuel
Incorrect spark plug gap or heat range
Replace with recommended fuel
Set gap to specs or replace plugs
104
TROUBLESHOOTING
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
Incorrect fuel
Clogged air filter
Clogged intake screen
Throttle release switch malfunction
Other mechanical failure
Solution
Inspect, clean and/or replace spark plugs
Your POLARIS dealer can assist.
Set gap to specs or replace plugs
Check all connections and tighten
Replace with new fuel
Recharge battery to 12.8 VDC
Replace with recommended fuel
Inspect and clean or replace
Inspect and clean (with soapy water) or replace
Your POLARIS dealer can assist.
Your POLARIS dealer can assist.
Engine Stops or Loses Power
Possible Cause
Out of fuel
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
Clogged intake screen
Throttle release switch malfunction
Other mechanical failure
Overheated engine
Solution
Refuel
Replace with new fuel
Inspect, clean and/or replace spark plug
Your POLARIS dealer can assist.
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
Inspect and clean (with soapy water) or replace
Your POLARIS dealer can assist.
Your POLARIS dealer can assist.
Clean radiator screen and core, clean engine exterior.
Your POLARIS dealer can assist.
105
WARRANTY
Limited Warranty
POLARIS Industries Inc., 2100 Highway 55, Medina, MN 55340 (POLARIS) gives a SIX MONTH LIMITED
WARRANTY on all components of your POLARIS vehicle against defects in material or workmanship.
POLARIS further warrants that the spark arrester in this product 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.
This warranty covers parts and labor charges for repair or replacement of defective parts and begins on the date of
purchase by the original retail purchaser. This warranty is transferable to another owner during the warranty
period through a POLARIS dealer, but any such transfer will not extend the original term of the warranty. The
duration of this warranty may vary by international region based upon local laws and regulations.
Registration
At the time of sale, the Warranty Registration Form must be completed by your dealer and submitted to
POLARIS within ten days of purchase. 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 your proof of warranty coverage. 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
This POLARIS limited warranty excludes any failures that are not caused by a defect in material or
workmanship. THIS WARRANTY DOES NOT COVER CLAIMS OF DEFECTIVE DESIGN. This warranty
also does not cover acts of God, accidental damage, normal wear and tear, abuse or improper handling. This
warranty also does not cover any vehicle, component, or part that has been altered structurally, modified,
neglected, improperly maintained or used for racing, competition or purposes other than for which it was
designed.
This warranty excludes damages or 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; snow, water, dirt or other
foreign substance ingestion/contamination; improper maintenance; modified components; use of aftermarket or
unapproved components, accessories, or attachments; unauthorized repairs; or repairs made after the warranty
period expires or by an unauthorized repair center.
106
WARRANTY
Warranty Coverage And Exclusions:
Limitations Of Warranties And Remedies
This warranty excludes damages or failures caused by abuse, accident, fire, or any other cause other than a defect
in materials or workmanship and provides no coverage for consumable components, general wear items, or any
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
Filters
Lubricants
Bushings
•
•
•
•
•
•
•
•
•
•
•
Finished and unfinished surfaces
Carburetor/Throttle body components
Engine components
Drive belts
Hydraulic components and fluids
Circuit breakers/Fuses
Electronic components
Spark plugs
Sealants
Coolants
Bearings
Lubricants and Fluids
1. Mixing oil brands or using non-recommended oil may cause engine damage. We recommend the use of
POLARIS engine oil.
2. Damage or failure resulting from the use of non-recommended lubricants or fluids is not covered by this
warranty.
This warranty provides no coverage for personal loss or expense, including mileage, transportation costs, hotels,
meals, shipping or handling fees, product pick-up or delivery, replacement rentals, loss of product use, loss of
profits, or loss of vacation or personal time.
THE EXCLUSIVE REMEDY FOR BREACH OF THIS WARRANTY SHALL BE, AT POLARIS' OPTION,
REPAIR OR REPLACEMENT OF ANY DEFECTIVE MATERIALS, 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. THIS EXCLUSION OF CONSEQUENTAL,
INCIDENTAL, AND SPECIAL DAMAGES IS INDEPENDENT FROM AND SHALL SURVIVE ANY
FINDING THAT THE EXCLUSIVE REMEDY FAILED OF ITS ESSENTIAL PURPOSE.
THE IMPLIED WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE IS EXCLUDED FROM THIS
LIMITED WARRANTY. ALL OTHER IMPLIED WARRANTIES (INCLUDING BUT NOT LIMITED TO
THE IMPLIED WARRANTY OF MERCHANTABILITY) ARE LIMITED IN DURATION TO THE ABOVE
SIX MONTH WARRANTY PERIOD. POLARIS DISCLAIMS ALL EXPRESS WARRANTIES NOT STATED
IN THIS WARRANTY. SOME STATES DO NOT PERMIT THE EXCLUSION OR LIMITATION OF
INCIDENTAL OR CONSEQUENTIAL DAMAGES OR ALLOW LIMITATIONS ON THE DURATION OF
IMPLIED WARRANTIES, SO THE ABOVE LIMITATIONS MAY NOT APPLY TO YOU IF
INCONSISTENT WITH CONTROLLING STATE LAW.
107
WARRANTY
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.
In the Country where your product 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 product was purchased, Warranty and Service Bulletin repairs may be
requested from any authorized POLARIS dealer that sells the same line as your product.
Outside the Country where your product was purchased:
If you are traveling temporarily outside the country where your product was purchased, you should take your
product 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. Product importation rules vary considerably from country to country.
You may be required to present documentation of your move to POLARIS in order to continue your warranty
coverage. You may also be required to obtain documentation from POLARIS in order to register your product in
your new country. You should warranty register your product at a local POLARIS dealer in your new country
immediately after you move to continue your warranty coverage and to ensure that you receive information and
notices regarding your vehicle.
If you purchase from a private party:
If you purchase a POLARIS product from a private party, to be kept and used outside of the country in which the
product was originally purchased, all warranty coverage will be denied. You must nonetheless register your
product under your name and address with a local POLARIS dealer in your country to ensure that you receive
safety information and notices regarding your product.
Exported Products
EXCEPT WHERE SPECIFICALLY REQUIRED BY LAW, THERE IS NO WARRANTY OR SERVICE
BULLETIN COVERAGE ON THIS PRODUCT IF IT IS SOLD OUTSIDE THE COUNTRY OF THE
SELLING DEALER'S AUTHORIZED LOCATION. This policy does not apply to products that have received
authorization for export from POLARIS. Dealers may not give authorization for export. You should consult an
authorized dealer to determine this product's warranty or service coverage if you have any questions. This policy
does not apply to products 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 Bulletins.
108
WARRANTY
Notice
If your product is registered outside of the country where it was purchased and you have not followed the
procedure set above, your product will no longer be eligible for warranty or service bulletin coverage of any kind,
other than safety bulletins. Products registered to government officials or military personnel on assignment
outside of the country where the product was purchased will continue to be covered by the Limited Warranty.
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 or
in different countries. If any of the above terms are void because of federal, state, local law, all other warranty
terms will remain in effect.
For questions call POLARIS Customer Assistance:
United States & Canada: 1-800-POLARIS (1-800-765-2747)
French: 1-800-268-6334
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 off road vehicles 100cc or greater emissions-certified vehicles starts on the date of
purchase by original retail purchaser 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. The
warranty period for ATVs less than 100cc emissions-certified vehicles starts on the date of purchase by original
retail purchaser and continues for a period of 250 hours of engine operation, 2500 kilometers (1550 miles) of
vehicle travel, or 30 calendar months from the date of purchase, whichever comes first. This EPA emissions
warranty period is extended for at least as long as the standard factory warranty that Polaris provides on the
vehicle as a whole. The EPA emissions warranty period does not further extend if you purchase additional
warranty coverage in the form of a service contract or other paid warranty extension, but emission-related parts
may be covered subject to the terms of any such paid service contract or paid warranty extension.
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
109
WARRANTY
U.S.A. EPA Emissions Limited Warranty
The following parts are considered emission-related components for evaporative emissions:
•
•
•
•
•
•
•
•
•
Fuel Tank
Fuel Cap
Fuel Line
Fuel Line Fittings
Clamps*
Pressure Relief Valves*
Control Valves*
Control Solenoids*
Electronic Controls*
•
•
•
•
•
•
•
•
•
Vacuum Control Diaphragms*
Control Cables*
Control Linkages*
Purge Valves
Vapor Hoses
Liquid/Vapor Separator
Carbon Canister
Canister Mounting Brackets
Carburetor Purge Port Connector
*As related to the evaporative emission control system.
Emission-related components also include any other part whose only purpose is to reduce emissions or whose
failure will increase emissions without significantly degrading engine/equipment performance. 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. THIS EXCLUSION OF CONSEQUENTIAL, INCIDENTAL, AND SPECIAL DAMAGES
IS INDEPENDENT FROM AND SHALL SURVIVE ANY FINDING THAT THE EXCLUSIVE REMEDY
FAILED OF ITS ESSENTIAL PURPOSE.
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. An authorized POLARIS dealer can perform any service that may be necessary for your vehicle.
POLARIS also recommends POLARIS parts, however equivalent parts may be used for such service. 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.
California Residents
Certain POLARIS Off-Road Vehicles are available in 49-state and 50-state versions. Only the 50-state models are
certified for sale in California. The 50-state models available for sale in California are identified by the letter “B”
in the ninth position of the model number (e.g., R16RTE87B). The POLARIS 50-state models are designed and
built with features such as a reduced cargo box capacity. Any modifications to these features may be a violation
of the applicable California regulations and may void this limited emissions warranty offered by the
manufacturer.
If you have any questions regarding your warranty rights and responsibilities, please contact POLARIS Customer
Assistance:
United States & Canada: 1-800-POLARIS (1-800-765-2747)
French: 1-800-268-6334
110
MAINTENANCE LOG
Use the following chart to record periodic maintenance.
DATE
MILES (KM)
OR HOURS
TECHNICIAN
SERVICE PERFORMED / COMMENTS
111
MAINTENANCE LOG
DATE
112
MILES (KM)
OR HOURS
TECHNICIAN
SERVICE PERFORMED / COMMENTS
INDEX
A
D
Air Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Air Filter Cleaning . . . . . . . . . . . . . . . . . . . . . . . . 82
All Wheel Drive
Disengaging AWD. . . . . . . . . . . . . . . . 54
Engaging AWD . . . . . . . . . . . . . . . . . . 54
Locking the Differential. . . . . . . . . . . . 55
Unlocking the Differential . . . . . . . . . . 55
All Wheel Drive Switch . . . . . . . . . . . . . . . . . . . . 24
All Wheel Drive/Active Descent Control System 56
All Wheel Drive/Rear Differential System. . . 54-55
Arrester, Spark, Warning . . . . . . . . . . . . . . . . . . . 83
AWD Drive Mode Switch . . . . . . . . . . . . . . . 24, 56
AWD Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Axle Nut Inspection . . . . . . . . . . . . . . . . . . . . . . . 87
Axle Nut Torque . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Differential, Unlocking. . . . . . . . . . . . . . . . . . . . . 55
Differential Lock Switch . . . . . . . . . . . . . . . . . . . 24
Differential Locking . . . . . . . . . . . . . . . . . . . . . . . 55
Disengaging AWD . . . . . . . . . . . . . . . . . . . . . . . . 54
Display Units, Standard/Metric . . . . . . . . . . . . . . 38
Drive Belt Wear . . . . . . . . . . . . . . . . . . . . . . . . . 103
Drive Mode Operation, AWD . . . . . . . . . . . . . . . 56
Drivetrain Break-In. . . . . . . . . . . . . . . . . . . . . . . . 41
Driving Downhill . . . . . . . . . . . . . . . . . . . . . . . . . 47
Driving in Reverse . . . . . . . . . . . . . . . . . . . . . . . . 49
Driving on a Sidehill. . . . . . . . . . . . . . . . . . . . . . . 47
Driving on Slippery Surfaces . . . . . . . . . . . . . . . . 46
Driving Over Obstacles . . . . . . . . . . . . . . . . . . . . 45
Driving Procedure. . . . . . . . . . . . . . . . . . . . . . . . . 44
Driving Through Water . . . . . . . . . . . . . . . . . . . . 48
Driving Uphill. . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Driving with a Passenger . . . . . . . . . . . . . . . . . . . 45
Driving, After Driving in Water . . . . . . . . . . . . . . 81
Drying the Transmission. . . . . . . . . . . . . . . . . . . . 81
Dumping the Cargo Box . . . . . . . . . . . . . . . . . . . . 53
B
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92-93
Charging. . . . . . . . . . . . . . . . . . . . . . . . 93
Installation . . . . . . . . . . . . . . . . . . . . . . 92
Removal . . . . . . . . . . . . . . . . . . . . . . . . 92
Storage . . . . . . . . . . . . . . . . . . . . . . . . . 92
Beam Adjustment, Headlight . . . . . . . . . . . . . . . . 90
Belt Burning . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Belt Life . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Belt Replacement . . . . . . . . . . . . . . . . . . . . . . 78-80
Belt Wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Boots . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Brake Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Brake Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Brake Light Inspection . . . . . . . . . . . . . . . . . . . . . 89
Brake Pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84-85
Braking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Break-In Period. . . . . . . . . . . . . . . . . . . . . . . . . . . 41
C
Cab Frame, ROPS. . . . . . . . . . . . . . . . . . . . . . . . . 30
Cab Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Cab Nets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Cargo. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Cargo Box, Dumping . . . . . . . . . . . . . . . . . . . . . . 53
Chart
Gearcase Specifications . . . . . . . . . . . . 73
Periodic Maintenance. . . . . . . . . . . 67-69
Check Engine Indicator . . . . . . . . . . . . . . . . . . . . 40
Cleaning and Storage . . . . . . . . . . . . . . . . . . . 94-96
Clothing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Clutching. . . . . . . . . . . . . . . . . . . . . . . . . . . . 99, 101
Component Locations . . . . . . . . . . . . . . . . . . . . . . 21
Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Coolant Level, Overflow Bottle (Coolant) . . . . . . 77
Coolant Level, Radiator . . . . . . . . . . . . . . . . . . . . 77
Coolant, Adding or Changing . . . . . . . . . . . . . . . . 76
Cooling Fan. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Cooling System. . . . . . . . . . . . . . . . . . . . . . . . 76-77
Crankcase Emission Control System . . . . . . . . . . 66
E
Electromagnetic Interference . . . . . . . . . . . . . . . . 66
Electronic Power Steering . . . . . . . . . . . . . . . . . . 28
Emission Control, Crankcase . . . . . . . . . . . . . . . . 66
Emission Control, Exhaust . . . . . . . . . . . . . . . . . . 66
Emission Control, Noise. . . . . . . . . . . . . . . . . . . . 66
Emissions Limited Warranty . . . . . . . . . . . 109-110
Engaging AWD . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Engine Break-In . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Engine Fogging. . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Engine Oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-72
Engine Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Engine Stopping . . . . . . . . . . . . . . . . . . . . . . . . . . 43
EPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Equipment Modifications . . . . . . . . . . . . . . . . . . . 15
Error Codes, Engine . . . . . . . . . . . . . . . . . . . . . . . 40
Exhaust Emission Control System . . . . . . . . . . . . 66
Exhaust System Warning . . . . . . . . . . . . . . . . . . . 83
Eye Protection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
F
Fan, Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Filter Cleaning, Air . . . . . . . . . . . . . . . . . . . . . . . .
Filter Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Filter, Air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fluid, Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fluid Change
Engine Oil . . . . . . . . . . . . . . . . . . . 71-72
Front Gearcase . . . . . . . . . . . . . . . . . . . 74
Main Gearcase . . . . . . . . . . . . . . . . . . . 73
Transmission . . . . . . . . . . . . . . . . . . . . 73
Fluid Level
Engine Oil . . . . . . . . . . . . . . . . . . . . . . 71
Front Gearcase . . . . . . . . . . . . . . . . . . . 74
Main Gearcase . . . . . . . . . . . . . . . . . . . 73
Transmission . . . . . . . . . . . . . . . . . . . . 73
76
82
82
82
84
113
INDEX
F
O
Fluid Levels During Storage . . . . . . . . . . . . . . . . 96
Fluid Part Numbers . . . . . . . . . . . . . . . . . . . . . . 102
Fogging the Engine . . . . . . . . . . . . . . . . . . . . . . . 96
Fouled Plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Front Gearcase . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Fuel Cap. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Fuel Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Fuel Stabilizer . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Fuel Tank Filler Cap . . . . . . . . . . . . . . . . . . . . . . 30
Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Obstacles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Oil
Engine . . . . . . . . . . . . . . . . . . . . . . . 70-72
Transmission. . . . . . . . . . . . . . . . . . . . 73
Oil and Filter Care During Storage . . . . . . . . . . . . 95
Oil Change
Engine . . . . . . . . . . . . . . . . . . . . . . . 71-72
Front Gearcase . . . . . . . . . . . . . . . . . . 74
Main Gearcase . . . . . . . . . . . . . . . . . . 73
Transmission. . . . . . . . . . . . . . . . . . . . 73
Oil Level
Engine . . . . . . . . . . . . . . . . . . . . . . . . . 71
Front Gearcase . . . . . . . . . . . . . . . . . . 74
Main Gearcase . . . . . . . . . . . . . . . . . . 73
Transmission. . . . . . . . . . . . . . . . . . . . 73
Oil Recommendation, Engine . . . . . . . . . . . . . . . . 70
Operation on Public Lands . . . . . . . . . . . . . . . . . . 66
Operator Safety . . . . . . . . . . . . . . . . . . . . . . . . 13-20
G
Gap, Spark Plug . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Gasoline Handling . . . . . . . . . . . . . . . . . . . . . . . . 18
Gear Selector . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Gearcase Specification Chart. . . . . . . . . . . . . . . . 73
Gearcase, Front . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Gearcases . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73-74
Gears, Shifting . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Gloves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
H
Hauling Cargo . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Headlight Beam Adjustment . . . . . . . . . . . . . . . . 90
Headlight Lamp Replacement . . . . . . . . . . . . . . . 89
Helmet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Hitch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Hitch Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Hood Latches . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
I
Ignition Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Indicator Lamps . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Inspection, Pre-Ride . . . . . . . . . . . . . . . . . . . . . . 42
Instrument Cluster . . . . . . . . . . . . . . . . . . . . . . 35-40
Intake Screens . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Interference, Electromagnetic . . . . . . . . . . . . . . . 66
K
Key, Periodic Maintenance Chart . . . . . . . . . . . . 67
L
Lamp Replacement, Headlight . . . . . . . . . . . . . . 89
Light Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89-90
Load Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Lubrication Recommendations . . . . . . . . . . . . . . 70
M
Maintenance Log . . . . . . . . . . . . . . . . . . . . . . . . 111
Maintenance, Periodic . . . . . . . . . . . . . . . . . . . 67-69
Metric Display . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Mode Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Modifications to Vehicle . . . . . . . . . . . . . . . . . . . 15
N
Noise Emission Control System . . . . . . . . . . . . . 66
114
P
Parking on an Incline. . . . . . . . . . . . . . . . . . . . . . . 50
Parking the Vehicle . . . . . . . . . . . . . . . . . . . . . . . . 50
Part Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
Periodic Maintenance Chart . . . . . . . . . . . . . . 67-69
Plug Gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Plug Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Plugs, Fouled . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Plugs, Spark . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Polaris Products . . . . . . . . . . . . . . . . . . . . . . . . . . 102
Polishing the Vehicle. . . . . . . . . . . . . . . . . . . . . . . 94
Power Steering. . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Power Steering Unit (Cleaning) . . . . . . . . . . . . . . 88
Pre-Ride Inspection . . . . . . . . . . . . . . . . . . . . . . . . 42
Product Part Numbers . . . . . . . . . . . . . . . . . . . . . 102
Public Lands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
PVT Break-In . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
PVT Drying . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
PVT System. . . . . . . . . . . . . . . . . . . . . . . . . . . 78-81
PVT Warning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
PVT, Cleaning Debris . . . . . . . . . . . . . . . . . . . 78-80
R
Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Radiator Coolant Level . . . . . . . . . . . . . . . . . . . . . 77
Rear Suspension Adjustment. . . . . . . . . . . . . . . . . 86
Rear Window Panel (if equipped) . . . . . . . . . . . . . 34
Receiver Hitch . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Registration, Warranty . . . . . . . . . . . . . . . . . . . . 106
Removing the Vehicle from Storage . . . . . . . . . . . 97
Reverse Operation . . . . . . . . . . . . . . . . . . . . . . . . . 49
Rider Information Center . . . . . . . . . . . . . . . . 36-40
Riding Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9
Rollover Protective Structure . . . . . . . . . . . . . . . . 30
ROPS Cab Frame . . . . . . . . . . . . . . . . . . . . . . . . . 30
INDEX
S
T
Safety Labels. . . . . . . . . . . . . . . . . . . . . . . . . . 10-12
Safety Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Safety, Winch Maintenance . . . . . . . . . . . . . . . . . 65
Seat Belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Seat Heaters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Seat Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Severe Use Definition . . . . . . . . . . . . . . . . . . . . . . 67
Shifter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Shifting Gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Shock Loading the Winch. . . . . . . . . . . . . . . . . . . 64
Shock Spring Adjustment . . . . . . . . . . . . . . . . . . . 86
Signal Words. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Spark Arrester Warning . . . . . . . . . . . . . . . . . . . . 83
Spark Plug Gap . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Spark Plug Inspection . . . . . . . . . . . . . . . . . . . . . . 75
Spark Plug Recommendations . . . . . . . . . . . . . . . 75
Spark Plug Torque . . . . . . . . . . . . . . . . . . . . . . . . 75
Spark Plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Spark Plugs, Fouled . . . . . . . . . . . . . . . . . . . . . . . 75
Specifications . . . . . . . . . . . . . . . . . . . . . . . . 98-101
Specifications, Gearcase . . . . . . . . . . . . . . . . . . . . 73
Speed, Towing . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Speedometer . . . . . . . . . . . . . . . . . . . . . . . . . . 35-36
Spring, Shock, Adjustment . . . . . . . . . . . . . . . . . . 86
Stabilizing the Fuel . . . . . . . . . . . . . . . . . . . . . . . . 95
Starting the Engine . . . . . . . . . . . . . . . . . . . . . . . . 43
Steering Wheel Inspection . . . . . . . . . . . . . . . . . . 85
Steering Wheel, Adjustment . . . . . . . . . . . . . . . . . 28
Stopping the Engine . . . . . . . . . . . . . . . . . . . . . . . 43
Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94-96
Storage Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Storage Compartment, Under-Seat . . . . . . . . . . . . 29
Storage, Battery . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Storage, Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Storage, Fluid Levels . . . . . . . . . . . . . . . . . . . . . . 96
Storage, Oil and Filter. . . . . . . . . . . . . . . . . . . . . . 95
Storage, Removal . . . . . . . . . . . . . . . . . . . . . . . . . 97
Suspension Adjustment, Rear . . . . . . . . . . . . . . . . 86
Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-27
AWD Drive Mode Switch . . . . . . . 24, 56
AWD Switch . . . . . . . . . . . . . . . . . . . . 24
AWD Switches. . . . . . . . . . . . . . . . . . . 24
Cab Heater Switches . . . . . . . . . . . . . . 26
Differential Lock Switch . . . . . . . . . . . 24
Ignition Switch. . . . . . . . . . . . . . . . . . . 25
Light Switch. . . . . . . . . . . . . . . . . . . . . 24
Mode Button . . . . . . . . . . . . . . . . . . . . 35
Remote Winch Switch . . . . . . . . . . . . . 25
Seat Heater Switches . . . . . . . . . . . . . . 25
Windshield Washer Switch . . . . . . . . . 27
Windshield Wiper Switch . . . . . . . . . . 27
Tachometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Throttle Pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Tilt Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Tire Tread Depth. . . . . . . . . . . . . . . . . . . . . . . . . . 87
Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87-88
Torque, Axle Nuts . . . . . . . . . . . . . . . . . . . . . . . . 87
Torque, Spark Plug . . . . . . . . . . . . . . . . . . . . . . . . 75
Torque, Wheel Nut . . . . . . . . . . . . . . . . . . . . . . . . 87
Towing a RANGER . . . . . . . . . . . . . . . . . . . . . . . 52
Towing Loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Towing Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Trailer Hitch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Transmission. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Transmission Operation . . . . . . . . . . . . . . . . . 78-81
Transmission System . . . . . . . . . . . . . . . . . . . 78-81
Transmission Warning . . . . . . . . . . . . . . . . . . . . . 78
Transmission, Drying . . . . . . . . . . . . . . . . . . . . . . 81
Transporting the Vehicle . . . . . . . . . . . . . . . . . . . 97
Tread Depth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
TURF Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
U
Under-Seat Storage . . . . . . . . . . . . . . . . . . . . . . . . 29
V
Vehicle Identification Numbers . . . . . . . . . . . . . . . 6
Vehicle Immersion . . . . . . . . . . . . . . . . . . . . . . . . 81
Vehicle Transport . . . . . . . . . . . . . . . . . . . . . . . . . 97
W
Warning Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Washing the Vehicle. . . . . . . . . . . . . . . . . . . . . . . 94
Water, Immersion of Vehicle . . . . . . . . . . . . . . . . 81
Wheel Installation. . . . . . . . . . . . . . . . . . . . . . . . . 88
Wheel Nut Inspection . . . . . . . . . . . . . . . . . . . . . . 87
Wheel Nut Torque . . . . . . . . . . . . . . . . . . . . . . . . 87
Wheel Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Winch Cable Care. . . . . . . . . . . . . . . . . . . . . . . . . 63
Winch Maintenance and Service Safety . . . . . . . . 65
Winch Operation. . . . . . . . . . . . . . . . . . . . . . . 60-63
Winch Safety Precautions. . . . . . . . . . . . . . . . 58-59
Winch Shock Loading . . . . . . . . . . . . . . . . . . . . . 64
Winch Switch, Remote . . . . . . . . . . . . . . . . . . . . . 25
Windshield (if equipped) . . . . . . . . . . . . . . . . . . . 33
Windshield Wiper and Washer (if equipped) . . . . 27
115
PMS 419
WARNING
Improper vehicle use can result in SEVERE INJURY or DEATH
NEVER Operate:
• If you are under age 16 and without a valid driver’s license.
• Without first viewing safety video and taking a ROHVA training course at
www.rohva.org.
• On excessively steep hills.
• On public roads (unless designated for off-road use).
• With a passenger who is not seated in a passenger seat, or with passengers
under age 12 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 can cause severe injury or death.
• Secure cab nets or doors and keep hands and feet inside vehicle at all times.
• Wear a helmet, eye protection, gloves, long-sleeve shirt, long pants and
over-the-ankle boots.
• 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 passengers read and understand all safety labels.
ALL RIDERS MUST WEAR AN APPROVED HELMET AND PROTECTIVE GEAR.
ALL RIDERS MUST WEAR SEAT BELTS. NEVER USE ON PUBLIC ROADS.
NEVER USE WITH DRUGS OR ALCOHOL.
READ OWNER’S MANUAL. FOLLOW ALL INSTRUCTIONS AND WARNINGS.
For your nearest Polaris dealer,
call 1-800-POLARIS (765-2747)
or visit www.polaris.com
Polaris Industries Inc.
2100 Highway 55
Medina, MN 55340
Part No. 9926461 Rev 01
Printed in USA