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RANGER XP® 900

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1. Tailgate 18 FEATURES AND CONTROLS Console Gear Selector Instrument gt Storage Cluster Shifter Tray Cup Holder 12V Auxiliary Storage Outlets Compartment Auxiliary Outlets The 12 volt receptacles have spade connections on the back that may be used to power an auxiliary light or other optional accessories or lights The connections are behind the con sole under the dash Gear Selector High Gear Low Gear Neutral Reverse Park Low gear is the primary driving range for the RANGER High gear is intended for use on hard packed surfaces with light loads YWZ To shift gears brake to a complete stop When the engine is idling move the lever to the desired gear NOTICE Shifting gears with the engine speed above idle or while the vehicle is moving could cause transmission damage Always shift when the vehicle is stationary and the engine is at idle Tip Maintaining shift linkage adjustment is important to assure proper transmission function See your dealer if you experience any shifting problems Using Low Range Always shift into low gear for any of the following conditions Operating in rough terrain or over obstacles Loading the vehicle onto a trailer Towing heavy loads FEATURES AND CONTROLS Switches Ignition Switch The ignition
2. 00 000 59 Vehicle Transport 233 34 sacsan cated end sacs 75 Ww Warning Symbols 00000 eee 5 Warning Transmission Modification 58 59 Washing the Vehicle 000 72 Water Immersion of Vehicle 59 Wheel Installation lle sees 66 Wheel Nut Inspection sa 69 aA R R A esses 65 Wheel Nut Torgus cereis tian ea 0 000000 e eee 65 Wheel Removal sara Ke R RRR R R R R 66
3. 00 58 R Radiator eee wy ey vea ed 56 Radiator Coolant Level 57 Rear Suspension Adjustment n aa aea 64 Receiver Hitch i2 isum et EE RES ER E 21 Removing the Vehicle from Storage 75 Reverse Operation 0 000002 ee eee 39 Rider Information Center 27 30 Riding Gear i ox eve emer pes 11 Rollover Protective Structure uuaa 24 ROPS Cab Frame a R 0 3 een 24 89 INDEX S Safety Labels a xvi ERREUR 8 10 Safety Symbols 4 552542 sda oda e reris 5 Seat Belts cn e r ane eee ever 25 Seat Removal en ede ene ere eren pde 22 Severe Use Definition 47 EI E E E ceke toes EET ET 19 Shifting Gears seses aR RRR RRR iris 19 Shock Spring Adjustment 64 Signal Words s 0549 R R R BEA RRR R R 00 5 Spark Arrester Warning 61 Spark Plug Gap ioco Rr Re Re 55 Spark Plug Inspection 55 Spark Plug Recommendations 55 Spark Plug Tode nanunua naan 55 Spark PlUBS 4 rox enso mnc er pei mee meds 55 Spark Plugs Fouled 00 55 Specifications 00 000 ses 76 77 Specifications Gearcase 0 53 Speed TOWING osse sor dtus neni e rr regne 42 Speedometer TTT 26 Spring Shock Adjustment 64 Stabilizing the Fuel prp 65 69 SATA S 73 Starting the Engine x e 0 a r 0 K dR R R R R N 33 Steering Wheel Inspection 63 Steering Wheel Adjustme
4. TR UPTD 31 Emission Control Systems L 46 Maintenance xs e ag a ee pe ake RR piunt Ve m IR Be dm 47 SPECINCAUONS ca s aeaa 99 N ga R R ce RRR R ee eee waa 76 POLARIS Products kx Rr enr kee ee Ree eee aes 78 Troubleshooting css sss tO Geechee EESTI LEES 79 Lr caaw hen A E E EEE E aaa a ewe adees 82 Maintenance Log 22229 hh x Re e mcn 87 WG GX sresti ee ene wor eati d deser eed Gee eee eee a E 88 INTRODUCTION Failure to follow the warnings contained in this manual can result in severe injury or death A POLARIS RANGER is not a toy and can be hazardous to operate This vehicle handles differently than other vehicles such as motorcycles and cars A collision or rollover can occur quickly even during routine maneuvers like turning or driving on hills or over obstacles if you fail to take proper precautions e 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 atleast 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 use the cab nets while riding in this vehicle
5. 22 FEATURES AND CONTROLS Fuel Cap The fuel tank filler cap is located on the left side of the vehicle near the driver s seat Use only unleaded gasoline with a minimum pump octane number of 87 R M 2 octane Unleaded fuel blends with up to 10 ethanol can be used NOTICE Never use fuel blends with more than 10 ethanol Engine damage could occur Hood Latches Remove the hood to access the coolant overflow bottle the radiator cap and the headlight adjustment screws To remove the hood rotate the hood ne latches 1 4 turn and lift the hood away from the vehicle 23 FEATURES AND CONTROLS Rollover Protective Structure ROPS The Rollover Protective Structure ROPS on this vehicle meets OSHA 1928 53 rollover performance requirements Always have your authorized POLARIS dealer thoroughly inspect the ROPS if it ever becomes damaged in any way No device can assure occupant protection in the event of a rollover Always follow all safe operating practices outlined in this manual to avoid vehicle rollover WARNING Vehicle rollover could cause severe injury or death Always avoid operating in a manner that could result in vehicle rollover Cab Nets Riding in this vehicle without using the cab nets increases the risk of serious injury or death in the event of an accident or overturn Cab nets must be used by both operator and passen gers at all times Make sur
6. On paved surfaces pavement may seriously affect handling and control With non POLARIS approved accessories they may seriously affect stability ALWAYS Wear your seat belt Vehicle rollover could cause severe injury or death Secure cab nets and keep hands and feet in vehicle at all times Wear a helmet and eye protection Reduce speed and use extra caution when carrying passengers Avoid sharp turns or turns while applying heavy throttle Operate slowly in reverse avoid sharp turns or sudden braking Make sure passengers read and understand all safety labels LOCATE AND READ OWNER S MANUAL FOLLOW ALL INSTRUCTIONS AND WARNINGS 7178544 SAFETY Safety Labels and Locations Load Passenger Tire Pressure Warning Storage Box Load 250 Ibs 113 kg WARNING Passengers can be thrown off This can cause serious injury or death Never carry passengers in cargo box 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 MAXIMUM CARGO BOX LOAD 1000 Ibs 454 kg TIRE
7. Some coolant level drop on new vehicles is normal as the system is purging itself of trapped air Observe coolant levels and maintain as recommended by adding coolant to the overflow bottle Adding or Changing Coolant To ensure that the coolant maintains its ability to protect the engine we recommend that the system be completely drained every two years and a fresh mixture of antifreeze and water added POLARIS recommends the use of POLARIS Premium 60 40 anti freeze coolant or a 50 50 mixture of high quality aluminum compatible anti freeze coolant and distilled water POLARIS Premium 60 40 is already premixed and ready to use Do not dilute with water See page 78 for the part numbers of POLARIS products Always follow the manufacturer s mixing recommendations for the freeze protection required in your area Any time the cooling system has been drained for maintenance or repair replace the coolant If the recovery bottle has run dry the level in the radiator should be inspected Add coolant as needed Radiator and Cooling Fan Always check and clean the screen and radiator fins at the intervals outlined in the Periodic Maintenance Chart beginning on page 47 Do not obstruct or deflect air flow through the radiator by installing unauthorized accessories in front of the radiator or behind the cooling fan Interference with the radiator air flow can lead to overheating and consequent engine damage NOTICE Washing the vehicle with a high p
8. 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 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 1s 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 INTRODUCTION Vehicle Identification Numbers Record your vehicle s identification numbers and key number in the spaces provided Remove the spare key and store it in a safe place An ignition key can be duplicated only by ordering a POLARIS
9. PMS 419 RANGER XP 900 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 A WARNING The engine exhaust from this product contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm 00 RECYCLED The text is printed on 100 recycled with 40 post consumer waste PCW PMS 419 AWARNING Improper vehicle use can result in SEVERE INJURY or DEATH NEVER Operate If you are under age 16 and without a valid driver s license At speeds too fast for your skills or the conditions After or while using Alcohol or Drugs On hills steeper than 15 degrees On public roads a collision can occur with another vehicle With more than two passengers or passengers under age twelve or who cannot comfortably reach the floor and hand holds On paved surfaces pavement may seriously affect handling and control With non Polaris approved accessories they may seriously affect stability ALWAYS Wear your seat belt Vehicle rollover can cause severe injury or death Secure cab nets and keep hands and feet inside vehicle at all times Wear a helmet eye protection gloves long sleeve shirt long pants and ov
10. 1 Place the transmission in PARK 2 Remove the retaining screw and remove the arrester from the end of the muffler Screen 3 Use a non synthetic brush to clean the arrester screen A synthetic brush may melt e if components are warm If necessary blow debris from the screen with compressed air Retaining 4 Inspect the screen for wear and damage Screw Replace a worn or damaged screen 5 Reinstall the arrester 6 Torque the bolts to 5 7 ft Ibs 7 9 Nm 61 MAINTENANCE Brakes The front and rear brakes are hydraulic disc type brakes activated by the brake pedal See page 21 Brake Fluid Inspect the brake system routinely Inspect the level of the brake fluid before each operation WARNING After opening a bottle of brake fluid always discard any unused portion Never store or use a partial bottle Brake fluid is hygroscopic meaning it rapidly absorbs moisture from the air The moisture causes the boiling temperature of the brake fluid to drop which can lead to early brake fade and the possibility of accident or severe injury Change the brake fluid every two years and any time the fluid becomes contaminated the fluid level is below the minimum or if the type and brand of the fluid in the reservoir are unknown l Position the vehicle on a level surface Maximum 2 Place the transmission in PARK 3 View the brake fluid level at the reservoir in the driver s side wheel well 4 Thelevel should be betwe
11. 2 Damage resulting from the use of non recommended lubricants may not be covered by warranty 83 WARRANTY SPARK ARRESTER POLARIS warrants that the spark arrester in this vehicle will meet the efficiency requirements of USFS standard 5100 1c for at least 1000 hours when subjected to normal use and when maintenance and installation are in accor dance with POLARIS recommendations 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 yo
12. All Wheel Drive cece cece ees 44 45 Disengaging AWD 44 Engaging AWD 44 Locking the Differential 45 All Wheel Drive Switch 0 20 Arrester Spark Warning 61 Auxiliary Outlets 6 ga R R da R R RRR RRR 19 Axle Nut Inspection sss esses 65 Axle Nut Torque i21 Rd coge t dp hs 65 B Battery 5 v x xx IRE sxx aren 70 71 Charging 0 0005 71 Installation 04 70 Removal aas cs ea kin eds en 70 DLODABE actus lt a aise kaha ca een Un te 70 Beam Adjustment Headlight 68 Belt Burning sssr song ck ecenin te E d 79 Bet E ocn ore nern dio diee 42 Belt Replacement 1 9 E serieren esses 58 Belt Wear asrin nzRPION GREY ena ae ERa 79 BOOtS rb o bs acere Db E Qu re eed 11 Brake Fluid aR ec kem eee 62 Brake Inspection osc T 2 ee ex 63 Brake Light Inspection 67 Brake Pedal 2 hri en rte 21 Brakes eA fed aces e e a eec dre aod 62 63 Braking 52 2 e e e ERREUR 33 Break In Period ead Raa Ra eee ee 31 C Cab Frame ROPS sci ck d estate erate ed eae 24 Cab Netse cones Pav aie eats Rep P Raed 24 CAL BO M Nr ERO 41 Cargo Box Dumping sasass asar nn n 43 Chart Gearcase Specifications 53 Chart Periodic Maintenance 47 49 Check Engine Indicator e una eesnnna 30 Cleaning and Storage anunaaan 72 74 Clothing igs eds ov See a bee hee 11
13. Clute hing se fon ciate acetals genie eeii TR oC ail T Component Locations 000 18 Console ces drei oe p dE 19 Coolant Level Overflow Bottle Coolant 57 Coolant Level Radiator n n nnan anaa 57 Coolant Adding or Changing 56 Cooling Panic dae go vem RE RD Res 56 Cooling System 0 00 0000 56 57 Crankcase Emission Control System 46 88 D Differential Lock Switch 20 Differential Locking ss ss Sag R R Ne Ra R R R 45 Disengaging AWD 0000 0000 44 Display Units Standard Metric 28 Drive Belt Wear cis cn edanacta sae tbe qr e 79 Drivetrain Break In 0000 31 Driving Downhill aunan naa aanne 37 Driving in Reverse 0 0 0 0 esses 39 Driving on a Sidehill 2 00 37 Driving on Slippery Surfaces 36 Driving Over Obstacles 35 Driving Procedure 0000 00000 34 Driving Through Water 38 Driving Uni 37 Driving with a Passenger 35 Driving After Driving in Water 59 Drying the Transmission 005 59 Dumping the Cargo Box 43 E Electromagnetic Interference 46 Electronic Power Steering nuununnna 21 Emission Control Crankcase 46 Emission Control Exhaust 0 46 Emission Control Noise sess 46 Emissions Limited Warranty 85 86 Engaging AWD vss
14. Turn on the headlights 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 If a headlight needs adjustment locate the adjustment screw on the side of the headlight Loosen the screw Adjust the headlight then tighten the screw Repeat steps 5 7 until the lamp is properly adjusted MAINTENANCE Fuses If the engine stops or will not start or if you experience other electrical failures a fuse may need replacement Locate and correct any short circuits that may have caused the blown fuse then replace the fuse Raise the passenger seat to access the fuses Spare fuses are provided in the fuse box The power steering fuse if equipped is located on the power steering wiring harness near the fuse box If you suspect that a fuse or relay may not be working properly please see your POLARIS dealer Fuse Feature Supported 10A Brake Lights 10A Fuel Pump 10A Drive System 20A Accessories 12V Power Receptacle 20A Engine Control Module 20A Lights 30A Power Steering if equipped EPS EFI FAN FUEL PUMP RELAY RELAY RELAY RELAY OPTI DRIVE 10A BRAKE T IS RELAY FUEL pume d S OA 7177868 Power Steering Fuse if equipped 69 MAINTENANCE Battery Your vehicle has a sealed battery which r
15. gt Perform these procedures more often for vehicles subjected to severe use E Emission Related Service D Have an authorized POLARIS dealer perform these services 48 Periodic Maintenance Chart MAINTENANCE Item Maintenance Interval Remarks whichever comes first Hours Calendar Miles Km D Throttle pedal 50 H 6M 500 800 Inspect for free movement replace E pedal as needed E Throttle body air intake ducts 50 H 6M 500 800 Inspect duct for proper sealing air leaks flange Drive belt 50 H 6M 500 800 Inspect adjust replace as needed Cooling system if applicable 50 H 6M 500 800 Inspect coolant strength seasonally pressure test system yearly K Engine oil and filter change 100 H 6M 1000 1600 Change the oil and filter gt Front gearcase oil 100 H 12M 1000 1600 Change fluid gt Transmission oil 100 H 12M 1000 1600 Change fluid D Fuel system 100 H 12M 1000 1600 Check for leaks at tank cap lines fuel E valve filter pump throttle body replace lines every two years gt Radiator if applicable 100 H 12M 1000 1600 Inspect clean external surfaces K Cooling Hoses if applicable 100 H 12M 1000 1600 Inspect for leaks K Engine mounts 100 H 12M 1000 1600 Inspect Exhaust muffler pipe 100 H 12M 1000 1600 Inspect D Spark plug 100 H 12M 1000 1600 Inspect replace as needed E K Wiring 100 H 12M 1000 1600 Inspect
16. if necessary 1 Remove the top shock mounting bolts from the inside mounting positions 2 Reposition the shocks to the outside mounting holes 3 Reinstall the shock mounting bolts Torque to 40 ft Ibs 54 2 Nm Outside Mounting Position Inside Mounting Position Adjustment is similar for Front Suspension Spring Adjustment Adjust the front and rear shock absorber springs by rotating the adjustment cam either clockwise or counter clockwise to increase or decrease spring tension 64 MAINTENANCE Tires A WARNING Operating your vehicle with worn tires improperly inflated tires non standard tires or improperly installed tires will affect vehicle handling and could cause an accident resulting in serious injury or death Always follow all tire maintenance procedures as outlined in this manual and on the labels on the vehicle Always use original equipment size and type when replacing tires Tire Tread Depth i Always replace tires when tread depth is 1 8 3 mm Z worn to 1 8 3 mm or less Axle and Wheel Nut Torque le ANS 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 Nut Type Location Nut Torque Lug Nut Front and Rear 120 ft Ibs 163 Nm Aluminum Wheels Lug Nut Tapered H Front and Rear 60 ft Ibs 81 Nm Spindle Nu
17. 204 14 Gear Selector esequi eet prot te me UHR cn 19 Gearcase Specification Chart iuis 53 Gearcas Front lt sone ceca ees 54 CIearcases 04 ea scedas ewe sce vehe qe ows 53 54 ETES TTT 19 GIOVES 9 6 seed eit Ee ede RE epa REOR K 11 H Hauling Cargo ione cals as 9 K ner eae ERE 41 Headlight Beam Adjustment 68 Headlight Lamp Replacement 67 Helmet eranen 0 er Re Pee cents 11 Hitch 27 es baal esd NTH R Sate dcr hee 21 Hitch Weight ses exe eee 42 Hood Latches ii ccs gene ns bs erar eb toh ee 23 l Ignition Switch o eiei sea eedan an a 20 Indicator Lamps lt c aa aga aar a R esses 26 Inspection Pre Ride 000 2000 32 Instrument Cluster 000 26 30 Intake Screens isses me ec 60 Interference Electromagnetic 46 K Key Periodic Maintenance Chart 47 L Lamp Replacement Headlight 67 Light Switch 0 0 0 0 2c eee eee eee eee 20 Lights 22 5px eremita oh mb tnos 67 68 Load Capacity c kebucfewcee bep me a 41 Lubrication Recommendations 50 M Maintenance Log lt sac as r aR a R R Rd sees 87 Maintenance Periodic v xS S R r K N R K 9 47 49 Metric Display rar 0 6 a 67T TE RRR nak 28 Mode Button 20 0 0c eee eee eee 20 Modifications to Vehicle 0 14 N Noise Emission Control System 46 O Obstacles eee aang tans ey aem NEE 04 35 Oil Pnpine veveseeeve
18. 51 Air Filter Air Box 1 Replace the air filter See page 60 2 Clean the air box 73 MAINTENANCE Cleaning and Storage Storage Tips Inspect and Lubricate Inspect all cables and lubricate all areas of the vehicle as recommended in the Periodic Main tenance Chart beginning on page 47 Battery Maintenance See page 70 for storage and charging procedures Fluid Levels Inspect the fluid levels Add or change fluids as recommended in the Periodic Maintenance Chart beginning on page 47 Front gearcase fluid Transmission fluid Brake fluid change every two years and any time the fluid looks dark or contaminated Coolant test strength fill Fog the Engine 1 Treat the fuel system with POLARIS Carbon Clean Follow the instructions on the con tainer Start the engine Allow it to idle for several minutes so the Carbon Clean reaches the injectors Stop the engine 2 Remove the spark plugs and add 2 3 tablespoons of engine oil To access the plug holes use a section of clear 1 4 hose and a small plastic squeeze bottle filled with the pre measured amount of oil Do this carefully If you miss the plug holes oil will drain from the spark plug cavities into the hole at the front of the cylinder head and appear to be an oil leak 3 Reinstall the spark plugs Torque to specification See page 55 4 Turn the engine over several times Oil will be forced in and around the piston rings and ring lands coating the cyli
19. Allow the engine RPM to settle to idle speed Apply the brakes Shift the transmission to the lowest available range Drain PI Test for belt slippage If the belt slips repeat the rur process Take the vehicle to your dealer for service as soon as possible Vehicle Immersion NOTICE If your vehicle becomes immersed major engine damage can result if the machine is not thoroughly inspected Take the vehicle to your dealer before starting the engine If it s impossible to take your RANGER to a dealer before starting it follow the steps outlined below 1 Move the vehicle to dry land or at the very least to water below the floorboard 2 Dry any water present in the air box Filter replacement is required if water is present 3 Dry any water present in the intake manifold 4 Remove the spark plugs Turn the engine over several times using the electric start 5 Dry the spark plugs and reinstall or replace with new plugs 6 Attempt to start the engine If necessary repeat the drying procedure 7 Take the vehicle to your dealer for service as soon as possible whether you succeed in starting 1t or not 8 If water has been ingested into the PVT follow the PVT Drying procedure 59 MAINTENANCE Filter Systems Air Filter Always change the air filter at the intervals outlined in the Periodic Maintenance Chart beginning on 5 Latches page 47 Service the air filter more frequently if the vehicle is operated in wet co
20. Yoke Locate fittings and grease 3 pumps POLARIS Premium U Joint Lube maximum Front Control Arm Pivot Grease 3 fittings on each side of the vehicle Bushings POLARIS Premium all Season Rear Control Arm Pivot Grease 4 fittings on each side of the vehicle Grease or grease conforming to Bushi NLGI No 2 ushings Rear Stabilizer Bar Bushings Grease one fitting on each side of the vehicle Engine Oil Always check and change the engine oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 47 Always change the oil filter whenever changing oil WARNING Vehicle operation with insufficient deteriorated or contaminated engine oil will cause accelerated wear and may result in engine seizure accident and injury Always perform the maintenance procedures as outlined in the Periodic Maintenance Chart Oil Recommendations POLARIS recommends the use of POLARIS PS 4 PLUS Performance Synthetic 2W 50 4 cycle oil or a similar oil Refer to the specifications section beginning on page 76 for capaci ties See page 78 for the part numbers of POLARIS products NOTICE Mixing brands or using a non recommended oil may cause serious engine damage Always use the recommended oil Never substitute or mix oil brands Always check and change the oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 47 Always use the recommended engine oil 50 MAINTENANCE Engine Oil Oil Check Always c
21. 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 consequential damages or implied warranties so the above limitations or exclusions may not apply to you if inconsistent with controlling state law California Residents The model year 2013 RANGER XP 900 is available in 49 state and 50 state versions Only the 50 state models are certified for sale in California The 50 state models available for sale in California are identified by the letter C in the 10th digit of the model name e g RI3UH88A C The 50 state RANGER XP 900 models are designed and built with a 600 pound 272 kg cargo box capacity Any modifications to the factory built suspension system or any other means of altering the cargo box capacity may be a violation of the applicable California regulations a
22. for wear routing security apply dielectric grease to connectors sub jected to water mud etc D Clutches drive and driven 100 H 12M 1000 1600 Inspect clean replace worn parts D Front wheel bearings 100 H 12M 1000 1600 Inspect replace as needed D Brake fluid 200 H 24M 2000 3200 Change every two years Spark arrester 300 H 36M 3000 4800 Clean out D Valve clearance 5000 8000 Inspect adjust as needed E D Toe adjustment Inspect periodically adjust when parts are replaced D Auxiliary brake if equipped Inspect daily adjust as needed Headlight aim Adjust as needed gt Perform these procedures more often for vehicles subjected to severe use E Emission Related Service D Have an authorized POLARIS dealer perform these services 49 MAINTENANCE Lubrication Recommendations Check and lubricate all components at the intervals outlined in the Periodic Maintenance Chart beginning on page 47 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 Method Lube Engine Oil Add to proper level on dipstick See page 51 PS 4 PLUS 2W 50 Brake Fluid Maintain level between fill lines See page 62 DOT 4 Main Gearcase Oil See page 53 AGL PLUS Transmission Fluid Transmission Front Gearcase Oil See pages 53 54 Demand Drive Plus Fluid Front Prop Shaft
23. hold down strap 6 Reinstall the storage bin and seat Battery Storage Whenever the vehicle is not used for a period of three months or more remove the battery from the vehicle ensure that it s fully charged and store it out of the sun in a cool dry place Check battery voltage each month during storage and recharge as needed to maintain a full charge See page 71 POLARIS recommends maintaining battery charge by using a POLARIS Battery Tender charger or by charging about once a month to make up for normal self discharge Battery Tender can be left connected during the storage period and will automatically charge the bat tery if the voltage drops below a pre determined point See page 78 for the part numbers of POLARIS products 70 MAINTENANCE Battery Battery Charging The following battery charging instructions apply only to the installation of a sealed battery Read all instructions before proceeding with the installation of this battery The sealed battery is already filled with electrolyte and has been sealed and fully charged at the factory Never pry the sealing strip off or add any other fluid to this battery The single most important thing about maintaining a sealed battery is to keep it fully charged Since the battery 1s sealed and the sealing strip cannot be removed you must use a voltmeter or multimeter to measure DC voltage WARNING An overheated battery may explode causing severe injury or death Always watch c
24. key blank using your key number and mating it with one of your existing keys The ignition switch must be replaced if all keys are lost Key Number Engine Serial Number Vehicle Model Number Frame VIN Engine Serial Number Key Number INTRODUCTION European Vibration and Noise The driver perceived noise and hand arm and whole body vibration levels of this machinery 1s 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 nstrument and calibration uncertainty Variations in the machine such as wear of components Variation of machine operators such as experience or physique Ability ofthe worker to reproduce typical work during measurements Environmental factors such as ambient noise or temperature 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 char
25. more than the recommended number of passengers for your vehicle See page 10 Allow a passenger to ride only in a passenger seat Slow down Always travel at a speed appropriate for your skills your passengers skills and operating conditions Avoid unexpected or aggressive maneuvers that could cause discomfort or injury to a passenger Vehicle handling may change with a passenger and or cargo on board Allow more time and distance for braking 10 Always follow all operating guidelines as outlined on safety labels and in this manual Driving Over Obstacles Follow these precautions when operating over obstacles l 2 3 Always check for obstacles before operating in a new area Look ahead and learn to read the terrain Be constantly alert for hazards such as logs rocks and low hanging branches Travel slowly and use extra caution when operating on unfamiliar terrain Not all obsta cles are immediately visible 35 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 1 Do not operate
26. of an accident Operator and all passengers must always wear an approved helmet that fits properly and eye protection goggles or face shield Cab Nets Riding in this vehicle without using the cab nets increases the risk of serious injury or death in the event of an accident or overturn Always use the cab nets while riding in this vehicle Always keep hands and feet inside the vehicle at all times Failure to Inspect Before Operating Failure to inspect and verify that the vehicle is in safe operating condition before operating increases the risk of an accident Always 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 15 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 an
27. 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 uen of cssc oce NA T L T4 C C Co C BY BS C C y 36 OPERATION Driving Uphill Whenever traveling uphill follow these precautions 1 Always travel straight uphill 2 Avold steep hills 15 maximum 3 Keep both feet on the floor 4 Always check the terrain carefully before ascending any hill 5 Never climb hills with excessively slippery or loose surfaces 6 Proceed at a steady rate of speed and throttle pedal position Never apply throttle suddenly 7 Never go over the crest of a hill at high speed 15 maximum An obstacle a sharp drop or another vehicle or person could be on the other side of the hill Driving on a Sidehill Sidehilling Driving on a sidehill is not recommended Improper procedure could cause loss of control or overturn Avoid crossing the side of any hill unless absolutely necessary If crossing a
28. operation and every 100 hours thereafter 8 Pull only light loads PVT Break in Clutches Belt A proper break in of the clutches and drive belt will ensure a longer life and better perfor mance Break in the clutches and belt by operating at slower speeds during the break in period as recommended Pull only light loads Avoid aggressive acceleration and high speed operation during the break in period Ifa belt fails always clean any debris from the duct and from the engine compartment 31 OPERATION Pre Ride Inspection Failure to inspect and verify that the vehicle is in safe operating condition before operating increases the risk of an accident Always inspect the vehicle before each use to make sure it s in safe operating condition Item Remarks Page Brake system pedal travel Ensure proper operation a Brake fluid Ensure proper level 62 Front suspension Inspect lubricate if necessary 50 Rear suspension Inspect lubricate if necessary 50 Steering Ensure free operation 63 Tires Inspect condition and pressure 65 Wheels fasteners Inspect ensure fastener tightness 65 Frame nuts bolts fasteners Inspect ensure tightness Fuel and oil Ensure proper levels di Coolant level Ensure proper level 57 Coolant hoses Inspect for leaks Throttle Pedal Ensure proper operation Indicator lights switches Ensure operation 20 Intake Screens 2 Inspect clean 60 Air fil
29. pressure may damage components POLARIS recommends washing the vehicle by hand or with a garden hose using mild soap NOTICE Certain products including insect repellents and chemicals will damage plastic surfaces Do not allow these types of products to contact the vehicle The best and safest way to clean your POLARIS vehicle is with a garden hose and a pail of mild soap and water 1 Use a professional type washing cloth cleaning the upper body first and the lower parts last 2 Rinse with clean water frequently 3 Dry surfaces with a chamois to prevent water spots Washing Tips Avoid the use of harsh cleaners which can scratch the finish Do not use a power washer to clean the vehicle Do not use medium to heavy duty compounds on the finish Always use clean cloths and pads for cleaning and polishing Old or reused cloths and pads may contain dirt particles that will scratch the finish Grease all zerk fittings immediately after washing Allow the engine to run for a while to evaporate any water that may have entered the engine or exhaust system 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 Brakes Switches and controls Radiator Cab and body panels Electrical components and wiring Transmission seals Labels an
30. purchase whichever comes first This emissions limited warranty covers components whose failure increases the vehicle s regulated emissions and it covers components of systems whose only purpose is to control emissions Repairing or replacing other components not covered by this warranty is the responsibility of the vehicle owner This emissions limited war ranty does not cover components whose failure does not increase the vehicle s regulated emissions For exhaust emissions emission related components include any engine parts related to the following systems Air induction system Ignition system Fuel system Exhaust gas recirculation systems The following parts are also considered emission related components for exhaust emissions Aftertreatment devices Sensors Crankcase ventilation valves Electronic control units The following parts are considered emission related components for evaporative emissions Fuel Tank Vacuum Control Diaphragms Fuel Cap Control Cables Fuel Line Control Linkages FuelLine Fittings Purge Valves Clamps Vapor Hoses Pressure Relief Valves Liquid Vapor Separator Control Valves Carbon Canister Control Solenoids Canister Mounting Brackets Electronic Controls Carburetor Purge Port Connector As related to the evaporative emission control system The exclusive remedy for breach of this limited warranty shall be at the exclusive option of POLARIS r
31. sidehill is unavoidable follow these precautions 1 Slow down 2 Exercise extreme caution 3 Avoid crossing the side of a steep hill 15 maximum Driving Downhill When driving downhill follow these precau tions 1 Avoid steep hills 15 maximum 2 Drive straight downhill Avoid descending a hill at an angle which would cause the vehicle to lean sharply to one side Travel straight downhill when possible Slow down 4 Apply the brakes s ightly to aid in slowing m 15 maximum 37 OPERATION Driving Through Water Your POLARIS RANGER can operate through water up to a maximum recommended depth equal to the floorboards NOTICE Immersion can result in major damage if the vehicle isn t serviced correctly and promptly After immersion always take the vehicle to your dealer service Do not start the engine If it s impossible to bring the vehicle to your dealer before starting the engine perform the service outlined on page 59 and take the vehicle to your dealer at the first opportunity Follow these procedures when operating through water 1 Determine water depths and current before entering water 2 Choosea crossing where both banks have gradual inclines 3 Proceed slowly avoiding rocks and obstacles 4 Avold operating through deep or fast flowing water WARNING The large tires on your RANGER may cause the vehicle to float in deep
32. 1500 Ibs 681 kg including operator passenger cargo accessories 1100 Ibs 499 kg Models sold in California Dry Weight 1360 lbs 617 kg Fuel Capacity 10 gal 37 8 1 Engine Oil Capacity 2 5 qts 3 4 1 Coolant Capacity 5 qts 4 75 1 Towing Capacity 2000 Ibs 907 kg Hitch Tongue Capacity 150 Ibs 68 kg Max Cargo Box Load 1000 Ibs 454 kg 600 Ibs 272 kg Models sold in California Overall Length 116 in 295 cm Overall Width box 60 in 152 4 cm Overall Width tires 58 in 147 3 cm Overall Height 76 in 193 cm Wheelbase 81 in 205 7 cm Cargo Box Dimensions Inside 36 5x 5Ax 11 5 in 93 x 137 x 29 em Ground Clearance 12 in 30 5 cm Min Turning Radius 161 in 409 cm Engine 4 Stroke DOHC Twin Cylinder Displacement 875 cc Bore x Stroke 93mm x 64 4mm Alternator Output 575 W 3000 RPM Compression Ratio 10 5 1 Starting System Electric Fuel System Electronic fuel injection Ignition System Electronic Spark Plug Gap RG4YCX 0 7 0 8 mm Front Suspension Dual A arm w 10 in 25 4 cm of travel Rear Suspension Independent w 10 in 25 4 cm of travel Lubrication System Wet Sump Engine Oil POLARIS 2W 50 76 SPECIFICATIONS RANGER XP 900 Tire Size Front Driving System Type PVT 4 wheel independent shaft lockable differe
33. 20 Ignition Switch Mode Button HIGH LOW OFF AWD Differential Lock Differential Unlock FEATURES AND CONTROLS Trailer Hitch Bracket This vehicle is equipped with a receiver hitch bracket for a trailer hitch To avoid injury and property damage always heed the warnings and towing capacities outlined on pages 41 42 Brake Pedal Throttle Depress the brake pedal to slow or stop the vehicle Apply the brakes while starting the engine BIKE pedal Throttle Pedal Push the throttle pedal down to increase engine speed Spring pressure returns the pedal to the rest position when released Always check that the throttle pedal returns normally before starting the engine Tip If the throttle pedal and brake pedal are applied simultaneously engine power may be limited Adjustable Steering Wheel The steering wheel can be tilted upward or downward Adjuster for rider preference Lift and hold the adjustment lever toward you while moving the steering wheel upward or downward Release the lever when the steering wheel is at the desired position Electronic Power Steering EPS Electronic power steering if equipped engages when the ignition key is turned to the ON position EPS remains engaged whether the vehicle is moving or idle To conserve battery power the EPS will shut down 5 minutes after the engine is stopped if the key remains i
34. ADS When handling off centered loads that cannot be centered securely fasten the load and operate with extra caution Always attach the tow load to the hitch point designated for your vehicle HEAVY LOADS CAN CAUSE BRAKING AND CONTROL PROBLEMS Use extreme caution when applying brakes with a loaded vehicle Avoid terrain or situations that may require backing downhill USE EXTREME CAUTION when operating with loads that extend over the rack sides Stability and maneuverability may be adversely affected causing the vehicle to overturn DO NOT TRAVEL FASTER THAN THE RECOMMENDED SPEEDS Vehicle should never exceed 10 MPH 16 km h while towing a load on a level grass surface Vehicle speed should never exceed 5 MPH 8 km h when towing loads in rough terrain while cornering or while ascending or descending a hill Load Capacity The RANGER has been designed to carry or tow specific capacities Always read and under stand the load distribution warnings listed on the warning labels The total load operator passenger accessories cargo and weight on hitch must not exceed the maximum weight capacity of the vehicle See page 10 WARNING Driving with passengers in the cargo box can result in severe injury or death Never allow passengers to ride in the cargo box Passengers must always ride in the cab with seat belts fastened securely 41 OPERATION Towing Loads Towing improperly can alter vehicle han
35. ARNING If the weight distribution on the box is located toward the rear of the box when the release lever is pulled forward the box may dump unexpectedly and cause serious injury to the operator or bystanders Never operate the dump lever without ensuring that the load is positioned evenly or at the front of the box 5 Stand clear and pull up on the cargo box release lever Lift the front of the cargo box to dump the cargo 6 Lower the cargo box and push down securely to latch WARNING Operating the vehicle while the cargo box is raised could result in severe injury The box could close unexpectedly and cause injury to the driver or passenger The rear tires could also catch the rear of a raised box damaging the vehicle and creating hazardous driving conditions Never operate this vehicle with the cargo box in the raised position 43 OPERATION All Wheel Drive AWD Engaging AWD Press the top of the switch to engage All Wheel Drive AWD The 4X4 indicator illuminates in the rider information center to indicate that the vehicle is in AWD AWD See page 27 When the AWD switch is on the front wheels will Differential Lock automatically engage any time the rear wheels lose traction When the rear wheels regain traction the Differential Unlock front wheels will automatically disengage There is no limit to the length of time the vehicle may remain in AWD Tip The AWD swit
36. D WARRANTY on all components of the POLARIS RANGER against defects in material or workmanship POLARIS also gives a one year limited warranty on the final drive chain if equipped for failure due to defects Waranty period will vary by region This warranty covers the parts and labor charges for repair or replacement of defective parts which are covered by this warranty This warranty begins on the date of purchase This warranty is transferable to another consumer during the warranty period through a POLARIS dealer REGISTRATION At the time of sale the Warranty Registration Form must be completed by your dealer and submitted to POLARIS within ten days Upon receipt of this registration POLARIS will record the registration for warranty No verification of registration will be sent to the purchaser as the copy of the Warranty Registration Form will be the warranty entitlement If you have not signed the original registration and received the customer copy please contact your dealer immediately NO WARRANTY COVERAGE WILL BE ALLOWED UNLESS YOUR VEHICLE IS REGISTERED WITH POLARIS Initial dealer preparation and set up of your vehicle is very important in ensuring trouble free operation 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 materi
37. Out of fuel Solution Refuel Water is present in fuel Drain the fuel system and refuel Old or non recommended fuel Replace with fresh recommended fuel Fouled or defective spark plugs Inspect plugs and replace if necessary No spark to spark plug Inspect plugs and replace if necessary Water or fuel in crankcase Immediately see your POLARIS dealer Low battery voltage Recharge the battery to 12 8 VDC Mechanical failure See your dealer Engine Backfires Possible Cause Weak spark from spark plug Solution Inspect clean and or replace spark plugs Incorrect spark plug gap or heat range Set gap to specs or replace plugs Old or non recommended fuel Replace with fresh recommended fuel Incorrectly installed spark plug wires See your dealer Mechanical failure See your dealer Loose ignition connections Check all connections and tighten Water present in fuel Replace with fresh recommended fuel Engine Pings or Knocks Possible Cause Poor quality or low octane fuel Solution Replace with recommended fuel Incorrect spark plug gap or heat range Set gap to specs or replace plugs TROUBLESHOOTING Engine Runs Irregularly Stalls or Misfires Possible Cause Solution Fouled or defective spark plugs Inspect clean and or replace spark plugs Worn or defective spark plug w
38. PRESSURE IN PSI KPa FRONT 10 69 REAR 12 83 MAXIMUM WEIGHT CAPACITY AND ACCESSORIES INCLUDES WEIGHT OF OPERATOR PASSENGER CARGO 1500 Ibs 682 kg Read Operation and Maintenance Manual for more detailed loading information 10 7178618 SAFETY Safe Riding Gear Always wear appropriate clothing when riding a POLARIS vehicle Wear protective clothing for comfort and to ei ad reduce the chance of injury T Eye 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 Over the Ankle Boots 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 051039 on the label 0006 31 Eye Protection 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 Helmet Gloves Wear glov
39. ain Failure to use extra caution when operating on excessively rough slippery or loose terrain could cause loss of traction loss of control accident or overturn Do not operate on excessively slippery surfaces Always reduce speed and use additional caution when operating on slippery surfaces 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 37 Stalling While Climbing a Hill Stalling or rolling backwards while climbing a hill could cause an overturn Always maintain a steady speed when climbing a hill If all forward speed is lost Apply the brakes Place the transmission in reverse and slowly allow the vehicle to roll straight downhill while applying light brake pressure to control speed If you begin rolling downhill Never apply engine power Apply the brakes gradually until the vehicle is fully stopped Place the transmission in reverse and slowly allow the vehicle to roll straight downhill while applying light brake pressure to control speed Improper Tire Maintenance Operating this vehicle with improper tires or with improper or uneven tire pressure could cause loss of control or accident Always use the size and type of tires specified for your vehicle Always maintain proper tire pressure as described in the owner s manual and on safety labels Operating on Frozen Bod
40. ains 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 Dealer MSD Technician Your POLARIS dealer knows your vehicle best and is interested in your total satisfaction Be sure to return to your dealership for all of your service needs during and after the warranty period POLRGRIS POLARIS RANGER and RANGER XP 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 ofthe 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 XP 900 Owner s Manual P N 9924098 2 TABLE OF CONTENTS Introduction pm d T L TTT 8 Features and Controls lll llllss 18 Operation M
41. al 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 components 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 mai
42. and driveways may adversely affect the handling of the vehicle and could result in loss of control and accident or overturn Avoid operating the vehicle on pavement If it s unavoidable travel slowly and avoid sudden turns or stops Operating on Public Roads Operating this vehicle on public streets roads or highways could result in a collision with another vehicle Never operate this vehicle on any public street road or highway including dirt and gravel roads In some areas it s unlawful to operate this vehicle on public streets roads and highways 16 SAFETY Operator Safety 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 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 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 on Slippery Terr
43. ation Clean lights frequently and replace burned out lamps promptly Always make sure lights are adjusted properly for best visibility When servicing a halogen lamp don t touch the lamp with bare fingers Oil from your skin leaves a residue causing a hot spot that will shorten the life of the lamp Headlight Lamp Replacement Access a headlamp wiring harness through the front wheel well CAUTION Hot components can cause burns to skin Allow lamps to cool before servicing 1 Unplug the headlamp from the wiring harness Be sure to pull on the connector not on the wir ing S i onnector 2 Turn the lamp counter clockwise to remove it 3 Install the new lamp Tip Make sure the tab on the lamp locates properly in the housing 4 Reinstall the harness assembly into the headlight assembly Brake Lights When the brake pedal is depressed the brake light comes on Check the brake light before each ride 1 Turn the ignition switch to the ON position 2 Depress the brake pedal The brake light should come on after about 10 mm 0 4 in of pedal travel 67 MAINTENANCE Lights Headlight Beam Adjustment 68 V 8 20 cm Place the vehicle on a level surface with the headlight approximately 25 ft 7 6 m from a wall Place the transmission in PARK Measure the distance from the floor to the center of the headlight and make a mark on the wall at the same height Apply the brakes Start the engine
44. ch may be turned on or off while the vehicle is moving Engage the AWD before getting into conditions where front wheel drive may be needed If the rear wheels are spinning release the throttle before switching to AWD NOTICE Switching to AWD while the rear wheels are spinning may cause severe drive shaft and clutch damage Always switch to AWD while the rear wheels have traction or are at rest Disengaging AWD Move the AWD switch to the center or bottom position to disengage AWD If the switch is turned off while the front hubs are driving they will not release until the rear wheels regain traction In some situations the front gearcase may remain locked after turning the AWD switch off If this occurs you may notice increased steering effort and some vehicle speed restriction Perform the following procedure to unlock the front gearcase 1 Stop the vehicle Operate in reverse for at least 10 feet 3 m Stop completely Shift into low gear and drive forward If the front gearcase remains locked after following these instructions see your dealer for service SA eec Ge 44 OPERATION All Wheel Drive AWD Locking the Differential NOTICE Damage to the differential can occur if it is 4r U engaged while the vehicle is traveling at high speeds or while the rear wheels are spinning Slow the vehicle to nearly stopped before T 4 engaging the differential Locking the differential in slippery or low traction conditi
45. ckstand 2 Remove the fill plug 3 Place a drain pan under the drain plug 4 Remove the drain plug Allow the oil to drain completely 5 Clean and reinstall the drain plug Torque to specification 6 Add the recommended oil 7 Reinstall the fill plug Torque to specification 8 Check for leaks Dispose of used oil properly 54 Wow 7 B A ISSO 102 Level Z Recessed Drain Plug MAINTENANCE Spark Plugs Spark Plug Recommendations Refer to the specifications section beginning on page 76 for the recommended spark plug type for your vehicle Always torque spark plugs to specification NOTICE Using non recommended spark plugs can result in serious engine damage Always use POLARIS recommended spark plugs Spark Plug Gap Torque Model Electrode Gap New Plug Torque Used Plug Torque RANGER XP 0 7 0 8 mm 10 ft Ibs 13 5 Nm 10 ft Ibs 13 5 Nm Spark Plug Inspection Spark plug condition is indicative of engine operation The spark plug firing end condition should be read after the engine is warmed up and the vehicle is driven at higher speeds Immediately check the spark plug for correct color CAUTION Always remove all cargo from the cargo box before lifting the box to access engine components 1 Lift the cargo box Remove the spark plug cap CAUTION A hot exhaust system and engine can cause burns Wear protective gloves when removing a spark plug for inspection 2 Using t
46. clean any debris from the duct and from the clutch and engine compart ments when replacing the belt WARNING Failure to remove ALL debris when replacing the belt could result in vehicle damage and severe injury or death 1 Remove the clutch cover screws and open the clutch cover Remove all debris wrapped in and around the PVT system 2 Remove all debris from the entire clutch air duct passage 3 Check for signs of damage to seals on the transmission and engine See your dealer promptly for service if any seals appear to Remove ALL Debris be damaged Tip Belt slip is responsible for creating excessive heat that destroys belts wears clutch components and causes outer clutch covers to fail Switch to low range while operating at slower speeds to extend the life of the PVT components belt cover etc 58 MAINTENANCE POLARIS Variable Transmission PVT System PVT Drying There may be some instances when water is accidently ingested into the PVT system Use the following instructions to dry it out before operating 1 2 T Position the vehicle on a level surface Place the transmission in PARK Stop the engine Remove the clutch cover drain plug Allow the water to drain completely Reinstall the drain plug Start the engine Apply varying throttle for 10 15 seconds to expel the moisture and air dry the belt and clutches Do not apply heavy throttle for more than 10 seconds
47. cover physical damage corrosion or defects caused by fire explosions or other similar causes beyond the control of POLARIS Owners are responsible for performing the scheduled maintenance identified in the owner s manual POLARIS may deny warranty claims for failures that have been caused by the owner s or operator s improper maintenance or use by accidents for which POLARIS has no responsibility or by acts of God Any qualified repair shop or person may maintain replace or repair the emission control devices or systems on your vehicle POLARIS recommends that you contact an authorized POLARIS dealer to perform any service that may be necessary for your vehicle POLARIS also recommends that you use only Pure POLARIS parts It is a potential violation of the Clean Air Act if a part supplied by an aftermarket parts manufacturer reduces the effec tiveness of the vehicle s emission controls Tampering with emission controls is prohibited by federal law If you have any questions regarding your warranty rights and responsibilities please contact the POLARIS War ranty Department at 1 888 704 5290 86 MAINTENANCE LOG Use the following chart to record periodic maintenance DATE MILES KM TECHNICIAN SERVICE PERFORMED COMMENTS OR HOURS 87 INDEX A Accessory Outlets esee 19 Air Filter 24s acu acu atu b Rn Re erga 60 Air Filter Cleaning nonn nanaaaaan aaa 60
48. d decals If an informational or graphic label becomes illegible or comes off contact your POLARIS dealer to purchase a replacement Replacement safety labels are provided by POLARIS at no charge Polishing the Vehicle POLARIS recommends the use of common household aerosol furniture polish for polishing the finish on your POLARIS vehicle Follow the instructions on the container Avoid the use of automotive products some of which can scratch the finish of your 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 12 MAINTENANCE Cleaning and Storage Storage Tips NOTICE Starting the engine during the storage period will disturb the protective film created by fogging and damage could occur Never start the engine during the storage period Clean the Exterior Make any necessary repairs and clean the vehicle as recommended See page 72 Stabilize the Fuel 1 Fill the fuel tank 2 Add POLARIS Carbon Clean Fuel Treatment or POLARIS Fuel Stabilizer Follow the instructions on the container for the recommended amount Carbon Clean removes water from fuel systems stabilizes fuel and removes carbon deposits from pistons rings valves and exhaust systems 3 Allow the engine to run for 15 20 minutes to allow the stabilizer to disperse through the entire fuel delivery system Oil and Filter Change the oil and filter See page
49. d on a label on the vehicle Always follow these guidelines Under ANY of these conditions Do ALL of these steps Passenger and or cargo exceeds half the maximum weight capacity 1 Slow down 2 Verify tire pressure 3 Use extra caution when Operating over obstacles operating Operating in rough terrain Climbing an incline Towing Exposure to Exhaust Engine exhaust fumes are poisonous and can cause loss of consciousness or death in a short time Never start the engine or let it run in an enclosed area The engine exhaust from this product contains chemicals known to cause cancer birth defects or other reproductive harm Operate this vehicle only outdoors or in well ventilated areas Operating a Damaged Vehicle Operating a damaged vehicle can result in an accident After any overturn or accident have a qualified service dealer inspect the entire machine for possible damage including but not limited to brakes throttle and steering systems Operating at Excessive Speeds Operating this vehicle at excessive speeds increases the operator s risk of losing control Always operate at a speed that s appropriate for the terrain the visibility and operating conditions 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
50. dden gear changes Never go over the top of a hill at high speed Always follow the proper procedures outlined in this manual for traveling downhill and for braking on hills Check the terrain carefully before descending a hill Never travel downhill at high speed Avoid going downhill at an angle which would cause the vehicle to lean sharply to one side Travel straight down the hill where possible Always check for obstacles before operating in a new area Never attempt to operate over large obstacles such as rocks or fallen trees Always follow the proper procedures outlined in this manual when operating over obstacles Always be careful of skidding or sliding On slippery surfaces such as ice travel slowly and exercise caution to reduce the chance of skidding or sliding out of control Never operate your vehicle in fast flowing water or in water deeper than that specified in this manual Wet brakes may have reduced stopping ability Test your brakes after leaving water If necessary apply them lightly several times to let friction dry out the pads Always be sure there are no obstacles or people behind your vehicle when operating in reverse When it s safe to proceed in reverse move slowly Avoid turning at sharp angles in reverse Always use the proper size and type of tires specified in this manual Always maintain proper tire pressure as specified on safety labels Never modify this vehicle through improper installation or use of acc
51. dling 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 Always shift to low gear for towing 3 Do not operate the vehicle faster than 10 MPH 16 km h when towing See page 41 Towing a trailer increases braking distance 4 Donottow more than the recommended weight for the vehicle See the towing capacity chart below and the specifications charts beginning on page 76 5 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 6 Never tow a trailer on a grade steeper than 15 Model Total Towed Load Weight Level Ground Total Towed Load Weight 15 grade Total Hitch Vertical Weight Maximum Towin Spee RANGER XP 900 2000 Ibs 907 kg 850 Ibs 386 kg 150 Ibs 68 1 kg 10 MPH 16 km h Belt Life To extend belt life use the lowest gear possible when hauling or towing heavy cargo 42 OPERATION Dumping the Cargo Box 1 Selecta level site to dump the cargo box Do Release Lever not attempt to dump or unload the vehicle while parked on an incline 2 Apply the brakes Place the transmission in PARK 3 Ensure that the cargo is positioned evenly or toward the front of the cargo box 4 Release the tailgate by pulling up on the tail gate latch W
52. e Re eda 44 Engine Break In 9 eR ea SN R 9 K esses 31 Engine Fogging 0 0 00 e eee eee 74 Engine OW fenced erepti ex 50 52 Engine Starting gt ianea aaa n E TAT Tg 33 Engine Stopping e e e e 0 33 EPS rrei x TERRE teeth ne ago eek 21 Equipment Modifications seses esse 14 Error Codes Engine 0 0005 30 Exhaust Emission Control System 46 Exhaust System Warning suus 61 Ey6 PrOleCUOn c biker EROR WP 11 F Fan Cooling 4 isses ee he 56 Filter Cleaning Air leseesssss 60 Filter Systems i e eR FERE ETAT 60 Sn JA c5 Gars ds conncieade ta de stepetedat unen ERO GU nadine 60 Fluid Brake eee eee 62 Fluid Change Engine Oil 0 000 51 52 Front Gearcase essere 0 8 0 5 0065 54 Main Gearcase acis ange een es 53 Tr nsmisslon ek sues EE RENE 53 Fluid Level Engine Oil esseere neneiia 51 Front Gearcase TT 54 Main Gearcase 5 5 55 35 sopar is 53 Transmission 0 00 53 F Fluid Levels During Storage 74 Fluid Part Numbers sare gg cg d 0 a ririo a 78 Fogging the Engine sss se e e e e ee 74 Fouled Plugs deny pai engin RR ha 55 Front Gearcase socra ne pye ette ev es 54 BUC C apy RM OM 23 P el Safety ee hvac eos etre t t eap rct cris 14 Fuel Stabilizer or Roc bd 73 Fuel Tank Filler Cap sc asea a r 0 R RR R a N N 23 lu Pn 69 G Gap Spark Pl g sieca eder eer RR RR 55 Gasoline Handling
53. e all latches are secure before operating the vehicle Always inspect cab nets for tightness wear and damage before each use of the vehicle Use the strap adjusters to tighten any loose straps Promptly replace worn or damaged cab nets with new cab nets available from your authorized Polaris dealer Securing a Net Latch 1 After entering the vehicle insert the lower net rod into the net mount on the floor Make sure the ball at the end of the rod is properly secured in the mount 2 Connect the latch at the top edge of the net to the receiver latch mounted on the front frame Opening a Net 1 To exit the vehicle release the latch at the top front edge of the cab net 2 Rotate the net rearward and pull upward on the Net Mount lower net rod to remove it from the mount 3 Allow the net to hang freely outside the vehicle while dismounting Ball Rod 24 FEATURES AND CONTROLS Seat Belts This POLARIS vehicle is equipped with three point lap and diagonal seat belts on all exter nal seats The center seat is equipped with a lap style seat belt Always make sure the seat belts are secured for all riders before operating WARNING Falling from a moving vehicle could result in serious injury or death Always fasten your seat belt securely before operating or riding in the RANGER To wear the seat belt properly follow this proce dure 1 For3 point belts pull the seat belt latch down ward and across your chest toward th
54. e buckle at the inner edge of the seat The belt should fit snugly across your hips and diagonally across your chest Make sure the belt is not twisted For lap style belts place the belt across your lap as low on your hips as possible Make sure that the belt is not twisted 2 Push the latch plate into the buckle until it clicks 3 Release the strap it will self tighten Tip The center belt must be tightened manually by pull ing on the strap 4 To release the seat belt press the square red button in the buckle s center 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 Pulleach 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 25 FEATURES AND CONTROLS Instrument Cluster High water pressure may damage components Wash the vehicle by hand or with a garden hose using
55. e the key on if you want to view the active code fail ure code The diagnostic mode becomes inaccessible if the key is turned off and on and the warning indicator is no longer active This allows the determination of persistent as well as intermit tent faults Inactive codes are stored in the history of the unit 29 FEATURES AND CONTROLS Instrument Cluster Rider Information Center Engine Error Codes The error screen displays only when the CHECK ENGINE light is on or when it goes on and off during one ignition cycle Error codes are not stored When the key is turned OFF the code and message is lost but will reappear if the fault reoccurs after restarting the engine If the CHECK ENGINE light illuminates retrieve the error codes from the display 1 Ifthe error codes are not displayed use the MODE button to toggle until Ck ENG displays on the main line of the display 2 Press and hold the MODE button to enter the diagnostics code menu Qv eee 30 Suspect Parameter Number SPN Error Code Number 0 9 Failure Mode Indicator FMI Record the three numbers displayed in the gear position clock and odometer displays Press the MODE button to advance to the next error code Press and hold the MODE button to exit the diagnostics code menu See an authorized POLARIS dealer for code details and diagnosis OPERATION Failure to operate the vehicle properly can result in a collision loss of control acc
56. eit Celsius Time 12 Hour Clock 24 Hour Clock 1 Turn the key to the OFF position Press and hold the MODE button while turning the key to the ON position 3 When the display flashes the distance setting tap the MODE button to advance to the desired setting 4 Press and hold the MODE button to save the setting and advance to the next display option 5 Repeat the procedure to change remaining display settings Clock Mode Tip The clock must be reset any time the battery has been disconnected or discharged 1 Turn the key to the ON position Use the MODE button to toggle to the odometer dis play Press and hold the MODE button until the hour segment flashes Release the button With the segment flashing tap the MODE button to advance to the desired setting Press and hold the MODE button until the next segment flashes Release the button Repeat steps 3 4 twice to set the 10 minute and 1 minute segments After completing the minute segment step 4 will save the new settings and exit the clock mode 6 Turm the key to the OFF position D ci uec be 28 FEATURES AND CONTROLS Instrument Cluster Rider Information Center Odometer Mode The odometer records and displays the distance traveled by the vehicle Trip Meter Mode The trip meter records the distance traveled by the vehicle if reset before each trip To reset select the trip meter mode Press and hold the MODE button until the meter resets to zero I
57. en the upper MAX and lower MIN level lines 5 Ifthe fluid level is lower than the upper level line add brake fluid to the upper MAX line 6 Apply the brake forcefully for a few seconds and check for fluid leakage around the fittings Minimum 62 MAINTENANCE Brakes Brake Inspection 1 Check the brake system for fluid leaks 2 Check the brake pedal for excessive travel or a spongy feel 3 Check the friction pads for wear damage and looseness Check brake discs for signs of cracks excessive corro sion warping or other damage Clean any grease using an approved brake cleaner or alcohol NOTICE Do not apply WD 40 or any petroleum product to brake discs 5 Inspect the brake disc spline and pad wear surface for excessive wear Change pads when worn to 3 64 1 mm 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 47 1 Position the vehicle on a level surface 2 Place the transmission in PARK 3 Lightly turn the steering wheel left and right There should be 0 8 1 0 20 25 mm of freeplay 4 If there is excessive freeplay or strange noises or the steering feels rough or catchy have the steering system inspected by an authorized POLARIS dealer 63 MAINTENANCE Suspension Adjustments The front and rear suspensions can be adjusted to provide a stiffer suspension
58. epair or replacement of any defective materials components or products THE REMEDIES SET FORTH IN THIS LIM ITED WARRANTY ARE THE ONLY REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF THIS WARRANTY POLARIS SHALL HAVE NO LIABILITY TO ANY PERSON FOR INCIDENTAL CONSE QUENTIAL 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 ALL IMPLIED WARRANTIES INCLUDING BUT NOT LIMITED TO ANY IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE ARE LIMITED IN DURATION TO THE WARRANTY PERIOD DESCRIBED HEREIN POLARIS DISCLAIMS ALL EXPRESS WARRANTIES NOT STATED IN THIS WARRANTY Some states do not allow limitations on how long an implied warranty lasts so the above limitation may not apply if it is inconsistent with the controlling state law 85 WARRANTY U S A EPA Emissions Limited Warranty This limited warranty excludes failures not caused by a defect in material or workmanship This limited warranty does not cover damage due to accidents abuse or improper handling maintenance or use This limited warranty also does not cover any engine that has been structurally altered or when the vehicle has been used in racing competition This limited warranty also does not
59. equires little maintenance Always keep battery ter minals and connections free of corrosion If cleaning is necessary remove the corrosion with a stiff wire brush Wash with a solution of one tablespoon baking soda and one cup water Rinse well with tap water and dry off with clean shop towels Coat the terminals with dielec tric grease or petroleum jelly Battery Removal Improperly connecting or disconnecting battery cables can result in an explosion and cause serious injury or death When removing the battery always disconnect the negative black cable first When reinstalling the battery always connect the negative black cable last 1 Remove the storage bin under the passenger seat to access the battery 2 Disconnect the black battery cable first Disconnect the red battery cable last 3 Lift the battery out of the vehicle Battery Installation Using a new battery that has not been fully charged can damage the battery and result in a shorter life It can also hinder vehicle performance Follow the battery charging instructions on page 71 before installing the battery 1 Ensure that the battery is fully charged 2 Place the fully charged battery in the battery holder Make sure the positive terminal is toward the driver s side of the vehicle 3 Coat the terminals with dielectric grease or petroleum jelly 4 Connect and tighten the red cable first Connect and tighten the black cable last 5 Install the
60. er the anke boots Reduce speed and use extra caution when carrying passengers Avoid sharp turns or turns while applying heavy throttle Operate slowly in reverse avoid sharp turns or sudden braking Make sure passengers read and understand all safety labels READ OWNER S MANUAL FOLLOW ALL INSTRUCTIONS AND WARNINGS For your nearest Polaris dealer A call 1 800 POLARIS PCSLP3RIS or visit www polarisindustries com Polaris Sales Inc 2100 Hwy 55 Medina MN 55340 Phone 1 888 704 5290 Part No 9924098 Rev 02 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 e RANGER utility vehicles e 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 cont
61. es 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 Handling Gasoline Gasoline is highly flammable and explosive under certain conditions Always exercise extreme caution whenever handling gasoline Always stop the engine when refueling Always refuel outdoors or in a well ventilated area Remove flammable material containers from the box before filling them with fuel Do not smoke or allow open flames or sparks in or near the area where refueling is performed or where gasoline is stored Do not overfill the tank Do not fill the tank neck d ge ne spills on your skin or clothing immediately wash it off with soap and water and change clothing Hot Exhaust Systems Exhaust system components are very hot during and after use of the vehicle Hot components can cause burns and fire Do not touch hot exhaust system components Always keep combustible materials away from the exhaust system Use caution when traveling through tall grass especially dry grass 14 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 injury or death Heed all safety warnings outlined in this section of the owner s manual See the OPERATION section of the owner s manual for proper operating procedu
62. es 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 outlined in further detail within your owner s manual Read this manual and all labels carefully Follow the operating procedures described Never allow anyone under age 16 to operate this vehicle and never allow anyone without a valid driver s license to operate this vehicle Do not carry a passenger until you have at least two hours of driving experience with this vehicle No person under the age of 12 may ride as a passenger in this vehicle Any passenger must be able to comfortably reach the floor and hand holds The driver and all passengers must wear helmet eye protection gloves long sleeve shirt long pants over the ankle boots and seat belt at all times Always use the cab nets while riding in this vehicle Always keep hands and feet inside the vehicle at all times Always keep both hands on the steering wheel and both feet on the floorboards of the vehicle during operation Never permit a guest to operate this vehicle unless the guest has read this manual and all product labels To reduce tipover risk be especially careful when encou
63. essories Never exceed the stated load capacity for this vehicle Cargo should be properly distrib uted and securely attached Reduce speed and follow the instructions in this manual for hauling cargo or pulling a trailer Allow a greater distance for braking Always place the transmission in PARK before getting out of the vehicle Always stop the engine before refueling Remove flammable material containers from the box before filling them with fuel Make sure the refueling area is well ventilated and free of any source of flame or sparks Gasoline is extremely flammable See page 14 for fuel safety warnings Always remove the ignition key when the vehicle is not in use to prevent unauthorized use or accidental starting FOR MORE INFORMATION ABOUT SAFETY call POLARIS at 1 800 342 3764 SAFETY Operator Safety Equipment Modifications We strongly recommend that consumers do not install on a POLARIS RANGER any equip ment that may increase the speed or power ofthe 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 tir
64. ever maintenance interval is reached first Item Maintenance Interval Remarks whichever comes first Hours Calendar Miles Km Steering Front suspension Rear suspension Tires Brake fluid level Pre Ride Make adjustments as needed Brake pedal travel See Pre Ride Checklist on page 32 Brake system Wheels fasteners Frame fasteners Engine oil level E Intake Screens Daily Inspect clean often as needed E Engine intake pre filter Daily Inspect clean often Coolant Daily Check level daily change coolant every 2 years K Power steering unit if equipped Daily Inspect daily clean often Headlamp tail lamp Daily Verify proper operation P Brake pad wear 10H Monthly 100 160 Inspect periodically Battery 25H Monthly 200 320 Check terminals clean test E Air filter 25H Monthly 200 320 Inspect replace as needed gt Front gearcase oil 25H 1M Perform a break in oil level check gt Transmission oil 25H 1M Perform a break in oil level check gt Engine oil change break in 25H 500 800 Perform a break in oil change gt General lubrication 50 H 3M 500 800 Lubricate all fittings pivots cables etc Shift Linkage 50 H 6M 500 800 Inspect lubricate adjust D Steering 50 H 6M 500 800 Lubricate gt Front Suspension 50 H 6M 500 800 Lubricate gt Rear Suspension 50 H 6M 500 800 Lubricate
65. ge The part number is printed on the label Age 16 Shift Discretionary Warning Caution Warning Clutch Cover Warning Clutch Cover Warning WARNING Improper service or maintenance of this PVT system can result in vehicle damage SEVERE INJURY or DEATH Always look for and remove debris inside and around clutch and vent system when replacing belt Read owner s manual or see authorized POLARIS dealer 7177469 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 SAFETY Safety Labels and Locations Shift Caution CAUTION To avoid transmission damage shift only when vehicle is stationary and at idle When vehicle is stopped place shift in parked position APPLY BRAKE TO START ftotal payload is greater than 500 Ibs the vehicle must be operated in LOW range 7178545 Discretionary Warning WARNING Improper vehicle use can result in Severe Injury or Death NEVER Operate Atspeeds too fast for your skills or the conditions After or while using Alcohol or Drugs On hills steeper than 15 degrees 15 On public roads a collision can occur with a another vehicle With more than two passengers five for CREW or passengers under the age of twelve or who cannot comfortably reach the floor and hand holds
66. harging times carefully Stop charging if the battery becomes very warm to the touch Allow it to cool before resuming charging For a refresh charge follow all instructions carefully 1 Check the battery voltage with a voltmeter or multimeter A fully charged battery will register 12 8 V or higher 2 Ifthe voltage is less than 12 8 volts recharge the battery at 1 2 amps or less until battery voltage 1s 12 8 or greater 3 When using an automatic charger refer to the charger manufacturer s instructions for recharging When using a constant current charger use the guidelines below for recharg ing Always verify battery condition before and 1 2 hours after the end of charging State of Charge Time Voltage Action Using constant current Charge charger standard amps specified on top of battery 10096 12 8 13 0 volts None check at 3 mos from date of None required manufacture 75956 10096 12 5 12 8 volts May need slight charge if no charge 3 6 hours given check in 3 months 5096 759 12 0 12 5 volts Needs charge 5 11 hours 2596 5096 11 5 12 0 volts Needs charge At least 13 hours verify state of charge 096 2596 11 5 volts or less Needs charge with desulfating charger At least 20 hours 71 MAINTENANCE Cleaning and Storage Washing the Vehicle Keeping your POLARIS vehicle clean will not only improve its appearance but it can also extend the life of various components NOTICE High water
67. he dipstick Wipe it dry with a clean cloth Reinstall the dipstick completely Remove the dipstick and check the oil level v Oil Oil Fil Filter Oil Cap Dipstick Access Crankcase Hole Drain Plug Bottom View of Skid Plate Remove the oil fill cap and add oil as needed to bring the level to the upper mark on the dipstick Do not overfill Reinstall the fill cap Reinstall the dipstick Lower the cargo box and push down securely to latch Dispose of used filter and oil properly MAINTENANCE Gearcases Gearcase Specification Chart RANGER XP 900 Gearcase Specifications Gearcase Lubricant Capacity Fill Plug Torque Drain Plug Torque Main Gearcase AGL PLUS 34 oz 12 ft Ibs 12 ft Ibs Transmission Transmission Fluid 1000 ml 16 3 Nm 16 3 Nm Front Gearcase Demand Drive Plus 7 6 oz 8 10 ft Ibs 8 10 ft Ibs i 225 ml 11 13 6 Nm 11 13 6 Nm Transmission Main Gearcase Always check and change the transmission oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 47 Refer to the Gearcase Specifications Chart for recommended lubricants capacities and torque specifications See page 78 for the part numbers of POLARIS products Oil Check The level check fill plug is located on the rear of the gearcase Maintain the oil level even with the bot Level P df tom of the level check fill plug hole threads Check Fill se Vs d 1 P
68. he spark plug wrench provided in the tool kit remove the plug by rotating it counter clockwise 3 Reverse the procedure for spark plug installation Apply anti seize compound to the spark plug threads 4 Torque to specification Spark Plugs Normal Plug The normal insulator tip is gray tan or light brown There will be few combustion depos its The electrodes are not burned or eroded This indicates the proper type and heat range for the engine and the service The tip should not be white A white insulator tip indicates overheating caused by use of an improper spark plug or incorrect throttle body adjustments Wet Fouled Plug The wet fouled insulator tip is black A damp oil film covers the firing end There may be a carbon layer over the entire nose Generally the electrodes are not worn General causes of fouling are excessive oil use of non recommended oil or poor fuel quality 55 MAINTENANCE Cooling System The engine coolant level is controlled or maintained by the recovery system The recovery system components are the overflow bottle radiator filler neck radiator pressure cap and connecting hose As coolant operating temperature increases the expanding heated excess coolant is forced out of the radiator past the pressure cap and into the overflow bottle As engine coolant tem perature decreases the contracting cooled coolant is drawn back up from the tank past the pressure cap and into the radiator
69. heck the oil when the engine is cold If the engine is hot when the oil is checked the level will appear to be overfull CAUTION Always remove all cargo from the cargo box before lifting the box to access engine components Access the oil fill cap dipstick and filter under the cargo box 1 Remove all cargo from the cargo box See page 43 Position the vehicle on a level surface Place the transmission in PARK Stop the engine Cn PSOE R3 Stand clear and pull up on the cargo box release lever Lift the front of the cargo box 6 Remove the dipstick Wipe it dry with a clean cloth l l Oil Fill Oil Oil 7 Reinstall the dipstick completely Remove Cap Filter Dipstick the dipstick and check the oil level 8 Remove the oil fill cap to add the recommended oil as needed Maintain the oil level between the minimum and maximum marks on the dipstick Do not overfill 9 Reinstall the fill cap Reinstall the dipstick 10 Lower the cargo box and push down securely to latch Oil and Filter Change Always change the oil and filter at the intervals outlined in the Periodic Maintenance Chart beginning on page 47 Always change the oil filter whenever changing oil The crankcase drain plug is located on the bottom of the crankcase Access the drain plug through the access hole in the skid plate under the crankcase see next page CAUTION Always remove all cargo from the cargo box before lifting the box to access engine comp
70. ident or overturn which may result in serious injury or death Read and understand all warnings outlined in the safety section of this manual Break In Period The break in period for your new RANGER is the first 25 hours of operation or the time it takes to use the first two tanks full of fuel No single action on your part is as important as a proper break in period Careful treatment of a new engine will result in more efficient perfor mance and longer life for the engine Perform the following procedures carefully NOTICE Excessive heat build up during the first three hours of operation will damage close fitted engine parts Do not operate at full throttle or high speeds for extended periods during the first three hours of use Engine and Drivetrain Break in 1 Fill the fuel tank with clean fresh fuel Review the fuel warnings on page 14 2 Check the oil level Add the recommended oil as needed to maintain the oil level in the normal safe operating range 3 Drive slowly at first Select an open area that allows room to familiarize yourself with vehicle operation and handling 4 Vary throttle positions Do not operate at sustained idle 5 Perform regular checks on fluid levels controls and areas outlined on the daily pre ride inspection checklist See page 32 6 During the break in period change both the oil and the filter at 25 hours 7 Check fluid levels of transmission and all gearcases after the first 25 hours of
71. ies of Water Severe injury or death can result if the vehicle and or the operator fall through the ice Never operate the vehicle on a frozen body of water unless you have first verified that the ice is sufficiently thick to support the weight and moving force of the vehicle you and your passengers and your cargo together with any other vehicles in your party Always check with local authorities and residents to confirm ice conditions and thickness over your entire route Vehicle operators assume all risk associated with ice conditions on frozen bodies of water Unauthorized Use of the Vehicle Leaving the keys in the ignition can lead to unauthorized use of the vehicle which could result in an accident or overturn Always remove the ignition key when the vehicle is not in use 17 FEATURES AND CONTROLS Component Locations Your vehicle is equipped with cab nets on both sides of the vehicle Cab nets must be used by both operator and passengers at all times Any illustrations without cab nets are only to allow component identification Always use the cab nets Not all models come with all features Refer to the specifications section on page 76 D a T w x lt 5 a Receiver CV Boot Rear Hitch Caliper Muffler Spark Arrester ROPS Cab Frame Intake Screens both sides Cargo Box Cab Net
72. ires See your dealer Incorrect spark plug gap or heat range Set gap to specs or replace plugs Loose ignition connections Check all connections and tighten Water present in fuel Replace with new fuel Low battery voltage Recharge battery to 12 8 VDC Incorrect fuel Replace with recommended fuel Clogged air filter Inspect and clean or replace Clogged intake screen Inspect and clean with soapy water or replace Throttle release switch malfunction See your dealer Other mechanical failure See your dealer Engine Stops or Loses Power Possible Cause Solution Out of fuel Refuel Water is present in fuel Replace with new fuel Fouled or defective spark plugs Inspect clean and or replace spark plug Worn or defective spark plug wires See your dealer Incorrect spark plug gap or heat range Set gap to specs or replace plug Loose ignition connections Check all connections and tighten Low battery voltage Recharge the battery to 12 8 VDC Incorrect fuel Replace with fresh recommended fuel Clogged air filter Inspect and clean or replace Clogged intake screen Inspect and clean with soapy water or replace Throttle release switch malfunction See your dealer Other mechanical failure See your dealer Overheated engine Clean radiator screen and core clean engine exterior see your dealer WARRANTY LIMITED WARRANTY POLARIS Sales Inc 2100 Highway 55 Medina MN 55340 gives a SIX MONTH LIMITE
73. mild soap Do not use alcohol to clean the instrument cluster Do not allow insect sprays to contact the lens Speedometer The speedometer displays vehicle speed in either miles per hour MPH or kilometers per hour km h See page 28 Center Indicator Lamps Speedometer Indicator Lamps Rider Information MODE Button Lamp Indicates Condition Vehicle Speed When standard mode is selected speed displays in miles per hour When metric mode is selected speed displays in kilometers per hour E Over Temperature This lamp illuminates to indicate an overheated engine If the indicator flashes the overheating condition remains and the system will automatically reduce engine power l EPS Warning if equipped This indicator illuminates briefly when the key is turned to the ON position If the light remains on the EPS system is inoperative See your authorized POLARIS dealer for service Neutral This lamp illuminates when the transmission is in neutral and the ignition key is in the ON position High Beam This lamp illuminates when the headlamp switch is set to high beam Helmet Seat Belt This lamp flashes for several seconds when the key is turned to the ON position The lamp is a reminder to the operator to ensure all riders are wearing helmets and seat belts before operating N zD Check Engine This indicator appears if an EFl related faul
74. n the Rider Information Center the trip meter display contains a decimal point but the odome ter displays without a decimal point Tachometer Mode The engine RPM is displayed digitally Tip Small fluctuations in the RPM from day to day may be normal because of changes in humidity temperature and elevation Engine Temperature Mode This mode displays current temperature of the engine coolant Hour Meter Mode This mode logs the total hours the engine has been in operation Programmable Service Interval When the hours of engine operation equal the programmed service interval setting the wrench icon will flash for 5 seconds each time the engine is started When this feature is enabled it provides a convenient reminder to perform routine maintenance The service interval is programmed at 50 hours at the factory Use the following procedure to change the service interval Press the MODE button until remaining service hours display 2 Press and hold the MODE button 3 When the service hours flash press and release the MODE button to advance the hours to the desired setting including OFF Press and hold the MODE button to set the new service hour interval Diagnostic Display Mode The EFI diagnostic display mode is for informational purposes only Please see your POLARIS dealer for all major repairs The diagnostic mode is accessible only when the check engine warning indicator activates after the key has been turned on Leav
75. n the ON position The EPS warning indicator will illuminate to indicate the EPS has shut down Turn the key off and on to reset the unit See page 26 for EPS warning indicator information 21 FEATURES AND CONTROLS Seat and Storage Compartments The battery fuses and storage compartments are located under the seats Pull the rear edge of a seat upward to release the latch pins from the grommets Roll the seat forward to access the under seat area The fuses are located under the center portion of the seat Never use this area for storage Storage compartments are located under both driver and passenger seats Remove the storage bin under the passenger seat to access the battery To completely remove a seat roll the seat forward and lift the seat tabs from the seat base mounts Always make sure all seats are properly installed and securely latched before operating Push down firmly on the rear of each seat until the latch pins are fully seated into the grommets m a vn s k S A K EAA 3 SS U ar aS wat j P 479 38 RSA DISAN 4 p o 7 1P lt MN T sel rE lion v Storage Compartment Battery Under Driver s Seat Under Storage Bin Electrical Fuse Compartment Not For Storage
76. nance 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 Frequent or prolonged operation in dusty environments Racing or race style high RPM use Prolonged low speed heavy load operation Extended idle Frequent short trip operation in cold weather engine frequently does not operate long enough to reach full operating temperature Pay special attention to the oil level A rise in oil level during cold weather can indicate con taminants collecting in the oil sump or crankcase Change oil immediately if the oil level begins to rise Monitor the oil level and if it continues to rise discontinue use and determine the cause or see your dealer Maintenance Chart Key gt Perform these operations more often for vehicles subjected to severe use E Emission related service Failure to conduct this maintenance will not void the emis sions warranty but may affect emissions D Have an authorized POLARIS dealer perform these services WARNING Improperly performing the procedures marked with a D could result in component failure and lead to serious injury or death Have an authorized POLARIS dealer perform these services 47 MAINTENANCE Periodic Maintenance Chart Perform all services at which
77. nd may void all warranty offered by the manufacturer 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 Lubricants 1 Mixing oil brands or using non recommended oil may cause engine damage We recommend the use of POLARIS engine oil
78. nder with a protective film of fresh oil 5 Apply dielectric grease to the inside of each spark plug cap and reinstall the caps onto the plugs 6 If POLARIS fuel system additive is not used fuel tank fuel lines and injectors should be completely drained of gasoline Storage Area Covers Be sure the storage area is well ventilated Cover the vehicle with a genuine POLARIS cover Do not use plastic or coated materials They do not allow enough ventilation to pre vent condensation and may promote corrosion and oxidation 74 MAINTENANCE Removal from Storage Bob E Charge the battery if necessary Install it in the vehicle Make sure the spark plug is tight Fill the fuel tank with fuel Check all the points listed in the Daily Pre Ride Inspection section on page 32 Tightness of the bolts nuts and other fasteners should be checked by an authorized POLARIS dealer Lubricate at the intervals outlined in the Periodic Maintenance Chart beginning on page 4T Transporting the RANGER Follow these procedures when transporting the vehicle 1 2 3 4 Place the transmission in PARK Stop the engine Secure the fuel cap hood seats and cargo box Always tie the frame of the RANGER to the transporting unit securely with suitable straps or rope Do not attach tie straps to the front A arm bolt pockets Remove the key to prevent loss during transporting 75 SPECIFICATIONS Maximum Weight Capacity RANGER XP 900
79. nditions or at high throttle for extended periods 1 Lift the cargo box to access the air box 2 Release the five 5 air box xs Right Side cover latches and lower the bot Left Side View View tom to expose the air filter 3 Remove the air filter 4 Inspect the air box for oil or water deposits Wipe away any deposits with a clean cloth 5 Install a new filter if needed Do not attempt to clean the air filter Intake Screens An engine intake screen is located on the driver s side of the vehicle A clutch intake screen is located on the passenger side of the vehicle y Intake Screens 7 both sides Inspect the screens before each use of the vehicle Remove the screens and clean them frequently with warm soapy water to ensure adequate air flow 60 MAINTENANCE Spark Arrester AWARNING Failure to heed the following warnings while servicing the spark arrester could result in serious injury or death Do not perform clean out immediately after the engine has been run as the exhaust system becomes very hot Serious burns could result from contact with the exhaust components Allow components to cool sufficiently before proceeding Wear eye protection and gloves Never run the engine in an enclosed area Exhaust contains poisonous carbon monoxide gas that can cause loss of consciousness or death in a very short time Periodically clean the spark arrestor to remove accumulated carbon
80. nt n o naaaaea 21 Stopping the Engine 33 hirci NOM 72 74 Storage ATOR e RR sess s oh oss ee e wed a 74 Storage Compartment Under Seat 22 storage Battery oa ace esses hm m ea 70 Storage COVEIS x cos cora cete t 9 tee ee 74 Storage Fluid Levels ia av poker enne 74 Storage Oil and Fer 73 Storage Removal 75 Suspension Adjustment Rear 64 Switches AWD Switch 20 Differential Lock Switch 20 Ignition veces e RR eR 20 JE EI MT E MERO 20 Mode Button 24 20 90 T Tachometer crux ome EP aoe ate Gand 29 Throttle Pedal 96 saos tue ees yes 21 Tilt Steering se sucos ee tege tee 21 Tire Tread Depth i v scr retos 65 STIS as Lector tede aodyandnasin Sob ipe torte oes e 65 66 Torque Axle Nuts 65 Torque Spark Plug 0 00 0005 55 Torque Wheel Nut ete RP erede 65 Towing Loads eaa Saa R ga Rd Ra RR iesise 42 Towing Speed cecce dE R EE RER ee ee 42 Trailer Hiteli o reeda ars RB REX RES RR 21 Transmission lt wed K cise diese a RE RR UR xc 53 Transmission Operation 58 59 Transmission System 00 58 59 Transmission Waming 58 59 Transmission Drying 2 005 59 Transporting the Vehicle 75 Tread Depth estes eee EE ls 65 U Under Seat Storage 4 69 R N ER thennis 22 V Vehicle Identification Numbers 6 Vehicle Immersion
81. ntenance or part of completing an effective repair The following items are excluded from warranty coverage in the event of a warranty claim Spark Plugs Lubricants such as oil grease etc Filters Batteries unless defective Fuel Cosmetic damage repair Sealants Coolants Hotel fees Meals Towing charges Shipping handling fees Mileage Product pick up delivery Rentals Loss of product use Loss of vacation personal time 82 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 unauthorized repair center use of the product in competition or for commercial purposes Warranty will not apply to any product which has been damaged by abuse accident fire or any other casualty not determined a defect of materials or workmanship This warranty does not cover the use of unauthorized lubricants chemicals or fuels that are not compatible with the vehicle The exclusive remedy for
82. ntering obstacles and slopes and when braking on hills or during turns This vehicle 1s 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 visibil ity and operating conditions and your experience Never attempt jumps or other stunts Always inspect the vehicle before each use to make sure it s in safe operating condition Always follow the inspection procedures described in this manual Always travel slowly and use extra caution when operating on unfamiliar terrain Be alert to changing terrain Never operate on excessively rough slippery or loose terrain Always follow proper procedures for turning Practice turning at slow speeds before attempting to turn at faster speeds Never turn at excessive speeds Always have this vehicle checked by an authorized POLARIS dealer if it has been involved in an accident Never operate this vehicle on hills too steep for the vehicle or for your abilities Practice on smaller hills before attempting larger hills 12 SAFETY sd Safety 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 slip pery or loose surfaces Never apply throttle suddenly Never make su
83. ntial Shift Type Single Lever H L N R P Gear Reduction Low 8 56 1 Gear Reduction Reverse 7 67 1 Gear Reduction High 3 48 1 Drive Ratio Front 3 818 1 25x 10 12 26 x 9 12 for select models Tire Size Rear 25x11 12 26 x 11 12 for select models Tire Pressure Front 10 psi 69 kPa Tire Pressure Rear 12 psi 83 kPa Brakes Front Rear Foot Activated 4 wheel hydraulic disc Hood Headlight 2 single beam 50W quartz halogen Taillights 10 L E D 28W Brake Light 10 L E D 3 1W Clutching See your POLARIS dealer for clutching specifications 77 POLARIS PRODUCTS Part Number Description Engine Lubricant 2870791 Fogging Oil 12 0z 355 ml Aerosol 2876244 PS 4 PLUS Performance Synthetic 2W 50 4 Cycle Oil qt 95 1 2876245 PS 4 PLUS Performance Synthetic 2W 50 4 Cycle Oil gal 3 8 Gearcase Transmission Lubricants 2878068 AGL PLUS Transmission Fluid qt 95 I 2878069 AGL PLUS Transmission Fluid gal 3 8 I 2877922 Demand Drive Plus Fluid qt 95 I 2877923 Demand Drive Plus Fluid gal 3 8 1 2871653 Premium ATV Angle Drive Fluid 8 0z 237 ml 2872276 Premium ATV Angle Drive Fluid 2 5 gal 9 5 I 2870465 Pump for Gallon 3 8 I Jug Coolant 2871323 60 40 Coolant gal 3 8 I 2871534 60 40 Coolant qt 95 I Grease Specialized Lubricants 2871312 Grease G
84. o low to keep the battery charged It may also occur when the engine is at idle and high electrical load lights cooling fan accessories is applied Drive at a higher Clock The clock displays time in a 12 hour or 24 hour format See page 28 for reset Service Indicator A flashing wrench symbol alerts the operator that the preset service interval has been reached The vehicle should be brought to your dealer for scheduled 4X4 Indicator This indicator illuminates when the 4X4 system is engaged switch is 2 the fuel icon will flash Refuel immediately Tip your dealer 3 temperature meter engine hour meter and programmable service hour interval 4 RPM or recharge the battery to clear the warning 5 ting instructions 6 maintenance See page 28 for resetting instructions 7 on 4X4 8 Turf Mode Indicator This indicator illuminates when the operator unlocks the differ ential See page 45 27 FEATURES AND CONTROLS Instrument Cluster Rider Information Center Use the MODE button to toggle through the information area options Display Units Standard Metric The display can be changed to display either standard or metric units of measurement Tip To exit the set up mode at any time wait 10 seconds The display automatically exits and returns to the odometer display Standard Display Metric Display Distance Miles Kilometers Fuel U S Gallons Liters Imperial Gallons Temperature Fahrenh
85. onents Access the oil fill cap dipstick and filter under the cargo box 1 Remove all cargo from the cargo box See page 43 2 Position the vehicle on a level surface 51 MAINTENANCE Engine Oil Oil and Filter Change 3 Place the transmission in PARK 4 Stand clear and pull up on the cargo box release lever Lift the front of the cargo box 5 6 Locate the crankcase drain plug access hole in the skid plate Clean the area around the crankcase drain plug CAUTION Hot oil can cause burns to skin Do not allow hot oil to contact skin T 10 11 12 13 14 15 16 17 18 19 20 21 52 Place a drain pan under the engine crankcase and remove the drain plug Allow the oil to drain com pletely Using an oil filter wrench turn the filter counter clockwise to remove it Using a clean dry cloth clean the filter sealing surface on the crankcase Lubricate the o ring on the new filter with a film of fresh engine oil Check to make sure the o ring is in good condition Install the new filter and turn by hand until the fil ter gasket contacts the sealing surface then turn an additional 1 2 turn Reinstall the drain plug Torque the drain plug to 12 ft Ibs 16 Nm Remove the oil fill cap and add 2 5 quarts 2 4 I of recommended oil Reinstall the fill cap Start the engine and check for leaks Stop the engine and wait 15 seconds before removing the dipstick Remove t
86. onic fuel injection EFI system The engine and EFI components are set at the factory for optimal performance and are not adjustable The emissions label is located on the main frame under the driver s seat and storage compartment Electromagnetic Interference This spark ignition system complies with Canadian ICES 002 This vehicle complies with the EMC requirements of European directives 97 24 EC and 2004 108 EC Non ionizing Radiation This vehicle emits some electromagnetic energy People with active or non active implantable medical devices such as heart monitoring or controlling devices should review the limitations of their device and the applicable electromagnetic standards and directives that apply to this vehicle 46 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 87 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 Mainte
87. ons 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 differ ential and allow the rear drive wheels to operate 4 independently This mode of operation is well suited to turf driving or whenever aggressive trac tion is not required 45 EMISSION CONTROL SYSTEMS Noise Emission Control System Do not modify the engine intake or exhaust components as doing so may affect compliance with U S A EPA noise control requirements 40 CFR 205 and local noise level require ments Operation on Public Lands in the U S A Your POLARIS vehicle has a spark arrester that was tested and qualified to be in accordance with the USFS standard 5100 1c Federal law requires that this spark arrester be installed and functional when the vehicle is operated on public lands Operation of off road vehicles on public lands in the U S A is regulated by 43 CFR 420 Violations are subject to monetary penalties Federal regulations can be viewed online at www gpoaccess gov ecfr Crankcase Emission Control System This engine is equipped with a closed crankcase system Blow by gases are forced back to the combustion chamber by the intake system All exhaust gases exit through the exhaust system Exhaust Emission Control System Exhaust emissions are controlled by an electr
88. or fast flowing water which could result in loss of control and lead to serious injury or death Never cross deep or fast flowing water with your RANGER 5 After leaving water always dry the brakes by applying light pressure to the pedal repeatedly until braking action is normal Avoid applying brake and throttle at the same time NOTICE After running your vehicle in water it s critical that you perform the services outlined in the Periodic Maintenance Chart beginning on page 47 Give special attention to engine oil transmission oil all gearcase fluids and all grease fittings 38 OPERATION Driving in Reverse Follow these precautions when operating in reverse 1 Qv be oc PA 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 ightly for stopping Avoid turning at sharp angles Apply only ight throttle Never apply throttle suddenly 39 OPERATION Parking the Vehicle 1 Apply the brakes Stop the vehicle on a level surface 2 When parking inside a garage or other structure be sure that the structure is well 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 transmission in PARK 4 Turn the engine off 5 Remove the ignition switch key to prevent unauthorized use Pa
89. osition the vehicle on a level surface Plug WE x 2 Place the transmission in PARK 3 os the level check fill plug Check the oil evel 4 Add the recommended oil as needed gt OB 5 Reinstall the fill plug Torque to specification K Oil Change R The drain plug is located near the bottom of the gearcase 1 Remove the level check fill plug Drain Plug Place a drain pan under the gearcase Remove the drain plug Allow the oil to drain completely Clean and reinstall the drain plug Torque to specification Add the recommended oil Reinstall the fill plug Torque to specification SN Me D p Check for leaks Dispose of used oil properly 53 MAINTENANCE Gearcases Front Gearcase Always check and change the front gearcase oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 47 Maintain the oil level even with the bottom thread of the fill plug hole Refer to the Gearcase Specifications Chart on page 53 for recommended lubricants capaci ties and torque specifications See page 78 for the part numbers of POLARIS products Oil Check The front gearcase fill plug is located on the right side of the front gearcase 1 Position the vehicle on a level surface 2 Place the transmission in PARK 3 Remove the fill plug Check the oil level 4 Add the recommended oil as needed 5 Reinstall the fill plug Torque to specification Oil Change 1 Support the vehicle securely with a ja
90. r repair But if the overflow bottle has run dry the level in the radiator should also be inspected 5 Reinstall the pressure cap Use of a non standard pressure cap will not allow the recov ery system to function properly See your dealer for the correct replacement part 57 MAINTENANCE POLARIS Variable Transmission PVT System AWARNING Failure to comply with the instructions in this warning can result in severe injury or death Do not modify any component of the PVT system Doing so may reduce its strength so that a failure may occur at a high speed The PVT system has been precision balanced Any modification will cause the system to be out of balance creating vibration and additional loads on components The PVT system rotates at high speeds creating large amounts of force on clutch components Extensive engineering and testing has been conducted to ensure the safety of this product However as the owner you have the following responsibilities to make sure this system remains safe Always follow all recommended maintenance procedures Always look for and remove debris inside and around the clutch and vent system when replacing the belt See your dealer as outlined in the owner s manual This PVT system is intended for use on POLARIS products only Do not install it in any other product Always make sure the PVT housing is securely in place during operation Belt Replacement Debris Removal If a belt fails always
91. res 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 Using Alcohol or Drugs Operating the vehicle after consuming alcohol or drugs could adversely affect operator judgment reaction time balance and perception 2 Never drink alcohol or use drugs or medications before or while operating NC this 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 Seat belts reduce the severity of injury in the event of a sudden stop or accident 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
92. ressure hose could damage the radiator fins and impair the radiator s effectiveness Using a high pressure system is not recommended 56 MAINTENANCE Cooling System Overflow Bottle Coolant Level Always check and change the coolant at the intervals outlined in the Periodic Maintenance Chart beginning on page 47 Maintain the coolant level between the minimum and maximum marks on the bottle when the fluid is cool 1 Position the vehicle on a level surface Maximum Level Place the transmission in PARK Cold S 2 Remove the hood See page 23 4 View the coolant level in the P L j Minimum overflow bottle n PM Level 5 Ifthe coolant level is below the safe operating range use a funnel to add coolant through the filler opening Reinstall the cap Tip If coolant must be added often or if the overflow bottle runs completely dry there may be a leak in the sys tem Have the cooling system inspected by your POLARIS dealer Radiator Cap Radiator Coolant Level 1 Remove the hood See page 23 CAUTION Escaping steam can cause burns Never remove the pressure cap while the engine is warm or hot Always allow the engine to cool before removing the pressure cap 2 Slowly remove the radiator cap 3 View the coolant level through the opening 4 Use a funnel and slowly add coolant as needed Tip This procedure is required only if the cooling system has been drained for maintenance and o
93. rking on an Incline Avoid parking on an incline if possible If it s unavoidable follow these precautions 1 Apply the brakes 2 Place the transmission in PARK 3 Turn the engine off 4 Block the rear wheels on the downhill side 15 maximum 40 OPERATION Hauling Cargo AWARNING Hauling cargo improperly can alter vehicle handling and may cause loss of control or brake instability which can result in serious injury or death Always follow these precautions when hauling cargo Never exceed the maximum weight capacity of the vehicle When determining the weight you are adding to the vehicle include the weight of the operator passenger accessories loads in the rack or box and the load on the trailer tongue The combined weight of these items must not exceed the maximum weight capacity REDUCE SPEED AND ALLOW GREATER DISTANCES FOR BRAKING WHEN HAULING CARGO Always load the cargo box with the load as far forward and as low as possible When operating over rough or hilly terrain reduce speed and cargo to maintain stable driving conditions Always operate the vehicle with extreme care when hauling or towing loads Slow down and drive in the lowest gear available Always use LOW gear when towing or hauling heavy loads 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 LO
94. s 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 have 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 84 WARRANTY U S A EPA Emissions Limited Warranty This emissions limited warranty is in addition to the POLARIS standard limited warranty for your vehicle POLARIS Industries Inc warrants that at the time it is first purchased this emissions certified vehicle is designed built and equipped so it conforms with applicable U S Environmental Protection Agency emission reg ulations POLARIS warrants that the vehicle is free from defects in materials and workmanship that would cause it to fail to meet these regulations The warranty period for this emissions certified vehicle starts on the date the vehicle is first purchased and con tinues for a period of 500 hours of engine operation 5000 kilometers 3100 miles of vehicle travel or 30 calen dar months from the date of
95. spev yes 50 52 Transmission es aeisi S RN S R ee 53 Oil and Filter Care During Storage 73 Oil Change EBDEIne oeei mie hiai v ERERTEERNS 51 52 Front Geatcase 2c see ees 54 Main Gearcase esses 53 Transmission lesse 53 Oil Level Engine eseri hi Er eee eet 51 Front Gearcase oeeo Ree ee ressas 54 Main Gearcase iiiar an a eaa 53 Transmission n sananne 53 Oil Recommendation Engine 50 Operation on Public Lands 46 Operator Safety cic ncaa eve dyi pre 12 17 Outlets Auxiliary lese 00000 19 P Parking on an Incline ess san n KR esses 40 Parking the Nehle 5 0 T EE 0 Z AE ATRE ATR RE a 40 Part Numbers 42522 ke eer e 78 Periodic Maintenance Chart 47 49 Plig Gaper recepere ERR RR ES 55 Plug Torge ieee ohh pando ennO GERE EE 55 Plug Accessory 09 R R 9 R dT R eee eee 19 Plugs Fouled a r EE eR T KAR L we 55 Plugs Spark sio kon ip ebbe IE pA RT RISQUE 55 Polaris Products lt 29 9 59 50 RR R renis 78 Polishing the Vehicle 0 72 Power Steeting els NA e EE R de nee 21 Power Steering Unit Cleaning 66 Pre Ride Inspection n nuunna annn 32 Product Part Numbers 0 78 Public Lands 5o iure wks REPRE SR ee 46 PVT Break In 4 55256 Rm eines 31 PVT Drying sis ene emere eee es 59 PVT System ems ri Wa NRE WER RS 58 59 PVT Warning RR RR Ra R 58 59 PVT Cleaning Debris
96. switch is a three position key operated switch The key can be removed from the switch when it is in the OFF position OFF The engine is off Electrical circuits are off except Acc 1 ON Electrical circuits are on Electrical equip ment can be used START Turn the key to the START poemon to engage the electric starter The key returns to the ON position when released Mode Button The MODE button is located on the instrument cluster Use the MODE button to toggle through mode options available in the instrument cluster See pages 26 30 Light Switch The ignition switch key must be in the ON RUN position to operate the headlights Press the top of the rocker switch toward the dash to place the headlights on high beam Move the rocker switch to the center position to place the headlights on low beam Press the bottom of the rocker switch to turn off the headlights AWD Differential Lock Switch The AWD Differential Switch has three positions All Wheel Drive AWD Differential Lock 2WD Differential Unlock Press the top of the rocker switch to engage All Wheel Drive AWD See page 44 for operating instructions Move the rocker switch to the center position to lock the differential and operate in rear wheel drive Press the bot tom of the switch to unlock the differential and allow the two rear drive wheels to operate independently See page 45 for differential lock operating instructions
97. t aggressive throt tle application to engage clutch WARNING Excessive throttle may cause loss of control and vehicle over turn Climbing over large objects from a stopped position Shift the transmission to low range and carefully use fast brief aggressive throttle application to engage clutch WARNING Excessive throttle may cause loss of control and vehicle over turn Belt slippage from water or snow ingestion into the PVT system Dry out the PVT See page 59 Inspect clutch seals for damage if repeated leaking occurs Clutch malfunction See your POLARIS dealer Poor engine performance Check for fouled plugs or foreign material in gas tank or fuel lines See your dealer Slippage from failure to warm up belt Always warm up the belt by operating below 30 MPH for one mile 5 miles or more when temperature is below freezing Wrong or missing belt Install the recommended belt Improper break in Always break in a new belt and or clutch See pages 31 and 58 79 TROUBLESHOOTING Engine Doesn t Turn Over Possible Cause Low battery voltage Solution Recharge the battery to 12 8 VDC Loose battery connections Check all connections and tighten Loose solenoid connections Check all connections and tighten Loose electronic control box connections Inspect clean reinstall connectors Engine Turns Over Fails to Start Possible Cause
98. t Front 75 ft Ibs 102 Nm Hub Retaining Nuts Rear 110 ft Ibs 150 Nm 65 MAINTENANCE Tires Wheel Removal Position the vehicle on a level surface Place the transmission in PARK Stop the engine Loosen the wheel nuts slightly Elevate the side of the vehicle by placing a suitable stand under the frame DP ee I Remove the wheel nuts and washers Remove the wheel Wheel Installation 1 Place the transmission in PARK 2 Place the wheel in the correct position on the Er wheel hub Be sure the valve stem is toward E the outside and rotation arrows on the tire r lt 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 3 Attach the wheel nuts and washers and fin ger tighten a 4 Carefully lower the vehicle to the ground 5 Torque the wheel nuts to specification See page 65 Power Steering Unit If your model is equipped with power steering fre quently clean the areas around and on the power steering unit to allow proper cooling Clean these areas thoroughly Clean Often 66 MAINTENANCE Lights Poor lighting can result in reduced visibility when driving Headlight and taillight lenses become dirty during normal oper
99. t occurs Do not operate the vehicle if this warning appears Serious engine damage could result See your dealer 26 Instrument Cluster Rider Information Center The rider information center is located in the instrument cluster All segments will light up for one sec ond at start up If the instrument cluster fails to illuminate a battery over voltage may have occurred and the instrument cluster may have shut off to protect the electronic speedometer If this occurs take the vehicle to your POLARIS dealer for proper diagnosis The information center is set to dis play standard units of measurement FEATURES AND CONTROLS WE Lent TERE T PU Trip 1 NA i pnp INTHN NI IAN GN N N NUN and a 12 hour clock at the factory To change to metric and or a 24 hour clock see page 28 1 Gear Indicator This indicator displays gear shifter position H High Gear L Low Gear N Neutral R Reverse Gear P Park Gear Signal Error or shifter between gears Fuel Gauge The segments of the fuel gauge show the level of fuel in the fuel tank When the last segment clears a low fuel warning is activated All segments including If the fuel icon fails to display an open or short circuit has occurred in the fuel sensor circuit See Information Display Area This area displays odometer trip meter tachometer engine Under Over Voltage This warning usually indicates that the vehicle is operating at an RPM to
100. ter Inspect clean 60 Headlamp Verify proper operation Brake light tail lamp Verify proper operation Seat Belts Check length of belt for damage check latches for 25 proper operation Cab Nets Check for wear or damage ensure proper installation 24 32 OPERATION Starting the Engine 1 Always start the engine outdoors or in a well ventilated area Sit in the driver s seat and fasten the seat belt Secure the cab nets Place the transmission in PARK Apply the brakes Do not press the throttle pedal while starting the engine Turn the ignition key past the ON RUN position to START Engage the starter for a max imum of five seconds Release the key when the engine starts QA Be MA Fo 6 Ifthe engine does not start within five seconds release the ignition switch and wait five seconds Repeat steps 5 and 6 until the engine starts Stopping the Engine 1 Release the throttle pedal completely and brake to a complete stop 2 Place the transmission in PARK 3 Tum the engine off WARNING A rolling vehicle can cause serious injury Always place the transmission in PARK when stopping the engine Braking 1 Release the throttle pedal completely Tip When the throttle pedal is released completely and the engine speed drops near an idle the vehi cle has no engine braking 2 Press on the brake pedal evenly and firmly Tip If the throttle pedal and brake pedal are applied simultaneously engine power may be limited 3 Prac
101. tice starting and stopping using the brakes until you re familiar with the controls 33 OPERATION Driving Procedure SO Go cp Oy UA ce US B3 34 Wear a helmet eye protection gloves long sleeve shirt long pants and over the ankle boots Perform the pre ride inspection See page 32 Sit in the driver s seat and fasten the seat belt Always use the cab nets while riding in this vehicle Place the transmission in PARK Start the engine Apply the service brakes and shift the transmission into gear Check your surroundings and determine your path of travel Keeping both hands on the steering wheel slowly release the brakes and slowly depress the throttle with your right foot to begin driving Drive slowly Practice maneuvering and using the throttle and brakes on level surfaces 11 Do not carry a passenger until you have at least two hours of driving experience with this vehicle OPERATION Driving with a Passenger l 2 9 Perform the pre ride inspection See page 32 Make sure all passengers are at least 12 years of age and tall enough to comfortably and safely sit in a passenger seat with the seat belt secured put both feet on the floor and grasp the hand hold Make sure all passengers are wearing helmet eye protection gloves long sleeve shirt long pants and over the ankle boots Make sure all passengers secure their seat belt Make sure all cab nets are properly secured Do not carry
102. un Kit Premium All Season 2871322 Premium All Season Grease 3 0z 89 ml cartridge 2871423 Premium All Season Grease 14 0z 414 ml cartridge 2871460 Starter Drive Grease 2871515 Premium U Joint Lube 3 oz 89 ml cartridge 2871551 Premium U Joint Lube 14 0z 414 ml cartridge 2871329 Dielectric Grease Nyogel 2872073 Chain Lube Aerosol 6 25 oz 2872348 Chain Lube Aerosol 16 oz Additives Miscellaneous 2871326 Carbon Clean Plus 2872189 DOT 4 Brake Fluid 2871956 Loctite 565 Thread Sealant 2871076 POLARIS Battery Tender Charger 78 TROUBLESHOOTING Drive Belt Wear Burn Possible Cause Solution Driving onto a pickup or tall trailer in high range Use low range during loading Starting out going up a steep incline Use low range See warnings on page 37 Driving at low RPM or ground speed 3 7 MPH Drive at a higher speed or use low range more frequently Insufficient warm up at low ambient temperatures Warm the engine at least 5 minutes With the transmission in neutral advance the throttle to about 1 8 throttle in short bursts 5 to 7 times The belt will become more flexible and prevent belt burning Slow easy clutch engagement Use the throttle quickly and effectively Towing pushing at low RPM low ground speed Use low range only Utility use plowing Use low range only Stuck in mud or snow Shift the transmission to low range and carefully use fas
103. ur vehicle Outside the Country where your vehicle was purchased If you are traveling temporarily outside the country where your vehicle was purchased you should take your vehicle to an authorized POLARIS dealer You must show the dealer photo identification from the country of the selling dealer s authorized location as proof of residence Upon residence verification the servicing dealer will be authorized to perform the warranty repair If You Move If you move to another country be sure to contact POLARIS Customer Assistance and the customs department of the destination country before you move Vehicles importation rules vary considerably from country to country You may be required to present documentation of your move to POLARIS Industries in order to continue your warranty coverage You may also be required to obtain documentation from POLARIS Industries in order to 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 addres

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