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Owner`s Manual

1. Item Remarks Page Brake system pedal travel Ensure proper operation M Brake fluid Ensure proper level 44 Front suspension Inspect lubricate if necessary 41 Rear suspension Inspect lubricate if necessary 41 Steering Ensure free operation 45 Tires Inspect condition and pressure a Wheels fasteners Inspect ensure fastener tightness 46 Frame nuts bolts fasteners Inspect ensure tightness Accelerator Ensure proper operation 27 Indicator lights switches Ensure operation 22 Headlamp Check operation apply POLARIS dielectric grease when 47 lamp is replaced Brake light tail lamp Check operation apply POLARIS dielectric grease when 48 lamp is replaced Seat belts Check length of belt for damage check latches for proper 28 operation Latches hood tailgate seat Ensure all latches are secure Batteries Ensure full charges proper water levels clean terminals 49 51 Battery cables Inspect for proper cable routing and secure connections 51 29 OPERATION Driving Procedure 1 Disconnect the charging cable if connected 2 Wear a helmet eye protection gloves long sleeve shirt long pants and over the ankle boots 3 Sit in the driver s seat and fasten the seat belt 4 Apply the brakes Place the direction selector in neutral N 5 Turn the key to the ON position Wait about a second for the con tactor to close before continu ing 6 Move the direction selector to forward or reverse Move the
2. 5 Vehicle T econtrario Se 25 Vehicle Will Not Operate 58 W Warning Symbols TTT 4 Washing the Vehicle 04 52 Weight Hitch ads 5 RRR R R N 36 Wheel Installation 0 0005 46 Wheel Nut Torque 0 0022 e ee eee 46 Wheel Removal ss 522m Re ee are dd 46
3. 00000 00 a 27 64 S Safety Labels somme RP RED Xe Ch ues 6 8 Safety Symbols cies sace codecs duel Fes 4 Seat Belt Inspection 005 28 Seat Belts eset erbe qUer e Ue poi PR UR RR 28 Seat Removal ses dovcnr ee hope we suns 27 Severe Use Definition 0 40 Shock Spring Adjustment 45 Signal Words es ad g Ra RR dR RR RAR N eee 4 Specifications Gearcase ununun 42 Speed TOWING is cesses aes we eye ale 36 Steering Wheel Inspection 45 T i irs es erm ecce eher ee MR deed 52 54 Storage Tips e vc ves IR RERO RED 54 Storage Removal 12i eR Re heres 55 Storing the Vehicle ss srs as Rae R RR dee aR 55 Switches AWD SITE eresien tagaan 21 Direction Selector 21 Drive Mode Switch 20 Headlight Switch 21 Key Switch nne deett nates de 19 T Tire Pressure o eee tee EE ABUS 6 Tires Nut Torque eccer csi esnie 46 Tread Depth ces 46 Wheel Installation 46 Wheel Removal 46 Towing Loads 0 00 eee eee eee 36 Towing Speed tee osseseesvt x erc esp 36 Towing the RANGER 000 36 Trailer Hitch Bracket 27 Transaxle iile tia bh hey ees 42 Transporting the RANGER 38 Troubleshooting Charge Status Indicator 23 Malfunction Indicator 23 Vehicle Will Not Operate 58 V Vehicle Identification Numbers
4. 24 FEATURES AND CONTROLS Batteries Battery Conditioning New batteries cannot initially hold all of their capacity The approximate capacity of the bat tery pack increases as the number of charge cycles increases of Charge Cycles New 15 30 45 Percent of Full Capacity 80 90 95 100 Ambient Temperature Implications on Batteries 1 Battery range decreases as ambient temperature decreases This can affect the range by up to 30 2 Batteries discharge when left uncharged They can discharge up to 13 per month higher rates in warmer climates with the key off and much faster if the key is left on 3 Batteries can freeze if left uncharged at low ambient temperatures Percent Charged 100 50 0 Approximate Freezing Point 60 F 0 E 25 F 51 C 18 C 4 C Charger Operation Open the hood and any door enclosures or zippers This will decrease charger temperature which allows it to operate more efficiently and shorten charge times See pages 49 50 for charging procedures 1 Always use extension cords with the appropriate ratings for the country in which it is used In North America this is a UL rating The cords must also be rated for the condi tions in which they are used such as being rated for protection from oil in a garage or workshop environment 2 Use the proper cord wire gauges for the cord length used Length lt 25 ft 7 5 m 50 ft
5. Main Gearcase Transaxle Always check and change the main gearcase oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 40 Maintain the oil level even with the bottom thread of the fill plug hole Refer to the Gearcase Specifications Chart for recom mended lubricants capacities and torque specifica tions See page 57 for the part numbers of POLARIS products Oil Check The fill plug is located at the right rear of the vehicle Fill Plug Drain Plug 1 Position the vehicle on a level surface 2 Remove the fill plug 3 Check the oil level 4 Add the recommended oil as needed 5 Reinstall the fill plug Torque to specification Oil Change The drain plug is located on the lower right side of the main gearcase near the fill plug Refer to the Gearcase Specifications Chart for recommended lubricants capacities and torque specifications 1 Remove the fill plug 2 Place a drain pan under the drain plug Remove the drain plug Allow the oil to drain completely Fill Plug Drain Plug Wipe the magnetic end of the drain plug clean to remove accumulated metallic filings Reinstall the drain plug Torque to specification Add the recommended oil as needed Do not overfill Reinstall the fill plug Torque to specification SD Mo obe Check for leaks Dispose of used oil properly 42 MAINTENANCE Gearcases Front Gearcase Always check and change the front gearcase
6. to controller to contactor B wire Front of vehicle FEATURES AND CONTROLS Trailer Hitch Bracket This vehicle is equipped with a receiver hitch bracket for a trailer hitch Trailer towing equip ment is not supplied with this vehicle To avoid injury and property damage always heed the warnings and towing capacities out lined on pages 35 36 Brake Pedal Push the brake pedal toward the floor to slow or stop the vehicle Apply the brakes before turning the key on Accelerator Pedal The accelerator pedal will function only when the key is Accelerator ON and the direction selector switch is set to either for Pedal ward or reverse To begin moving or to increase vehicle gu speed gradually push the accelerator pedal toward the floor Holding the accelerator pedal down continuously will accelerate the vehicle to the maximum speed To slow the vehicle release the accelerator pedal Elec tric motor braking provides braking when the pedal is released For additional speed control or to stop the vehi cle apply the service brakes Roll Over Protection System ROPS The Rollover Protective Structure ROPS on this e vehicle meets OSHA 1928 53 rollover i doa N 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 o
7. 3 Make sure the key is off 4 Open the hood and any door enclosures or zippers 5 Always use a extension cord with a minimum rating of 20 amps 6 Inspect the charging cord and extension cord for cracks loose connections and frayed wiring Replace any damaged components promptly 7 Always connect the vehicle charger to the extension cord first then plug the cord into a wall receptacle 8 Make sure the charger uses a dedicated circuit to prevent overloading If charging multi ple vehicles each vehicle should use a dedicated circuit Tip After the batteries have fully recharged the battery charger will automatically cycle in and out of the trickle charge mode to maintain the charge 9 When disconnecting the charger always disconnect the extension cord from the wall receptacle first then disconnect the cord from the vehicle s charging cord 50 MAINTENANCE Batteries Battery Access To access the batteries remove the seat See page 27 Remove the storage tray if equipped NOTICE Before removing the seat to access the batteries make sure any wire or metal items including seat belt latches remain clear of the battery compartment to avoid causing a short circuit to the electrical system Battery Inspections Inspect battery terminal connections monthly Clean batteries as recommended Using an insulated wrench torque bolts to 8 ft Ibs 11 Nm Battery Cleaning Always keep battery terminals and connections
8. FEATURES AND CONTROLS FEATURES AND CONTROLS Console Battery Discharge Indicator The battery discharge indicator displays the amount of charge removed used from fully charged batter g 100 Remains Full Charge D ies When the batteries are fully charged the right most bar illuminates indicating 096 has been used The charge status indicator will be solid green see page 19 As the batteries discharge the bar moves leftward _ 30 70 Discharged Tip If batteries are not allowed to recharge fully solid green light the battery discharge indicator may be inaccurate Recharge the batteries When the second bar from the left flashes battery discharge is at 7096 The batteries should be recharged as soon as possible Avoid discharging the batteries more than 80 NOTICE If the two left most bars begin to flash battery damage may occur with continued operation Stop the vehicle and recharge the batteries 4 50 Remains l 50 Discharged Hour Meter The hour meter records and displays the hours of actual vehicle movement since manufac ture Auxiliary 12 Volt Terminal Board The 12 volt terminal board is located under the hood It contains constant 12 volt switched 12 volt and ground terminals that can be used to power auxiliary lights and accessories The terminals are limited to 10 amps Auxiliary Outlets The 12 volt receptacle can be used to power accessories but is limited to 10 amps
9. Failure to provide adequate ventilation while charging batteries can result in an explosion Volatile hydrogen gas is emitted during charging and may accumulate in pockets at the ceiling Always ensure a minimum of 5 air changes per hour in the charging area Always remove any storage covers from the vehicle and open any cab doors if equipped before charging Failure to Inspect Before Operating Failure to inspect and verify that the vehicle is in safe operating condition before operating increases the risk of an accident Always inspect your RANGER before each use to make sure it s in safe operating condition Always follow all inspection and maintenance procedures and schedules described in the owner s manual 12 SAFETY Operator Safety 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
10. Battery Compartment Warning SAFETY Safety Labels and Locations Battery Caution Discretionary Warning CAUTION Do not drive through water above the floor of the vehicle Battery damage will occur Batteries require regular maintenance Failure to maintain batteries in accordance with the owners manual can result in battery damage vehicle malfunction fire and or severe injury or death Maxtowing speed 10 MPH 16 km h drivetrain damage Will occur if towed faster than 10 MPH 16 km h Set parking brake before leaving vehicle Turn Power On key to Off position and remove when not in use Battery When towing vehicle turn Power On key to Off position Caution Age 16 7176204 Warning Age 16 Warning Operating this vehicle if you are under the age of 16 increases your chance of severe injury or death NEVER operate this vehicle if you are under age 16 and NEVER operate this vehicle without a valid driver s license 7175566 Discretionary Warning WARNING Improper vehicle use can result in Severe Injury or Death NEVER Operate At speeds too fast for your skills or the conditions After or while using Alcohol or Drugs e On hills steeper than 15 degrees 15 On public roads a collision can occur with a another vehicle With more than one passenger or a passenger under age twelve or who cannot comfortably reach the floor and hand holds On paved surfaces pavement may seri
11. When the brake pedal is depressed the brake light comes on Check the brake light before each ride 1 2 Turn the key to the ON position Depress the brake pedal The brake light should come on after about 10mm 0 4 in of pedal travel If the light doesn t come on check the bulb Indicator Lamp Replacement 1 2 3 48 Lift the hood Reach in behind the console panel and lift the Release Tab release to unplug the light from the harness Using a flathead screwdriver press on the tab on the top of the light to remove the indicator light assembly from the console panel Locate the expired lamp Using a screwdriver rotate the lamp 1 4 turn counter clockwise Grip the lamp with a needle nose pliers and remove it from the assembly Install the new lamp Using a screwdriver rotate the lamp 1 4 turn clockwise to seat it Snap the assembly back into the console panel Reconnect the harness Close the hood MAINTENANCE Batteries AWARNING Battery posts terminals and related components contain lead and lead compounds chemicals known to cause cancer and reproductive harm Always wash your hands after touching or handling the batteries AWARNING Charging a damaged battery can result in serious injury Never attempt to charge a frozen or bulging battery Discard the battery appropriately and install a new battery AWARNING Improperly connecting or disconnecting battery cables can result in an explosion a
12. rOm 59 Maintenance Log ia e own a RR n RR ROTE eed 62 ior Jp p 63 INTRODUCTION The RANGER is an off road vehicle Familiarize yourself with all laws and regulations con cerning 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 A 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 O The Mandatory Action Sign indicates an action that NEEDS to be taken to avoid a hazard A WARNING Failure to follow the warnings contained in this manual can result in severe injury or death A POLARIS RANGER is not a toy and can be hazardous to operate This vehicle handles differently than other vehicles A collision or rollover can occur quickly even during routine maneuvers like turning or driving on hills or over
13. the termi nal board and 12 volt outlet are fused together at 10 amps Charging Cord The charging cord is located inside the charge plug holder on the console See page 50 for charging instructions Charging Cord 18 FEATURES AND CONTROLS Console Park Brake Lever To help prevent the vehicle from rolling set the park brake when parking the vehicle When the park brake is set and the park brake indicator is illuminated motor speed is limited If the accelerator is applied this limiting feature prevents operation which protects the park brake pads from excessive wear Tip This feature will not operate properly if the park brake connector or switch under the hood mal functions or becomes disconnected or if the switch has moved Check for disconnection then see your dealer promptly if this feature fails to operate properly Always apply the service brakes before engaging or releasing the park brake 1 Apply the brakes 2 Pull the park brake lever downward as far as possible 3 To release the park brake apply the brakes Press the park brake release inward and move the lever upward as far as possible Charge Status Indicator When charging the batteries the charge status indicator light flashes and changes color to indicate the status of the charge Refer to the table below Color Indication Code Definition Green Solid Charge is complete charger is in maintenance mode Green Fast F
14. 15 m 100 ft 30 m Gauge 16AWG 1 5mm2 14AWG 2 5mm2 10AWG 6 0mm2 Battery Operation Range Range is significantly affected by tire pressure alignment terrain and driving style Always maintain proper tire pressure as specified on safety labels 25 FEATURES AND CONTROLS Main Power Connector NOTICE Damage to electrical connections and components will occur if they are unplugged before the main power connector is disconnected Always disconnect the main power connector before servicing or unplugging any electrical components When disconnected the main power con nector disconnects the battery pack from all electrical components with the excep tion of the contactor After servicing the vehicle the main power connector should be the last connection to be made The main power connector is located under the seat on the driver s side of the controller tray adjacent to the main line contactor To disconnect unplug the con nector To disconnect the battery pack from the vehicle completely disconnect the main power connector then remove the B wire from the battery terminal WARNING Insulate any tools used within the battery area to prevent sparks or battery explosion caused by shorting the battery terminals or wiring Remove the batteries or cover the exposed terminals with an insulating material 26 Main Power Connector Battery Installation and Wire Lead Connection
15. 81 x 107 x 29 cm Box Capacity 500 Ibs 227 kg Payload Capacity 1000 Ibs 455 kg Hitch Towing Capacity 1250 Ibs 567 kg Motor configuration Cargo System Lock amp Ride Seating 2 Skid Plate Plastic Performance Single 48 volt high efficiency AC induction motor Motor peak 30 HP Controller 650 Amp Sevcon Gen IV controller with multi mode driving and regenerative braking Battery pack 11 7 kw battery pack at 48V DC with 8 12 volt US12VXC batteries in series parallel configuration Maximum speed 25 MPH 40 2 km h Range in Max Range mode on flat ground 50 miles 80 5 km may vary with driving conditions Throttle Redundant non contact inductive sensing pedal On board charger Delta Q 120 volt AC input 48 volt DC output Charge time Main gearcase transaxle 8 hours dependent on depth of discharge Drivetrain Direct drive motor to transaxle with low noise gears Drive On demand AWD 2WD turf mode SPECIFICATIONS Brakes RANGER EV Brake System 4 Wheel hydraulic disc w dual bore front calipers Park Brake Front suspension Dash mounted lever activated mechanical park brake Independent Macpherson struts w 8 in 20 3 cm travel Rear suspension Dual A Arm w 9 in 22 9 cm travel Tires 25x9 12 Carlisle All Trail II Tire pressure Cup holders 20 psi 137 9 kPa Dual cup hold
16. Cab and body panels Labels and decals Switches and controls Electrical components and wiring If an informational or graphic label becomes illegible or comes off contact your POLARIS dealer to purchase a replacement Replacement safety labels are provided by POLARIS at no charge Grease all zerk fittings immediately after washing 52 MAINTENANCE Cleaning and Storage Polishing the Vehicle POLARIS recommends the use of common household aerosol furniture polish for polishing the finish on your POLARIS vehicle Follow the instructions on the container Polishing Tips ae the use of automotive products some of which can scratch the finish of your vehi cle 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 Chrome Wheel Care if equipped Proper maintenance will protect chrome wheels from corrosion preserve wheel life and ensure a like new appearance for many years Chrome wheels exposed to road salt or salt in the air in coastal areas are more susceptible to corrosion if not properly cleaned Clean chrome wheels more often if they re exposed to salt or other corrosive elements 1 Wash chrome wheels frequently Use a mild detergent Never use abrasive cleaners on plated or painted surfaces 2 Rinse well with clear water Soap detergents salt dirt mud and other elements can cause corrosion 3 Polish the clean c
17. Release the strap it will self tighten 4 To release the seat belt press the square red button in the buckle s center Buckle Seat Belt Inspection Inspect all seat belts for proper operation before each use of the vehicle 1 Push the latch plate into the buckle until it clicks The latch plate must slide smoothly into the buckle A click indicates that it s securely latched 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 oper ate 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 28 AWARNING OPERATION Failure to operate the vehicle properly can result in a collision loss of control accident or overturn which may result in serious injury or death Read and understand all safety warnings outlined in the safety section of this owner s manual 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
18. and maneuverability may be adversely affected causing the vehicle to overturn DO NOT TRAVEL FASTER THAN THE RECOMMENDED SPEEDS Vehicle should never exceed 10 MPH 16 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 The RANGER has been designed to carry or tow specific capacities Always read and under stand the load distribution warnings listed on the warning labels Move the drive mode switch to low mode if needed See page 20 The total load operator passenger accessories cargo and weight on hitch must not exceed the maximum weight capacity of the vehicle Never exceed the following capacities Model Maximum Capacities Cargo Box Level Ground RANGER EV 1000 Ibs 455 kg 500 Ibs 227 kg WARNING Driving with passengers in the cargo box can result in severe injury or death Never allow passengers to ride in the cargo box A passengers must always ride in the cab with seat belt fastened securely 35 OPERATION Towing Loads Towing improperly can alter vehicle handling and may cause loss of control or brake insta bility Always follow these precautions when towing 1 Never load more than 150 Ibs 68 1 kg tongue weight on the towing bracket 2 Do not operate the vehicle faster than 10 MPH 16 km h when towing See page 35 Towing a trailer incre
19. brake pressure to control speed Driving on a Sidehill Sidehilling Driving on a sidehill is not recommended Improper procedure could cause loss of control or overturn Avoid crossing the side of any hill unless absolutely necessary If crossing a sidehill is unavoidable follow these precautions 1 2 3 Slow down Exercise extreme caution Avoid crossing the side of a steep hill 15 maximum Driving Downhill When driving downhill follow these precautions l 2 32 Avoid steep hills 15 maximum Always descend a hill with the direction selector switch on forward Never descend a hill with the switch on neutral 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 Slow down Apply the brakes s ightly to aid in slowing OPERATION Driving Through Water Your POLARIS vehicle can operate through water up to a maximum recommended depth equal to the floorboards NOTICE Serious damage can occur to the Follow these procedures when operating electrical system and batteries if the vehicle is operated in water deeper than the floorboards through water 1 Determine water depths and current before entering water 2 Choosea crossing where both banks have gradual inclines sp i 3 Proceed slowly avoiding rocks and obsta lt Floorboard 7 cles T PON 4 Avoid oper
20. 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 over obstacles operating Operating in rough terrain Climbing an incline Towing Using Alcohol or Drugs Operating the vehicle after consuming alcohol or drugs could adversely affect operator judgment reaction time balance and 2 perception ze Never drink alcohol or use drugs or medications before or while operating this vehicle Operating a Damaged Vehicle Operating a damaged vehicle can result in an accident After any overturn or accident have a qualified service dealer inspect the entire machine for possible damage including but not limited to brakes accelerator steering system and electrical system 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 your passenger s skills Operating on Pavement This vehicle s tires are designed for off road use only not for use on pavement Operating this vehicle on paved surfaces including sidewalks paths parking lots and driveways may adversely affect the handling of the vehicle and could result in loss of control and accident or overtu
21. free of corrosion To clean remove 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 battery terminals with dielectric grease or petroleum jelly NOTICE Do not allow cleaning solution or tap water to enter the batteries Battery Replacement With proper care and maintenance as outlined in this owner s manual battery life could be extended up to four years or longer depending on the amount of use When battery replace ment is necessary please see your authorized POLARIS dealer WARNING Handling batteries and electrical components improperly can result in serious injury or death Do not attempt to remove batteries or battery cables Always see your dealer for battery related service Battery Fluid A poorly maintained battery will deteriorate rapidly Check the battery fluid level often Add only distilled water Tap water contains minerals that are harmful to a battery Unless the plates are exposed before charging distilled water should be added to a battery after charging If the plates are exposed add water to about 1 8 inch 3 mm above the plates then charge Check the fluid level again after charging Maintain the fluid level 1 4 inch 6 mm below the bottom of the fill well in the cell cover Do not overfill V Cell Covers Plates 51 MAINTENANCE Cleaning and Storage Washing the Vehicle Keep
22. h and regenerative braking increases to improve control in aggressive terrain Return the mode switch to high mode for normal operation Move the switch to the center position to select the maximum range mode Use this mode to operate the vehicle a greater distance or for a longer time period This mode limits both speed and torque to obtain the maximum driving range Low Mode Maximum Torque Deceleration Application Speed percent of regenerative brak maximum ing torque High 25 MPH 70 Minimum Trail riding 40 km h Max 15 MPH 50 Minimum Whenever possible to maximum driving Range 24 km h range of battery pack Low 10 MPH 100 Maximum Towing hauling loads driving on steep hills 16 km h or aggressive terrain 20 FEATURES AND CONTROLS Console Direction Selector Switch When the direction selector is in the center position the vehicle is in neutral The vehicle will not move if the accel erator is depressed Place the switch in neutral before turn Forward ing the key on Push the top of the switch to choose forward operation Push Neutral the bottom of the switch to choose reverse operation Always come to a complete stop before reversing direction Tip The malfunction light will illuminate after reversing direction if Reverse you press the accelerator pedal before coming to a complete stop AWD Switch The AWD switch has three positions All Wheel Drive AWD D
23. instability which can result in serious injury or death Always follow these precautions when hauling cargo Never exceed the maximum weight capacity of the vehicle When determining the weight you are adding to the vehicle include the weight of the operator passenger accessories loads in the rack or box and the load on the trailer tongue The combined weight of these items must not exceed the maximum weight capacity REDUCE SPEED AND ALLOW GREATER DISTANCES FOR BRAKING WHEN HAULING CARGO Always load the cargo box with the load as far forward and as low as possible When operating over rough or hilly terrain reduce speed and cargo to maintain stable driving conditions Always operate the vehicle with extreme care when hauling or towing loads Slow down and drive in the lowest gear available SECURE ALL LOADS BEFORE OPERATING Unsecured loads can create unstable operating conditions which could result in loss of control of the vehicle OPERATE ONLY WITH STABLE AND SAFELY ARRANGED LOADS When handling off centered loads that cannot be centered securely fasten the load and operate with extra caution Always attach the tow load to the hitch point designated for your vehicle HEAVY LOADS CAN CAUSE BRAKING AND CONTROL PROBLEMS Use extreme caution when applying brakes with a loaded vehicle Avoid terrain or situations that may require backing downhill USE EXTREME CAUTION when operating with loads that extend over the rack sides Stability
24. obstacles if you fail to take proper precautions Read this owner s manual Understand all safety warnings precautions and operating procedures before operating the vehicle Keep this manual with the vehicle This vehicle is an ADULT VEHICLE ONLY 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 Any passenger must be able to comfortably reach the floor and hand holds Never permit a guest to operate this vehicle unless the guest has read this manual and all product labels Always wear a helmet eye protection gloves long sleeve shirt long pants and over the ankle boots Always keep hands and feet inside the vehicle at all times 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 A key can be duplicated only by ordering a key blank using your key number and mating it with one of your existing keys The key switch must be replaced if all keys are lost Key Number Frame VIN Vehicle Model Number Frame VIN Motor Serial Number on side of motor Key Number Equipment Modifications Never install any accessory that grounds to the vehicle chassis The chassis is a floating ground to protect against electrical short circuits and hazards We strongly recommend that consu
25. oil level check gt Main gearcase oil Transaxle 100 H 12M Perform a break in oil level check K Wiring 100 H 12M Inspect for wear routing security apply dielectric grease to connectors subjected to water mud etc D Front wheel bearings 100 H 12M Inspect replace as needed D Brake fluid 200 H 24M Change every two years D Toe adjustment Inspect periodically adjust when parts are replaced D Headlight aim Adjust as needed gt Perform these procedures more often for vehicles subjected to severe use D Have an authorized POLARIS dealer perform these services Lubrication Recommendations Check and lubricate all components at the intervals outlined in the Periodic Maintenance Chart beginning on page 40 or more often under severe use such as wet or dusty conditions Items not listed in the chart should be lubricated at the general lubrication interval Item Lube Method Brake Fluid DOT 4 See page 44 Main Gearcase Oil Transaxle Premium ATV Angle Drive Fluid See page 42 Front Gearcase Oil Demand Drive Plus Fluid See page 43 41 MAINTENANCE Gearcases Gearcase Specification Chart Gearcase Lubricant Capacity Fill Plug Torque Drain Plug Torque Main Gearcase Premium ATV Angle Drive 20 3 oz 14 ft Ibs 14 ft Ibs Transaxle Fluid 600 ml 19 4 Nm 19 4 Nm Front Gearcase Demand Drive Plus Fluid 5 1 oz 8 10 ft Ibs 11 ft Ibs 150 ml 11 13 6 Nm 15 Nm
26. storage or weather cover on vehicle or with the cab enclosure doors closed as fire and explosion are possible Refer to Owner s Manual or contact your local POLARIS dealer with any questions TO MAXIMIZE BATTERY LIFE Always check and maintain water level monthly Use only distilled water Water level should be kept 1 4 6 mm below fill well Do not overfill the battery Always keep batteries fully charged For maximum life charge your vehicle at every opportunity Use only the charger supplied with the vehicle Inspect battery connections regularly Failure to properly maintain your batteries will void warranty coverage 7176414 Battery Compartment Warning WARNING SULFURIC ACID in batteries will burn skin eyes and clothing Do not tip batteries Keep vent caps tight and level In event of injury flush with water and call physician immediately HIGH VOLTAGE CABLES and terminals are contained within this compartment Improper contact between battery terminals can result in electrical shorts ELECTRICAL SHORTS can result in burns Do not use high pressure water to wash the battery compartment Damage to the vented batteries will result Tampering with or unauthorized modification of this unit could result in serious personal injury will void the warranty and can result in permanent damage to the vehicle Refer to your Owner s Manual or contact your local POLARIS dealer with any questions 7176206
27. that the cargo is positioned evenly or toward the front of the cargo box Release the tailgate latches OPERATION 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 9 Stand clear and pull up on the cargo box release lever 10 Lift the front of the cargo box to dump the cargo 11 Lower the cargo box and push down securely to latch 12 Close the tailgate and secure both tailgate latches WARNING Operating the vehicle while the cargo box is raised could result in severe injury The box could close unexpectedly and cause injury to the driver or passenger The rear tires will also catch the rear of a raised box damaging the vehicle and creating hazardous driving conditions Never operate this vehicle with the cargo box in the raised position 37 OPERATION Parking the RANGER 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 venti lated and that the vehicle is not close to any source of flame or sparks including any appliance with pilot lights 3 Place the direction selector in neutral 4 Setthe park brake 5 Turn the key off Remove the key to prevent u
28. 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 tipover risk be especially careful when encountering obstacles and slopes and when braking on hills or during turns This vehicle is for off road use only Never operate on public roads Always avoid paved surfaces Never consume alcohol or drugs before or while operating this vehicle Never operate at excessive speeds Always travel at a speed proper for the terrain visibility and operating conditions and your experience Never attempt jumps or other stunts Always inspect your vehicle each time you use it to make sure it s in safe operating condition Always follow the inspection and maintenance procedures and schedules described in this manual Always travel slowly and use extra caution when operating on unfamiliar terrain Be alert to changing terrain Never operate on excessively rough slippery or loose terrain Always follow proper procedures for turning Practice turning at slow speeds before attempting to turn at faster speeds Never turn at excessive speeds Always have this vehicle checked by an authorized POLARIS dealer if it has been involved in an accident Never operate this vehicle on hills too steep for the vehicle or for your abilities Practice on smaller hills before attempting large
29. 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 Turn in skid direction of D D LA ME rl CIty TT C C Co C v C 4 31 OPERATION Driving Uphill Whenever traveling uphill follow these precautions 1 2 3 4 Always travel straight uphill Avoid steep hills 15 maximum Keep both feet on the floor Always check the terrain carefully before ascending any hill Never climb hills with excessively slip pery or loose surfaces Proceed at a steady rate of speed 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 Ifthe vehicle stalls while climbing a hill apply the brakes Place the direction selector in neutral turn the key off and on then select low range Place the direction selector switch in reverse and slowly allow the vehicle to roll straight downhill while applying light
30. AINTENANCE Steering Wheel Inspection Check the steering wheel for specified freeplay and smooth operation at the intervals out lined in the Periodic Maintenance Chart beginning on page 40 1 Position the vehicle on a level surface 2 Lightly turn the steering wheel left and right There should be 0 8 1 0 20 25 mm of freeplay at the outer rim of the steering wheel 3 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 Spring Adjustment Adjust the rear shock absorber springs by rotating the adjustment cams either clockwise or counter clockwise to increase or decrease spring tension 45 MAINTENANCE Tires AWARNING Operating your vehicle with worn tires improperly inflated tires non standard tires or improperly installed tires will affect vehicle handling and could cause an accident resulting in serious injury or death Always follow all tire maintenance procedures as outlined in this manual and on the labels on the vehicle Always use original equipment size and type when replacing tires Tire Tread Depth Always replace tires when tread depth is 1 8 3 mm Y worn to 1 8 3 mm or less Axle and Wheel Nut Torque P ASS Specifications Inspect the following items occasionally for tightness and if they ve been loosened for main tenance service Do not lubricate the stud or the lug nut N
31. 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 res ervoir are unknown See page 41 for fluid recommenda tions 1 2 Position the vehicle on a level surface View the brake fluid level at the reservoir in the driver s side wheel well The level should be between the upper MAX and lower MIN level lines If the fluid level is lower than the upper level line add brake fluid to the upper MAX line Apply the brake forcefully for a few seconds and check for fluid leakage around the fittings Brake Inspection 1 2 44 Check the brake system for fluid leaks Check the brake pedal for excessive travel or a spongy feel Check the friction pads for wear damage and loose ness Change pads when worn to 3 64 1 mm Check the security and surface condition of the disc Clean any grease using a recommended brake cleaner or alcohol Do not use spray lubricants or other petro leum based products If you discover any damage cracks excessive corrosion warping see your dealer for service before operating Maximum Minimum M
32. RANGER EV Owner s Manual for Maintenance and Safety A 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 ONG The text is printed on 10096 recycled with 4096 post consumer waste PCW AWARNING Improper vehicle use can result in SEVERE INJURY or DEATH NEVER Operate e f you are under age 16 and without a valid driver s license e At speeds too fast for your skills or the conditions e After or while using Alcohol or Drugs e On hills steeper than 15 degrees 15 e On public roads A collision can occur with another vehicle e With more than ONE passenger or with passengers under age twelve or who cannot comfortably reach the floor and hand holds On paved surfaces pavement may seriously affect handling and control e With non Polaris approved accessories they may seriously affect stability ALWAYS e Wear your seat belt Vehicle rollover could cause severe injury or death e Wear a helmet eye protection gloves long sleeve shirt long pants and over the anke boots e Reduce speed and use extra caution when carrying a passenger e Avoid sharp turns or turns while applying heavy throttle Operate slowly in reverse avoid sharp turns or sudden braking e Make sure passenger reads and understands all safety la
33. arged condition operation of the battery in an uncharged condition below half charge 1 200 specific gravity and use of a battery charged by systems other than those supplied or recommended by POLARIS This warranty does not cover the use of unauthorized lubricants chemicals or fuels that are not compatible with the vehicle The exclusive remedy for breach of this warranty shall be at POLARIS exclusive option repair or replacement of any defective materials or components or products THE REMEDIES SET FORTH IN THIS WARRANTY ARE THE ONLY REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF THIS WAR RANTY POLARIS SHALL HAVE NO LIABILITY TO ANY PERSON FOR INCIDENTAL CONSEQUEN TIAL OR SPECIAL DAMAGES OF ANY DESCRIPTION WHETHER ARISING OUT OF EXPRESS OR IMPLIED WARRANTY OR ANY OTHER CONTRACT NEGLIGENCE OR OTHER TORT OR OTHER WISE THIS EXCLUSION OF CONSEQUENTIAL INCIDENTAL AND SPECIAL DAMAGES IS INDE PENDENT FROM AND SHALL SURVIVE ANY FINDING THAT THE EXCLUSIVE REMEDY FAILED OF ITS ESSENTIAL PURPOSE Some states do not permit the exclusion or limitation of incidental or consequen tial damages or implied warranties so the above limitations or exclusions may not apply to you if inconsistent with controlling state law U S Battery s liability shall be to replace the defective battery Replacement shall mean furnishing a new battery or used battery with sufficient life to complete the warranty term which is incidental or reasonably equivalent to
34. ases braking distance 3 Do not tow more than the recommended weight for the vehicle See the towing capacity chart below and the specifications charts beginning on page 56 4 Attach a trailer to the trailer hitch bracket only Do not attach a trailer to any other loca tion or you may lose control of the vehicle 5 Never tow a trailer on a grade steeper than 15 Model Total Towed Total Towed Total Hitch Maximum Load Weight Load Weight Vertical Towin Level Ground 15 grade Weight Spee RANGER EV 1250 Ibs 850 Ibs 150 Ibs 10 MPH 567 kg 386 kg 68 1 kg 16 kph Towing the RANGER NOTICE When towing the vehicle the key MUST be in the OFF position or severe motor damage will occur Follow these procedures when towing the vehicle 1 2 3 36 Place the direction selector in neutral Turn the key off Always follow these precautions when towing this vehicle Do not operate faster than 10 MPH 16 km h Do not tow on public streets Do not allow passengers in the towed vehicle Avoid abrupt starts and stops Avoid sharp turns and abrupt steering maneuvers Avoid towing on a hill Dumping the Cargo Box 1 SON M e Uy d 8 Select a level site to dump the cargo box Do not attempt to dump or unload the vehicle while parked on an incline Apply the brakes Set the park brake Place the direction selector in neutral Turn the key off Dismount the vehicle Ensure
35. ating through deep or fast flowing water 5 After leaving water always dry the brakes by applying light pressure to the pedal repeat edly until braking action is normal Driving Over Obstacles Follow these precautions when operating over obstacles 1 2 Always check for obstacles before operating in a new area Look ahead and learn to read the ter rain Be constantly alert for hazards such as logs rocks and low hanging branches Travel slowly and use extra caution when operating on unfamiliar ter rain Not all obstacles are immedi ately visible Move the drive mode switch to low mode if needed See page 20 33 OPERATION Driving in Reverse Follow these precautions when operating in reverse 1 Oy oU ce eh Always check for obstacles or people behind the vehicle Always inspect left and right fields of vision before backing Always avoid backing downhill Back slowly Apply the brakes lightly for stopping Avoid turning at sharp angles Never accelerate suddenly Parking on an Incline Avoid parking on an incline if possible If it s unavoidable follow these precautions vam lS 34 Apply the brakes Set the park brake Place the direction selector in neutral Turn the key off Block the rear wheels on the downhill side 15 maximum OPERATION Hauling Cargo AWARNING Hauling cargo improperly can alter vehicle handling and may cause loss of control or brake
36. ave not followed the proce dure set out above your vehicle will no longer be eligible for warranty or service bulletin coverage of any kind other than safety bulletins Vehicles registered to Government officials or military personnel on assignment out side of the country where the vehicle was purchased will continue to be covered by the basic warranty For questions call POLARIS Customer Assistance United States 1 888 704 5290 Canada 1 204 925 7100 61 MAINTENANCE LOG Use the following chart to record periodic maintenance DATE MILES KM TECHNICIAN SERVICE PERFORMED COMMENTS OR HOURS 62 A Accelerator Pedal 2 entem RE saves 27 All Wh l Drive sessie sranie tentonin 39 Auxiliary 12 Volt Terminal Board 18 Auxiliary Outlets llle esee eee 18 AWD usineeseescte eessesu ri e dE 39 AWD SWitCl uu nete s aea PE 21 Axle Nut Torque 0 0 2 esee 46 B Batteries ACCESSING ox eoe sank gehen Gate 51 Ambient Temperature Implications 25 Charge Status Indicator 19 23 Charger Operation 25 Charging osse nace nace ne ae ena 50 Charging Cord rere 18 25 Cleaning 000 0000 eee 51 Conditioning 0 25 Discharge Indicator 18 Fluid stig buch ets ode eres 51 Handling Precautions 24 Inspections 0000005 51 Main Power Connector 26 O
37. bels Watch for branches or other hazards that could enter vehicle READ OWNER S MANUAL FOLLOW ALL INSTRUCTIONS AND WARNINGS e For your nearest Polaris dealer POLARIS sa 1 500 PoLans or visit www polarisindustries com Polaris Sales Inc 2100 Hwy 55 Medina MN 55340 Phone 1 888 704 5290 Part No 9923941 Rev 01 Printed in USA 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 polarisindustries 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 e Snowmobiles All terrain vehicles ATVs RANGER utility vehicles Victory Motorcycles Low Emission Vehicles LEVs We believe POLARIS sets a standard of excellence for all utility and recreational vehicles manufactured in the world today Many years of experience have gone into the engineering design and development of your POLARIS vehicle making it the finest machine we ve ever produced For safe and enjoyable operation of your vehicle be sure to follow the instructions and rec ommendations in this owner s manual Your manual contains instructions for minor mainte nance but information about major repairs is outlined in the POLARIS Service Manual and should be performed only by a Factory Certified Master Service Deal
38. box 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 Be careful if load extends over the side of the box RANGER 4x4 Crew EV MAXIMUM CARGO BOX LOAD 500 Ibs 500 Ibs 500 Ibs 226 kg 226 kg 226 kg TIRE PRESSURE IN PSI KPa FRONT 10 69 FRONT 14 97 FRONT 20 138 REAR 12 83 REAR 16 110 REAR 20 138 MAXIMUM WEIGHT CAPACITY 1000 Ibs 1250 Ibs 1000 Ibs INCLUDES WEIGHT OF 454 kg 547 kg 454 kg OPERATOR PASSENGER CARGO AND ACCESSORIES Read Operation and Maintenance Manual for more detailed loading information 7177690 SAFETY Safety Labels and Locations Battery Charging Warning WARNING Explosive gases are released when batteries are charged Keep Battery Charging Warning sparks flames and cigarettes away Shield eyes when working near batteries Do not charge batteries in a non ventilated enclosed area or near flammable materials Do not attempt to charge frozen leaking or damaged batteries Connect battery charger to properly rated electrical receptacle with GFCI Do not charge with
39. cending a hill Avoid traveling down a hill at an angle which would cause the vehicle to lean sharply to one side Travel straight downhill Improper Tire Maintenance Operating this vehicle with improper tires or with improper or uneven tire pressure could cause loss of control or accident Always use the size and type of tires specified for your vehicle Always maintain proper tire pressure as described in the owner s manual and on safety labels Operating on Frozen Bodies of Water Severe injury or death can result if the vehicle and or the operator fall through the ice Never operate the vehicle on a frozen body of water 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 vehicle can lead to unauthorized use of the vehicle which could result in an accident or overturn Always remove the key when the vehicle is not in use Hot Drive Systems The motor and controller are very hot during and after use of the vehicle Hot components can cause burns and fire Do not touch hot drive system components Always keep combustible
40. ching to AWD NOTICE Switching to AWD while the rear wheels are spinning may cause severe drive train damage Always switch to AWD while the rear wheels have traction or are at rest 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 Locking the differential in slippery or low traction conditions helps improve traction Move the rocker switch to the center position 2WD to lock the differential and operate in rear wheel drive Press the bottom of the switch to unlock the differential and allow the rear drive wheels to operate independently This mode of operation is well suited to turf driving or whenever aggressive traction is not required 1WD TURF Disengaging AWD Move the AWD switch to the center or bottom position to disengage AWD If the switch is turned off while the front gearcase is moving it will not disengage 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 Move the direction selector to reverse Operate in reverse for at least 10 feet 3 m Stop completely Move the dire
41. connections clean and free of corrosion at all times See page 51 Always maintain a full charge on the batteries For best battery life avoid discharging the batteries more than 8096 See page 18 Make sure new batteries are fully charged before using New deep cycle batteries need to be cycled several times before reaching full capacity 50 125 cycles depending on type Capacity will be limited during this time Make sure vent caps are installed properly and securely during vehicle operation and bat tery charging Recharge batteries fully at the end of each day the vehicle is operated allowing adequate time for the charger to complete its charge cycle The batteries in this vehicle do not have a memory effect Frequent charging will extend their life Avoid charging at temperatures above 120 F 49 C ambient air temperature Closed unvented storage buildings often exceed this temperature when exposed to direct sunlight Never connect an auxiliary battery to the factory installed DC to DC converter If more than 10 amps are needed for accessories always install the POLARIS approved auxiliary accessory battery kit Never connect a 12 volt accessory directly to the batteries Always connect any powered accessory to a 12 volt auxiliary outlet or terminal board See page 18 Never connect jumper cables to any of the batteries of this vehicle Use only insulated tools when working in the battery compartment
42. ction selector to forward and drive forward If the front gearcase remains locked after following these instructions return the vehicle to your dealer for service QA ge Ue ba 39 MAINTENANCE Periodic Maintenance Chart Careful periodic maintenance will help keep your vehicle in the safest most reliable condi tion Inspection adjustment and lubrication of important components are explained in the periodic maintenance chart Inspect clean lubricate adjust and replace parts as necessary When inspection reveals the need for replacement parts use genuine POLARIS parts available from your POLARIS dealer Record maintenance and service in the Maintenance Log beginning on page 62 Tip Service and adjustments are important for proper vehicle operation If you re not familiar with safe service and adjustment procedures have a qualified dealer perform these operations Maintenance intervals in the following chart are based upon average riding conditions and an average vehicle speed of approximately 10 MPH 16 km h Vehicles subjected to severe use must be inspected and serviced more frequently Severe Use Definition Frequent immersion in mud water or sand Racing or race style high RPM use Prolonged low speed heavy load operation Maintenance Chart Key gt Perform these operations more often for vehicles subjected to severe use D Have an authorized POLARIS dealer perform these services WARNING Improperly performi
43. dealer preparation and set up of your vehicle is very important in ensuring trouble free operation Purchas ing a machine in the crate or without proper dealer set up will void your warranty coverage WARRANTY COVERAGE AND EXCLUSIONS LIMITATIONS OF WARRANTIES AND REMEDIES The POLARIS limited warranty excludes any failures that are not caused by a defect in material or workmanship This warranty does not cover accidental damage normal wear and tear abuse or improper handling This war ranty also does not cover any vehicle that has been altered structurally modified neglected improperly main tained used for racing or used for purposes other than for which it was manufactured or for any damages which occur during trailer transit or as a result of unauthorized service or the use of unauthorized parts In addition this warranty does not cover physical damage to paint or finish stress cracks tearing or puncturing of upholstery material corrosion or defects in parts components or the vehicle due to fire explosions or any other cause beyond POLARIS control Warranty does not apply to parts exposed to friction surfaces stresses environmental conditions and or contami nation for which they were not designed or not intended including but not limited to the following items Wheels and tires Finished and unfinished surfaces Suspension components Carburetor Throttle body components Brake components Engine components Seat comp
44. diagnosis and repair f A T S Code Definition Solution Blinks 1 Battery high voltage Check battery size and condition reset 2 Battery low voltage charger interrupt AC power for 15 seconds 3 Charge time out battery pack not reaching Check connections operate charger at required voltage charger output reduced lower ambient temperature due to high temperatures 4 Battery could not be trickle charged to Check battery for shorted or damaged cells minimum voltage 5 Charger shut down due to overheating Ensure sufficient cooling air flow open the hood and reset the charger interrupt AC power for 15 seconds 6 Charger internal fault Reset charger interrupt AC power for 15 seconds return to qualified service provider if fault persists 23 FEATURES AND CONTROLS Batteries This vehicle is equipped with eight 12 volt batteries that supply the power needed to operate the vehicle The batteries are located under the seat See page 51 for battery access instruc tions Always observe all battery safety warnings and safe handling procedures as outlined on vehicle safety labels and in this manual Refer to the battery maintenance section beginning on page 49 Battery Handling Precautions Always make sure that all electrical accessories are grounded directly to the negative post on the terminal board Never use the chassis or body as a ground connection Always keep battery terminals and
45. drive mode switch to the desired setting See page 20 Release the park brake soe es Check your surroundings and determine your path of travel 10 Keeping both hands on the steering wheel release the brake pedal and gradually push the accelerator toward the floor to begin driving 11 Drive slowly Practice maneuvering and using the accelerator and brakes on level sur faces 12 Do not carry a passenger until you have at least two hours of driving experience with this vehicle Never carry more than one passenger in this vehicle Never allow a passenger to ride in the cargo box 13 To stop the vehicle release the accelerator pedal completely and brake to a complete stop Tip Always come to a complete stop before reversing direction 14 Set the park brake 15 Place the direction selector in neutral 16 Turn the key off WARNING A rolling vehicle can cause serious injury Always set the park brake when leaving the vehicle unattended 30 OPERATION Driving On Slippery Surfaces AWARNING Skidding or sliding can cause loss of control or overturn if tires regain traction unexpectedly When operating on slippery surfaces such as ice or loose gravel reduce speed and use extra caution to reduce the chance of skidding or sliding out of control Do not operate on excessively slippery surfaces Whenever riding on slippery surfaces such as wet trails or loose gravel or during freezing weather follow these precautions
46. er MSD Technician Your POLARIS dealer knows your vehicle best and is interested in your total satisfaction Be sure to return to your dealership for all of your service needs during and after the warranty period POLRGRIS POLARIS and RANGER are registered trademarks of POLARIS Industries Inc Copyright 2012 POLARIS Sales Inc All information contained within this publication is based on the latest product information at the time of publication Due to constant improvements in the design and quality of produc tion 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 liabil ity 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 origi nal instructions Printed in U S A 2013 RANGER EV Owner s Manual P N 9923941 TABLE OF CONTENTS Introduction m d T L TTT D Features and Controls sse eee 16 Operation cra ene Geren eben ce ener E 29 Maintenance ovs egasra ires t Iia dodo IR peewee eee ecu erat 40 SPECINCAUONS EMT 56 POLARIS Produce x13 ssc eaa RORRUN RUN XO RRR e RR RO 57 Troubleshooting cs ER eee 58 Warranty PC
47. ers Indicator panel Indicates directional selection park brake and motor or controller malfunction Charge indicator Digital indicates battery discharge Hour meter Digital indicates cumulative hours of vehicle movement Auxiliary power 12 volt accessory outlet Rider restraints Automotive style 3 point seat belts Multi mode switch L M H Low Max Range High Headlights taillights brake lights Dual 50 watt Storage Glove box POLARIS PRODUCTS Gearcase Lubricants 2871653 Premium ATV Angle Drive Fluid 8 0z 237 ml 2872276 Premium ATV Angle Drive Fluid 2 5 gal 9 5 I 2877922 Demand Drive Plus Fluid qt 95 I 2877923 Demand Drive Plus Fluid 2 5 gal 9 5 I Grease Specialized Lubricants 2871312 Grease Gun Kit Premium All Season 2871322 Premium All Season Grease 3 0z 89 ml cartridge 2871423 Premium All Season Grease 14 0z 414 ml cartridge 2871515 Premium U Joint Lube 3 0z 89 ml cartridge 2871551 Premium U Joint Lube 14 0z 414 ml cartridge 2871329 Dielectric Grease Nyogel Additives Miscellaneous 2872189 DOT 4 Brake Fluid 57 TROUBLESHOOTING Vehicle Will Not Operate Possible Cause Solution Low battery voltage Recharge the battery overnight Loose battery connections Check all connections and tighten Loose contactor connections Check all connections and tighten Loose electro
48. hill RR R a Rr 32 Dumping the Cargo Box 37 E Equipment Modifications 5 Eye Protections lt ss Sa aE eee em 9 F Fluid Change Front Gearcase esses em rero 43 Main Gearcase 0 00 42 HS lur repe he npe 42 Fluid Level Front Gearcase 200 43 Main Gearcase 0 42 Transaxle sels eR es 42 Fluid Levels During Storage 54 Fluid Recommendation Gearcases 42 Fluid Battery eren 51 Fluid Brake lt a RE reete ttu dires 44 Front G6eatease ias qase esee tare mera 43 Fuel Stabilizer exkr bL e Irure 54 G Gearcase Specification Chart 42 Crearcase ETOfI s ice ecc er set levee eine ders 43 Gearcase Main 42 GEALCASES usu a ve ey Maly er eme mp da 42 43 GIOVES cx etas ias mer eroe t PPP ETAN 9 H Hauling Cargo s a enra esses 35 Headlight Beam Adjustment 47 Headlight Lamp Replacement 47 Headlight Switch a ER d RE ser RR 21 Helmet ie a s bur Eo ees e ded 9 Hitch Bracket 20 0 0 esee 27 Hitch Weight is osrex ere RE 36 Hout Meter oec ex Ve echo teu Son 18 l Indicator Light Replacement 48 Indicator Tes aa 6 Rage R RR R d 22 Indicator Charge Status 19 K Key Switch esce e Reg FRE RE YS 19 Key Periodic Maintenance Chart 40 63 INDEX L Lamp Replacement Indicator Lights 48 Lights Bra
49. hrome wheels periodically Use an automotive grade chrome polish Routinely and liberally apply a weather resistant wax to each polished chrome wheel Choose a product suitable for chrome finishes Read and follow the product labels and instructions Removing Corrosion If light rust is found on the chrome finish use steel wool 20000 OTT grade to remove it Gently rub the affected areas with the steel wool until the corrosion has been removed Clean and polish the wheel as outlined above 53 MAINTENANCE Cleaning and Storage Storage Tips Clean the Exterior Make any necessary repairs and clean the vehicle as recommended See page 52 Inspect and Lubricate Inspect all cables and lubricate all areas of the vehicle as recommended in the Periodic Main tenance Chart beginning on page 40 Battery Maintenance See pages 49 51 for procedures Fluid Levels Inspect the fluid levels Add or change fluids as recommended in the Periodic Maintenance Chart beginning on page 40 Front and rear gearcase fluid if equipped Main gearcase fluid Brake fluid change every two years and any time the fluid looks dark or contaminated 54 MAINTENANCE Storing the Vehicle Any time the vehicle will be parked for more than a few hours follow the recommended storage procedures OPS Ov ee QU B RE Tip Make any necessary repairs and clean the vehicle See page 52 Clean the batteries See page 51 Store the vehicle out of the su
50. ifferential Lock Two Wheel Drive 2WD and Off 1 WD Turf Mode Press the top of the switch to engage All Wheel Drive AWD See page 39 for operating instructions Move the switch to the center position to lock the differ ential and operate in two wheel drive 2WD Press the bottom of the switch to unlock the differential and allow the rear drive wheels to operate independently 1WD This mode of operation is well suited to turf driving or when active traction is not needed See page 39 for Differential Lock operating instructions Headlight Switch Press the top of the switch to turn the headlights on Press the bottom of the switch to turn the headlights off 21 FEATURES AND CONTROLS Console Indicator Panel Lights The indicator lights activate Indicator Panel when the key is in the ON position Indicator Status Indicates Malfunction Electrical malfunction flash sequence on controller indicates type see troubleshooting guide on page 23 Steady Key was turned on in forward or reverse switch to neutral then to forward or reverse Park Brake Steady Engaged park brake Gear Position Steady Selected gear forward neutral reverse Motor Controller High Flashing Reduced performance due to elevated temperature Temperature Steady Power delivery terminated to protect against overheating If either occurs stop the vehicle and turn the key off Allow the motor and controller to cool adequate
51. ing 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 Avoid directing water toward electrical components including batteries wiring and switches Washing the Vehicle Ifa 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 Main gearcase seals Brakes
52. jury or death Heed all safety warnings outlined in this section of the owner s manual See the OPERATION section of the owner s manual for proper operating procedures Age Restrictions This vehicle is an ADULT VEHICLE ONLY NEVER operate this vehicle if you are under age 16 and NEVER operate without a valid driver s license No person under the age of 12 may ride as a passenger in this vehicle Any passenger must be able to comfortably reach the floor and hand holds Operating Without Instruction Operating this vehicle without proper instruction increases the risk of an accident The operator must understand how to operate the vehicle properly in different situations and on different types of terrain All operators must read and understand the Owner s Manual and all warning and instruction labels before operating the vehicle Seat Belts Riding in this vehicle without wearing the seat belt increases the risk of serious injury in the event of an accident or sudden stop Riders must wear seat belts at all times Always make sure the seat belts are secured for both the operator and passenger before riding 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 passenger must always wear an approved helmet that fits properly and eye protection goggles or face shield Ventilation When Charging Batteries
53. ke Lights 48 Headlight Beam Adjustment 47 Headlight Lamp Replacement 47 Indicator Lamp Replacement 48 Indicator Lights 22 Lubrication Recommendations 41 M Main Garcassouno io a a sees 42 Main Power Connector 26 Maintenance Log 0000e eee 62 Maintenance Precautions onana nunun 15 Maintenance Pernod 40 41 Malfunction Indicator nanana 23 Modifications 5 0 Obstacles lt icc ecsec ee d Or raia ea 33 Oil Change Front Gearcase 0 5 43 Main Gearcase 42 Transaxle 2 02 0 0 e ee eee ee 42 Oil Level Front Gearcase 43 Main Gearcase 42 Transaxle iiec ee 42 Operation Range etre Le ER woes 25 Operator Safety vss ceoVeci rev evans 3 10 15 P Park Brake Levers es cia cece sees eee ceed 19 Parking on an Incline o an nananana 34 Parking the RANGER 4 38 Periodic Maintenance Chart 40 41 Polaris Products 0000 eee eee 57 Polishing the Vehicle 53 Pre Ride Inspection serors E TE A REE 2000 29 Pressure Tire lt hoses 4 actin ers ee deck Id 6 R Range of Operation sannan aan annn 25 Removing the Vehicle from Storage 55 Reverse Operatot ics eve eae eth een ae we 34 Riding Gear ere sates Rp ache eae 9 Roll Over Protection System 27 ROPS Cab Frame
54. lash Less than 80 of charge is completed Green Slow Flash More than 80 of charge is completed Amber Flashing Power mode is reduced low AC voltage or high internal charger temperature exists open hood to improve air flow Red Flashing Charger error exists reset charger power and refer to Trou bleshooting Guide on page 23 Key Switch Move the direction selector switch to neutral then turn the key to the ON position to activate the electrical circuits Tip The accelerator will not start the motor if the direction selector switch is in forward or reverse when the key is turned on Switch to neutral then choose forward or reverse Turn the key to the OFF position to disable all electrical cir cuits The key can be removed from the switch when it is in the OFF position 19 FEATURES AND CONTROLS Console Drive Mode Switch CAUTION Changing the drive mode switch position while driving High could result in an automatic increase or decrease in speed without a g change to accelerator pedal pressure Press the top of the switch to select high mode Use high Maximum mode for most trail riding conditions The vehicle will oper Range ate at speeds up to 25 MPH 40 km h Press the bottom of the switch to select low mode Low mode is recommended for short term operation in extreme load conditions Use low mode when towing hauling loads or maneuvering over obstacles Speed will be limited to a maximum of 10 MPH 16 km
55. ly before operating Malfunction Park Brake Neutral Gear p Pt Y Y 2 SHEP S2 N M S Y X N Motor Controller Reverse Forward High Temperature Gear Gear 22 FEATURES AND CONTROLS Malfunction Indicator Troubleshooting Guide The malfunction codes will blink on the controller The code definitions provided here are for informational purposes only Tip If the indicator illuminates due to a minor issue such as a low voltage condition or a sequence fault reversing direction without releasing the accelerator turning the key on while in forward or reverse select neutral and turn the key off and on to clear the error If the error does not clear please see your POLARIS dealer for diagnosis and repair of Blinks Code Definition Steady Key was turned on in forward or reverse switch to neutral then to forward or reverse Data or configuration error Sequence fault Power fault Contactor issue Throttle input error Voltage protection j N Oo A GI N gt Controller or motor out of temperature range 13 Software fault Charge Status Indicator Troubleshooting Guide The code definitions provided are for informational purposes only Please see your POLARIS dealer for
56. materials away from the drive system Precautions During Maintenance WARNING Do not work in or near the battery compartment or on any other electrical component of the vehicle while charging the batteries Always disconnect the main power connector before servicing or unplugging any electrical components See page 26 Always follow all safety instructions in the maintenance portion of this owner s manual as well as the following Make sure the vehicle is properly immobilized before beginning any maintenance Always block the chassis securely before working under the vehicle Turn the key off and remove it from the vehicle Insulate any tools used within the battery area to prevent sparks or battery explosion caused by short ing the battery terminals or wiring Remove the batteries or cover the exposed terminals with an insu lating material FOR MORE INFORMATION ABOUT SAFETY call POLARIS at 1 800 342 3764 15 FEATURES AND CONTROLS Component Locations ROPS ae Headlights S Z 31 Go S Tailgate Latch Releases Tailgate J n iSi DRY H IN pa Taillight Reflector CV Boot Rear Caliper 16 Console WO JO EM MA 10 11 12 Park Brake Lever Headlight Switch Charge Status Indicator AWD Switch Battery Discharge Indicator Hour Meter Charge Plug Holder 12V Auxiliary Outlet Drive Mode Switch Direction Selector Key Switch Indicator Lights
57. mers do not install on a POLARIS RANGER any equip ment that may increase the speed or power of the vehicle or make any other modifications to the vehicle for these purposes Any modifications to the original equipment of the vehicle create a substantial safety hazard and increase the risk of bodily injury The warranty on your POLARIS RANGER is terminated if any equipment has been added to the vehicle or if any modifications have been made to the vehicle that increase its speed or power The addition of certain accessories including but not limited to mowers blades tires sprayers or large racks may change the handling characteristics of the vehicle Use only POLARIS approved accessories and familiarize yourself with their function and effect on the vehicle 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 Passenger Tire Pressure Warning WARNING Passengers can be thrown off This can cause serious injury or death Never carry passengers in cargo
58. n in a cool dry place Be sure the storage area is well ventilated Turn the key off Do not set the park brake Verify that tire pressure is at specification Block the wheels to prevent rolling Fully charge the batteries Leave the charger connected to maintain a full charge during the storage period or check battery voltage each month during storage and recharge as needed to maintain a full charge If the charger remains connected check it monthly to verify proper operation Do not use plastic or coated materials They do not allow enough ventilation to prevent condensa tion and may promote corrosion and oxidation WARNING Do not cover the vehicle while the charger is connected Dangerous levels of hydrogen gas could accumulate Removal from Storage ON tn de U r5 x Inspect all battery connections Verify that batteries are fully charged Verify that tire pressure is at specification Perform the pre ride inspection See page 29 Inspect and verify the tightness of the bolts nuts and other fasteners Lubricate at the intervals outlined in the Periodic Maintenance Chart beginning on page 55 SPECIFICATIONS Dry Weight RANGER EV 1750 Ibs 793 8 kg Ground Clearance 10 in 25 4 cm Length 108 in 274 3 cm Width 56 5 in 143 5 cm Height 73 in 185 4 cm Wheelbase 72 in 183 cm Turning Radius Box Dimensions Inside 150 in 381 cm Load Capacity 32 x 42 x 11 5 in
59. nauthorized use Transporting the RANGER When transporting the RANGER for a long distance or on public streets always use a trailer with an approved load rating greater than the RANGER 5 curb vehicle weight of 1700 lbs 771 kg plus any installed accessories or cargo Follow these guidelines when transporting the RANGER 1 Place the direction selector in neutral 2 Setthe park brake 3 Remove the key to prevent loss 4 Secure the seat hood and tailgate latches 5 Always tie the frame of the RANGER to the transporting unit securely with suitable straps 6 Ifusing an open trailer remove the windshield if equipped Never allow passengers on a trailer or in a trailered vehicle 8 Reduce speed and drive with caution 38 OPERATION All Wheel Drive AWD Press the top of the rocker switch to engage All Wheel Drive AWD Once enabled the AWD remains enabled until the switch is turned off T T The AWD switch may be turned on or off while the vehi 7 cle is moving When the AWD switch is on the front gt 4 gearcase will automatically engage any time the rear wheels lose traction When the rear wheels regain trac AWD 2WD tion the front gearcase will automatically disengage Tip AWD will not engage initially until speed is less than 5 MPH 8 km h Engage the AWD before getting into conditions where front wheel drive may be needed If the rear wheels are T spinning release the accelerator before swit
60. nd cause serious injury or death AWARNING Battery electrolyte is poisonous It contains sulfuric acid Serious burns can result from contact with skin eyes or clothing Antidote External Flush with water Internal Drink large quantities of water or milk Follow with milk of magnesia beaten egg or vegetable oil Call physician immediately Eyes Flush with water for 15 minutes and get prompt medical attention Batteries produce explosive gases Keep sparks flame cigarettes etc away Ventilate when charging or using in an enclosed space Always shield eyes when working near batteries KEEP OUT OF REACH OF CHILDREN 49 MAINTENANCE Batteries Battery Charging When not in use park the vehicle and connect the battery charger The vehicle s charging cord is located inside the charge plug holder on the console WARNING Failure to provide adequate ventilation while charging batteries can result in an explosion Hydrogen gas is emitted during charging and will rise and accumulate at the ceiling Always ensure a minimum of five 5 air changes per hour in the charging area Never charge the batteries in an area subject to a flame or spark including areas containing gas or propane water heaters and furnaces Do not smoke in the charging area Always follow these precautions when charg Charging Cord ing the batteries 1 Position the vehicle on a level surface 2 Make sure the charging area is well ventilated
61. ng the procedures marked with a D could result in component failure and lead to serious injury or death Have an authorized POLARIS dealer perform these services 40 Periodic Maintenance Chart Perform all services at whichever maintenance interval is reached first MAINTENANCE Item Maintenance Interval Remarks whichever comes first Hours Calendar Miles Km Steering Front suspension Rear suspension Tires Brake fluid level PreRie needed See Pre Ride Checklist on Brake pedal travel page 29 Brake system Wheels fasteners Frame fasteners Batteries Headlamp tail lamp Daily Check operation apply dielectric grease if replacing Fs Brake pad wear 10H Monthly Inspect periodically Battery terminals 25H Monthly Inspect and clean page 51 Battery fluid levels 25H Monthly Add as needed page 51 Battery terminals 25H Monthly Inspect torque to specification gt Front gearcase oil 25H 1M Perform a break in oil level check gt Main gearcase oil Transaxle 25H 1M Perform a break in oil level check gt General lubrication 50 H 3M Lubricate all fittings pivots cables etc D Steering 50 H 6M Lubricate gt Front Suspension 50 H 6M Lubricate gt Rear Suspension 50 H 6M Lubricate gt Front gearcase oil 100 H 12M Perform a break in
62. nic control box connections Inspect clean reinstall connectors Required torque exceeds motor capability In neutral cycle key off and on select low range then select direction 58 WARRANTY LIMITED WARRANTY POLARIS Sales Inc 2100 Highway 55 Medina MN 55340 gives a SIX MONTH LIMITED WARRANTY on all components of the POLARIS RANGER against defects in material or workmanship Waranty period will vary by region POLARIS also supports a one year limited supplier warranty covering defects in material or workman ship on the factory installed 12 volt batteries in the 48 volt system This warranty covers the parts and labor charges for repair or replacement of defective parts which are covered by this warranty This warranty begins on the date of purchase This warranty is transferable to another consumer during the warranty period through a POLARIS dealer REGISTRATION At the time of sale the Warranty Registration Form must be completed by your dealer and submitted to POLARIS within ten days Upon receipt of this registration POLARIS will record the registration for warranty No verification of registration will be sent to the purchaser as the copy of the Warranty Registration Form will be the warranty entitlement If you have not signed the original registration and received the customer copy please contact your dealer immediately NO WARRANTY COVERAGE WILL BE ALLOWED UNLESS YOUR VEHICLE IS REGISTERED WITH POLARIS Initial
63. of traction loss of control accident or overturn Do not operate on excessively slippery surfaces Always reduce speed and use additional caution when operating on slippery surfaces Stalling While Climbing a Hill Stalling or rolling backwards while climbing a hill could cause an overturn Always maintain a steady speed when climbing a hill If all forward speed is lost Apply the brakes Switch to reverse and slowly allow the vehicle to roll straight downhill while applying light brake pres sure to control speed If you begin rolling downhill Never press the accelerator Apply the brakes gradually until the vehicle is fully stopped Switch to reverse and slowly allow the vehicle to roll straight downhill while applying light brake pres sure to control speed Improper Hill Climbing Climbing hills improperly can cause loss of control or vehicle overturn Always follow proper procedures for climbing hills as described in the owner s manual See page 32 14 SAFETY Operator Safety Descending Hills Improperly Improperly descending a hill could cause loss of control or overturn Always follow proper procedures for traveling down hills as described in the owner s manual Use the brake pedal to control speed when descending a hill Never travel down a hill at high speed Always descend a hill with the direction selector on FORWARD Never descend a hill in neutral Always check the terrain carefully before des
64. oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 40 Maintain the oil level even with the bottom thread of the fill plug hole Refer to the Gearcase Specifications Chart on page 42 for recommended lubricants capaci ties and torque specifications See page 57 for the part numbers of POLARIS products Oil Check The front gearcase fill plug is located on the left side of the front gearcase 1 Position the vehicle on a level surface 2 Remove the fill plug Check the oil level 3 Add the recommended oil as needed 4 Reinstall the fill plug Torque to specification Oil Change 1 Support the vehicle securely with a jackstand Remove the front tire on the driver s side Remove the fill plug Place a drain pan under the drain plug QA e MZ Jd Remove the drain plug Allow the oil to drain completely 6 Clean the drain plug Reinstall the drain plug Torque to specification 7 Add the recommended oil 8 Reinstall the fill plug Torque to specification 9 Check for leaks 10 Discard used oil properly 7 Drain Plug s Fill Plug 43 MAINTENANCE Brakes The front and rear brakes are hydraulic disc type brakes Press down on the brake pedal to engage the brakes See page 27 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
65. onents Drive belts Clutches and components Hydraulic components Steering components Circuit breakers Fuses Batteries Electronic components Light bulbs Sealed beam lamps Warranty applies to the product only and does not allow for coverage of personal loss Some items are considered consumable meaning they are considered part of normal maintenance or part of completing an effective repair The following items are excluded from warranty coverage in the event of a warranty claim Filters Lubricants such as oil grease etc Sealants Cosmetic damage repair Hotel fees Meals Towing charges Shipping handling fees Mileage Product pick up delivery Rentals Loss of product use Loss of vacation personal time Batteries unless deemed defective by the POLARIS Warranty Department and the battery supplier 59 WARRANTY LIMITATIONS OF WARRANTIES AND REMEDIES This warranty also excludes failures resulting from improper lubrication improper engine timing improper fuel surface imperfections caused by external stress heat cold or contamination operator error or abuse improper component alignment tension adjustment or altitude compensation failure due to snow water dirt or other for eign substance ingestion contamination improper maintenance modified components use of aftermarket com ponents resulting in failure unauthorized repairs repairs made after the warranty period expires or by an una
66. ously affect handling and control With non POLARIS approved accessories they may seriously affect stability ALWAYS Wear your seat belt Vehicle rollover could cause severe injury or death Wear a helmet and eye protection and keep hands and feet in vehicle at all times Reduce speed and use extra caution when carrying a passenger Avoid sharp turns or turns while applying heavy throttle Operate slowly in reverse avoid sharp turns or sudden braking Make sure passenger reads and understands all safety labels Watch for branches or other hazards that could enter vehicle LOCATE AND READ OWNER S MANUAL FOLLOW ALL INSTRUCTIONS AND WARNINGS 7176169 Safe Riding Gear Always wear appropriate clothing when riding a POLARIS vehicle Wear protective clothing for comfort and to reduce 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 followed by the distinguishing number of the country which has granted approval The approval number and serial number will also be displayed on the label Eye Protection SAFETY K Long Sleeves 0 Over
67. p angles in reverse Always use the proper size and type of tires specified in this manual Always maintain proper tire pressure as specified on safety labels Never modify this vehicle through improper installation or use of accessories Never exceed the stated load capacity for this vehicle Cargo should be properly distributed and securely attached Reduce speed and follow the instructions in this manual for hauling cargo or pulling a trailer Allow a greater distance for braking Always set the park brake and remove the key when leaving the vehicle unattended 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 11 SAFETY Operator Safety AWARNING Failure to operate the RANGER properly can result in a collision loss of control accident or overturn which may result in serious in
68. perat ing practices outlined in this manual to avoid vehi cle rollover WARNING Vehicle rollover could cause severe injury or death Always avoid operating in a manner that could result in vehicle rollover Seat Removal Pull up on the front of the seat to disengage the front latches Slide the seat forward and lift it away from the seat base To reinstall the seat align the rear seat tabs with the slots on the rear of the seat base Slide the seat fully rearward then push down firmly along the front edge of the seat to secure the latches 27 FEATURES AND CONTROLS Seat Belts This POLARIS vehicle is equipped with three point lap and diagonal seat belts for the operator and passenger Always make sure the seat belts are secured for all riders before oper ating Latch Plate The center of the seat is NOT equipped with a seat belt Never allow a passenger to ride between the operator and passenger seats 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 For 3 point belts pull the seat belt latch downward and across your chest toward the buckle at the inner edge of the seat The belt should fit snugly across your hips and diagonally across your chest Make sure the belt is not twisted 2 Push the latch plate into the buckle until it clicks 3
69. peration Range 25 Replacement 0 51 BO E 9 Brake Lever Park 0 0 0 0 RN eee eee 19 Brake Lights eedem EE RR RES 48 Brake Pedal i eere reete 27 DATARS L irc since ae tire ee ARIS MIR ATIS 44 Brake Fluid v sce cy Z E d ET RTE RL pe bem es 44 Brake Inspection e oec da Raceway 44 C Cab Frame ROPS isse pas R RRR 27 Cat Os osc energie deed xe d he Paes QE ace bats 35 Cargo Box Dumping 0 37 Charge Status Indicator 19 23 Charger Operation 0 siss 25 Charging Batteries 2 0000 50 Charging Cotd scores hi mor heen ees E 18 Chrome Wheel Care 00000004 53 Cleaning and Storage 52 54 Clothing i e eee bt mes 9 Component Locations 04 16 Console c e eee E e d v 17 22 Corrosion Removal Chrome 53 D Differential Locking n an aaa RR Rae R 39 Direction Selector 02 005 21 Discharge Indicator llis esses 18 Disengaging AWD 0 00 0 000 39 Drive Mode Switch R R R e R 20 D Driving Downhill 0 0000 32 Driving in Reverse 0000 00 34 Driving on a Sidehill n nnn nananana 32 Driving on Slippery Surfaces 31 Driving Over Obstacles 33 Driving Proc dure sexe tIBORPTEG ER 30 Driving Through Water ls suse 33 Driving Up
70. ponent damage We recommend the use of POLARIS lubricants for this vehicle Damage resulting from the use of non recommended lubricants may not be covered by warranty Exported Vehicles EXCEPT WHERE SPECIFICALLY REQUIRED BY LAW THERE IS NO WARRANTY OR SERVICE BUL LETIN COVERAGE ON THIS VEHICLE IF IT IS SOLD OUTSIDE THE COUNTRY OF THE SELLING DEALER S AUTHORIZED LOCATION This policy does not apply to vehicles that have received authorization for export from POLARIS Industries Dealers may not give authorization for export You should consult an authorized dealer to determine this vehicle s warranty or service bulletin coverage if you have any questions This policy does not apply to vehicles registered to government officials or military personnel on assignment out side the country of the selling dealer s authorized location This policy does not apply to Safety Bulletins How to Get Service In the Country where your vehicle was purchased Warranty or Service Bulletin repairs must be done by an authorized POLARIS dealer If you move or are travel ing within the country where your vehicle was purchased Warranty or Service Bulletin repairs may be requested from any authorized POLARIS dealer who sells the same line as your vehicle Outside the Country where your vehicle was purchased If you are traveling temporarily outside the country where your vehicle was purchased you should take your vehicle to an authorized POLARIS dealer You m
71. r hills Always follow proper procedures for climbing hills as described in this manual Check the terrain carefully before attempting to climb a hill Never climb hills with excessively slippery or loose surfaces Never go over the top of a hill at high speed SAFETY Operator Safety Always follow the proper procedures outlined in this manual for traveling downhill and for braking on hills Check the terrain carefully before descending a hill Never travel downhill at high speed Avoid going downhill at an angle which would cause the vehicle to lean sharply to one side Travel straight down the hill where possible Always check for obstacles before operating in a new area Never attempt to operate over large obstacles such as rocks or fallen trees Always follow the proper procedures outlined in this manual when operating over obstacles Always be careful of skidding or sliding On slippery surfaces such as ice travel slowly and exercise caution to reduce the chance of skidding or sliding out of control Never operate your vehicle in fast flowing water or in water deeper than that specified in this manual Wet brakes may have reduced stopping ability Test your brakes after leaving water If necessary apply them lightly several times to let friction dry out the pads Always be sure there are no obstacles or people behind your vehicle when operating in reverse When it s safe to proceed in reverse move slowly Avoid turning at shar
72. rn Avoid operating the vehicle on pavement If it s unavoidable travel slowly and avoid sudden turns or stops 13 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 In some areas it s unlawful to operate this vehicle on public streets roads and highways Turning Improperly Turning improperly could cause loss of traction loss of control accident or overturn Always follow proper procedures for turning Never turn abruptly or at sharp angles Never turn at high speeds Practice turning at slow speeds before attempting to turn at faster speeds Jumps and Stunts Attempting wheelies jumps and other stunts increases the risk of an accident or overturn Never attempt wheelies jumps or other stunts Avoid exhibition driving Operating in Unfamiliar Terrain Failure to use extra caution when operating on unfamiliar terrain could result in an accident or overturn Unfamiliar terrain may contain hidden rocks bumps or holes that could cause loss of control or overturn Travel slowly and use extra caution when operating on unfamiliar terrain Always be alert to changing terrain conditions Operating on Slippery Terrain Failure to use extra caution when operating on excessively rough slippery or loose terrain could cause loss
73. the Ankle Boots 051039 0006 31 Do not depend on eyeglasses or sunglasses for eye protection Whenever riding a 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 Do not ride a POLARIS vehicle with bare feet Clothing Wear long sleeves and long pants to protect arms and legs SAFETY Operator Safety AWARNING Serious injury or death can result if you do not follow these instructions and procedures which are ou 10 tlined in further detail within your owner s manual Read this manual and all labels carefully Follow the operating procedures described Never allow anyone under age 16 to operate this vehicle and never allow anyone without a valid driver s license to operate this vehicle Do not carry a passenger until you have at least two hours of driving experience with this vehicle No person under the age of 12 may ride as a passenger in this vehicle Any passenger must be able to comfortably reach the floor and hand holds The driver and all passengers must wear helmet eye protection gloves long sleeve shirt long pants over the ankle boots and seat belt at all
74. the warranted product at no cost to the purchaser during the replacement period ALL IMPLIED WARRANTIES INCLUDING BUT NOT LIMITED TO THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE ARE LIMITED IN DURATION TO THE ABOVE SIX MONTH WARRANTY PERIOD POLARIS FURTHER DISCLAIMS ALL EXPRESS WARRANTIES NOT STATED IN THIS WARRANTY Some states do not allow limitations on how long an implied warranty lasts so the above limitation may not apply to you if inconsistent with controlling state law HOW TO OBTAIN WARRANTY SERVICE If your vehicle requires warranty service you must take it to a POLARIS Servicing Dealer When requesting war ranty service you must present your copy of the Warranty Registration form to the dealer THE COST OF TRANSPORTATION TO AND FROM THE DEALER IS YOUR RESPONSIBILITY POLARIS suggests that you use your original selling dealer however you may use any POLARIS Servicing Dealer to perform warranty service Please work with your dealer to resolve any warranty issues Should your dealer require any additional assistance they will contact the appropriate person at POLARIS This warranty gives you specific legal rights and you may also have other rights which vary from state to state If any of the above terms are void because of state or federal law all other warranty terms will remain in effect 60 WARRANTY Lubricants Mixing lubricant brands or using non recommended lubricants may cause com
75. ust show the dealer photo identification from the country of the selling dealer s authorized location as proof of residence Upon residence verification the servicing dealer will be authorized to perform the warranty repair If You Move If you move to another country be sure to contact POLARIS Customer Assistance and the customs department of the destination country before you move Vehicles importation rules vary considerably from country to country You may be required to present documentation of your move to POLARIS Industries in order to continue your warranty coverage You may also be required to obtain documentation from POLARIS Industries in order to reg ister your vehicle in your new country You should warranty register your vehicle at a local POLARIS dealer in your new country immediately after you move to continue your warranty coverage and to ensure that you receive safety information and notices regarding your vehicle If Purchased From A Private Party If you purchase a POLARIS product from a private citizen to be kept and used outside of the country in which the vehicle was originally purchased all warranty coverage will be denied You must nonetheless warranty regis ter your vehicle under your name and address with a local POLARIS dealer in your country to ensure that you receive safety information and notices regarding your vehicle Notice If your vehicle is registered outside of the country where it was purchased and you h
76. ut Type Location Nut Torque Lug Nut Aluminum Wheels Front and Rear 30 ft Ibs 41 Nm PLUS 1 4 TURN 90 degrees Nut and Washer Steel Wheels O Front and Rear 35 ft Ibs 47 Nm O Spindle Nut Front 70 ft Ibs 95 Nm Hub Retaining Nuts Center and Rear 110 ft Ibs 150 Nm Wheel Removal Apply the brakes Set the park brake Turn the key off Loosen the wheel nuts slightly Elevate the side of the vehicle by placing a suitable stand under the frame Poe NS Remove the wheel nuts and washers Remove the wheel Wheel Installation 1 Set the park brake Place the wheel in the correct position on the wheel hub Be sure the valve stem is toward the outside and rotation arrows on the tire point toward forward rotation WARNING Improperly installed wheels can adversely affect tire wear and vehicle handling which can result in serious injury or death Always ensure that all nuts are torqued to specification Do not service axle nuts that have a cotter pin installed See your POLARIS dealer 2 Attach the wheel nuts and washers and finger tighten 3 Carefully lower the vehicle to the ground 4 Torque the wheel nuts to specification See page 46 46 MAINTENANCE Lights Poor lighting can result in reduced visibility when driving Headlight and taillight lenses become dirty during normal operation Clean lights frequently and replace burned out lamps promptly Always make sure lights are adjusted properly for best
77. uthorized repair center use of the product in competition or for commercial purposes Warranty will not apply to any product which has been damaged by abuse accident fire or any other casualty not determined a defect of materials or workmanship The POLARIS limited warranty excludes any battery failures that are not caused by a defect in material or work manship Warranty claims for battery replacements require specific testing as outlined by the POLARIS Warranty Department and the battery manufacturer U S Battery prior to replacement If the POLARIS Warranty Depart ment in conjunction with U S Battery determines that the failure of the battery is caused by a defect in material or workmanship POLARIS will assist with the processing of the warranty claim through U S Battery for a replacement battery This warranty does not cover the time required to test and or diagnose issues with the bat tery Consequential damage caused by defective batteries are excluded from this warranty Use of any charger not recommended by POLARIS and or modifications to the vehicle will void any stated or implied warranty on the battery Battery warranty exclusions include damage caused by abuse or neglect such as improper fluid levels loose wiring or rusted or corroded hardware lack of proper maintenance improper installation of the battery neglect breakage freezing fire explosion or wreckage the addition of any chemical operation of the battery in an overch
78. visibility When servicing a halogen lamp don t touch the lamp with bare fingers Oil from your skin leaves a residue causing a hot spot that will shorten the life of the lamp Headlight Lamp Replacement 1 Open the hood CAUTION Hot components can cause burns to skin Allow lamps to cool before servicing Wiring Harness 2 Unplug the headlamp from the wiring har ness Be sure to pull on the connector not on the wiring 3 Turn the lamp counter clockwise to remove it 4 Install the new lamp Tip Make sure the tab on the lamp locates properly in the housing 5 Reinstall the harness assembly into the headlight assembly Headlight Beam Adjustment 1 Place the vehicle on a level surface with the headlight approxi mately 25 ft 7 6 m from a wall 2 Measure the distance from the floor to the center of the headlight and make a mark on the wall at the same height 3 Apply the brakes Turn the key on Turn the headlights on 4 Observe the headlight aim The most intense part of the headlight beam should be aimed 8 20 cm below the mark placed on the wall Include the weight of a rider on the seat while performing this step 5 Ifa headlight needs adjustment access the adjustment screw under the hood or through the wheel well 6 Loosen the screw adjust the headlight and tighten the screw 7 Repeat steps 4 6 until the lamp is properly adjusted 47 MAINTENANCE Lights Brake Lights

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