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2015 RGR 325 570 4X4 Crew.fm

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1. Auxiliary Outlet The 12 volt receptacle has spade connections on the back that may be used to power an auxiliary light or other optional accessories or lights The connections are behind the console under the hood Mode Button The yellow button located near the instrument cluster is used to toggle through mode options available See pages 30 34 Ignition Switch Light Switch The ignition switch is a four position key operated switch The key can be removed from the switch when it is in the OFF position OFF The engine is off Electrical circuits are off except Acc 12V LIGHTS ON Lights are on Electrical circuits are on Electrical equipment can be used LIGHTS OFF Lights are off Electrical circuits are on Electrical equipment can be used START Turn the key to the START position to engage the electric starter Turn the key to the LIGHTS ON position after starting the engine 22 FEATURES AND CONTROLS Console All Wheel Drive AWD Switch if equipped The AWD Switch has two positions All Wheel Drive AWD Two Wheel Drive 2WD Press the top of the rocker switch to engage All Wheel Drive Press the bottom of the switch to operate in two wheel drive AWD See page 46 for AWD operating instructions AWD Differential Lock Switch if equipped The AWD Differential Switch has three positions All Wheel Drive AWD AWD Differential Lock Two Wheel Drive 2WD Differential Unl
2. 1 2 9 Perform the pre ride inspection See page 36 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 or doors are properly secured Do not carry more than the recommended number of passengers for your vehicle See pages 11 11 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 38 OPERATION Driving On Slippery Surfaces A WARNING Skidding or sliding can cause loss of control or rollover if tires regain traction unexpectedly When operating on slippery surfaces such as ice or loose gravel reduce speed and use extra caution to reduce the chance of skidding or sliding out of control Do not operate on excessively slippery surfaces Whenever riding on slippery
3. If your factory installed 14 AH battery cannot maintain a charge because of operation in extreme cold or with multiple electrical accessories please see your POLARIS dealer to purchase a 30 AH battery Before installing the 30 AH battery remove the plastic spacer at the bottom of the battery compartment Save the spacer for future use 1 Ensure that the battery is fully charged 2 Place the fully charged battery in the battery holder 3 With conventional batteries install the battery vent tube sealed batteries do not have a vent tube The vent tube must be free of obstructions and securely installed Route the tube away from the frame and vehicle body to prevent contact with electrolyte WARNING Battery gases could accumulate in an improperly installed vent tube and cause an explosion resulting in serious injury or death Always ensure that the vent tube is free of obstructions and is securely installed as recommended 4 Coat the terminals with dielectric grease or petroleum jelly 5 Connect and tighten the red cable first Connect and tighten the black cable last 6 Verify that cables are properly routed Cables should be safely tucked away at the front and rear of the battery 7 Install the battery hold down strap 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 plac
4. Using a clean dry cloth clean the surface of the crankcase Lubricate the o ring for the new filter with a film of fresh engine oil Check to make sure the o ring is in good condition Install the o ring to the filter cover Reinstall the oil filter spring then install the new filter MAINTENANCE Sealing Vent Pede Spring P gt Drain S e Plug EZ Q Filter re a O Ring Filter Cover Reinstall the oil filter cover and o ring Torque the screws to 88 in lbs 10 Nm Fill the sump with 1 75 quarts 1 65 1 of the recommended oil Reinstall the upper fill cap if removed and tighten the dipstick Make sure the transmission is in PARK Apply the brakes Start the engine Allow it to idle for one to two minutes Stop the engine Inspect for leaks Re check the oil level on the dipstick and add oil as necessary to bring the level to the upper mark on the dipstick Dispose of used filter and oil properly 65 MAINTENANCE Gearcases Gearcase Specification Chart Gearcase Lubricant Capacity Fill Plug s Drain Plug Torque Torque 570 Main Gearcase AGL Gearcase 41 oz 10 14 ft Ibs 10 14 ft Ibs Transmission Lubricant amp 1200 ml 14 19 Nm 14 19 Nm ETX Main Gearcase l ansmission Fluid 44 oz 10 14 ft lbs 10 14 ft Ibs Transmission 1300 ml 14 19 Nm 14 19 Nm Front Gearcase Demand Drive Fluid 9 3 oz 8 10 ft Ibs 11 ft Ibs 275 ml 11 13 6 Nm
5. gearcase will automatically disengage There is no limit to Differential Unlock the length of time the vehicle may remain in AWD AWD Initially the vehicle s electronic system will not enable the AWD until the engine RPM is below 3100 Once enabled the AWD remains enabled until the AWD switch is turned off If the switch is turned off while the front gearcase is moving it will not disengage until the rear wheels regain traction Engage the AWD before getting into conditions where front wheel drive may be needed If the rear wheels are spinning release the throttle before switching to AWD NOTICE Switching to AWD while the rear wheels are spinning may cause severe drive shaft and clutch damage Always switch to AWD while the rear wheels have traction or are at rest Disengaging AWD 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 UA de Ug If the front gearcase re
6. Allow it to idle for two to three minutes Stop the engine 62 Engine Oil 570 Oil and Filter Change 3 Clean the area around the drain plug CAUTION Hot oil can cause burns to skin Do not allow hot oil to contact skin 4 Place a drain pan beneath engine crankcase and remove the drain plug Allow the oil to drain completely Reinstall the sealing washer on the drain plug The sealing surfaces on drain plug and crankcase should be clean and free of burrs nicks or scratches Reinstall the drain plug Torque to 12 ft lbs 16 Nm Using a cap style oil filter wrench turn the filter counter clockwise to remove it Using a clean dry cloth clean the filter sealing surface on the crankcase Make sure the old fil ter o ring is completely removed 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 rotate it clockwise by hand until the filter gasket contacts the sealing surface then turn it an additional 3 4 turn Always clean away all dirt and debris from the dipstick area before removing the dipstick Remove the dipstick or the oil fill cap on the top of the engine and fill the sump with two quarts 1 9 I of recommended oil Reinstall and tighten the dipstick Make sure the transmission is in PARK Apply the brakes Start the engine Allow it to idle for one to two minutes Stop th
7. be sure to contact POLARIS Customer Assistance and the customs department of the destination country before you move Product importation rules vary considerably from country to country You may be required to present documentation of your move to POLARIS in order to continue your warranty coverage You may also be required to obtain documentation from POLARIS in order to register your product in your new country You should warranty register your product at a local POLARIS dealer in your new country immediately after you move to continue your warranty coverage and to ensure that you receive information and notices regarding your vehicle If you purchase from a private party If you purchase a POLARIS product from a private party to be kept and used outside of the country in which the product was originally purchased all warranty coverage will be denied You must nonetheless register your product under your name and address with a local POLARIS dealer in your country to ensure that you receive safety information and notices regarding your product Exported Products EXCEPT WHERE SPECIFICALLY REQUIRED BY LAW THERE IS NO WARRANTY OR SERVICE BULLETIN COVERAGE ON THIS PRODUCT IF IT IS SOLD OUTSIDE THE COUNTRY OF THE SELLING DEALER S AUTHORIZED LOCATION This policy does not apply to products that have received authorization for export from POLARIS Dealers may not give authorization for export You should consult an authorized dealer to determine this
8. 15 Nm Transmission Main Gearcase Always check and change the transmission oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 59 Maintain the oil level even with the bottom thread of the fill plug hole Refer to the Gearcase Specifications Chart for recommended lubricants capacities and torque specifications See page 92 for the part numbers of POLARIS products Fluid Check The fill plug is located on the rear of the gearcase View from Maintain the fluid level at the bottom of the fill plug hole P E rear of vehicle 1 Position the vehicle on a level surface 2 IE 2 Remove the fill plug i 3 Check the fluid level d i 4 Add the recommended fluid to the bottom of the fill zl plug hole Do not overfill 5 Reinstall the fill plug Torque to specification Fluid Change The drain plug is located on the bottom of the gearcase Access the drain plug through the hole in the skid plate f 1 o mi Fill Plug View from rear left side of vehicle 1 Remove the fill plug 2 Place a drain pan under the drain plug 3 Remove the drain plug Allow the fluid to drain completely 4 Clean and reinstall the drain plug Torque to specification 5
9. ATV Angle Drive Fluid 2 5 gal 9 5 I 2871460 Premium Starter Grease 2871515 U Joint Grease 3 0z 89 ml cartridge 2871551 U Joint Grease 14 0z 414 ml cartridge 2871329 Dielectric Grease Nyogel Additives Miscellaneous 2871326 Carbon Clean 2870652 Fuel Stabilizer 2872189 DOT 4 Brake Fluid 2871956 Loctite 565 Thread Sealant 2859044 POLARIS Battery Tender Charger 5253552 POLARIS Battery Strap Bracket for 30 AH Battery 4010630 POLARIS 30 AH Battery 2521372 POLARIS Air Filter 92 TROUBLESHOOTING Drive Belt Wear Burn Possible Cause Driving onto a pickup or tall trailer in high range Solution Use low range during loading Starting out going up a steep incline Use low range See warnings on page 40 Driving at low RPM or ground speed 3 7 MPH Drive at a higher speed or use low range more frequently See page 71 Insufficient warm up at low ambient temperatures Warm the engine at least 5 minutes With the transmission in neutral advance the throttle to about 1 8 throttle in short bursts 5 to 7 times The belt will become more flexible and prevent belt burning Slow easy clutch engagement Use the throttle quickly and effectively Towing pushing at low RPM low ground speed Use low range only Utility use plowing Use low range only Stuck in mud or snow Shift the transmission to low range and carefully use fast aggressive throt tle application to eng
10. Add the recommended fluid to the bottom of the fill plug hole Do not overfill 6 Reinstall the fill plug Torque to specification 7 Check for leaks Discard used fluid properly Drain Plug 66 MAINTENANCE Gearcases Front Gearcase Always check and change the front gearcase oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 59 Maintain the oil level even with the bottom thread of the fill plug hole Refer to the Gearcase Specifications Chart on page 66 for recommended lubricants capaci ties and torque specifications See page 92 for the part numbers of POLARIS products Oil Check The front gearcase fill plug is located on the right side of the front gearcase 1 Position the vehicle on a level surface 2 Remove the fill plug Check the oil level 3 Add the recommended oil as needed 4 Reinstall the fill plug Torque to specification Oil Change 1 Support the vehicle securely with a jackstand Remove the front tire on the driver s side Remove the fill plug B wr Place a drain pan under the drain plug on the bottom right hand side Drain Plug Remove the drain plug Drain the oil Clean and reinstall the drain plug Torque to specification Add the recommended fluid to the bottom of the fill plug hole Do not overfill Reinstall the fill plug Torque to specification Check for leaks 10 Discard used oil properly Q9 n O0 t 67 MAINTENANCE Spark P
11. See page 40 Check the terrain carefully before descending a hill Never travel downhill at high speed Avoid going downhill at an angle which would cause the vehicle to lean sharply to one side Travel straight down the hill where possible Always check for obstacles before operating in a new area Never attempt to operate over large obstacles such as large rocks or fallen trees Always follow the proper procedures outlined in this manual when operating over obstacles See page 39 Always be careful of skidding or sliding On slippery surfaces such as ice travel slowly and exercise caution to reduce the chance of skidding or sliding out of control Never operate your vehicle in fast flowing water or in water deeper than that specified in this manual See page 42 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 SAFETY Operator Safety Always use the proper size and type of tires specified in this manual Always maintain proper tire pressure as specified on safety labels Never modify this vehicle through improper installation or use of non POLARIS approved accessories Never exceed the stated load capacity for this vehicle Cargo should
12. 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 Rinse the entire length of the belt webbing Use a garden hose to flush out the retractor and latch housings regularly 27 FEATURES AND CONTROLS Cab Nets Riding in this vehicle without using the cab nets or doors if equipped increases the risk of serious injury or death in the event of an accident or rollover Cab nets or doors must be used by both operator and passengers at all times Make sure all latches are secure before operating the vehicle Always inspect cab nets and latches for tightness wear and damage before each use of the vehicle Use the strap adjusters to tighten any loose straps Promptly replace worn or dam aged cab nets and latches with new cab nets and latches Please see your authorized POLARIS dealer Securing a Net 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 slot at the base of 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 top front latch 2 Rotate the net rearward and slide the lower net rod out of the mount to remove it 3 Allow the net to hang freely outside the vehicle while dismounting Rod Mount 28 FEATURES AND CONTROLS Rollover Pr
13. a shatterproof helmet face shield POLARIS recommends wearing approved Personal Protective Equipment PPE bearing markings such as VESC 8 V 8 Z87 1 or CE Make sure protective eye wear is kept clean Gloves Wear gloves for comfort and for protection from sun cold weather and other elements Boots Wear sturdy over the ankle boots for support and protection Never ride a POLARIS vehicle with bare feet or sandals Clothing Wear long sleeves and long pants to protect arms and legs Rider Comfort Under certain operating conditions heat generated by the engine and exhaust system can ele vate temperatures in the driver and passenger cab area The condition occurs most frequently when a vehicle is being operated in high ambient temperatures at low speeds and or high load conditions for an extended period of time The use of certain windshield roof and or cab systems may contribute to this condition by restricting airflow Any discomfort due to heat buildup in this area can be minimized by wearing proper riding apparel and by varying speeds to increase airflow 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 co
14. in the belt Rotate the driven L re clutch by hand until the belt falls into place 7 14 Reinstall the clutch cover in the reverse order of Remove ALL Debris removal fitting the top of the cover into place then working the bottom of the cover over the suspension 15 Install all clutch cover screws Torque to 4 5 ft lbs 5 5 6 5 Nm 72 MAINTENANCE POLARIS Variable Transmission PVT System PVT Drying There may be some instances when water is ingested into the PVT system Use the following instructions to dry it out before operating 1 2 8 a Position the vehicle on a level surface Remove the red drain plug on the outer clutch n Tp ex cover Allow the water to drain completely E p EE o Reinstall the drain plug i Place the transmission in PARK Start the engine NS i gt N Apply varying throttle for 10 15 seconds to 5 S em j ER expel the moisture and air dry the belt and clutches Do not hold the throttle wide open for more than five 5 seconds Drain Plug Allow the engine RPM to settle to idle speed Apply the brakes Shift the transmission to the lowest available range lt in Sel Test for belt slippage If the belt slips repeat the 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 yo
15. maximum weight capacity REDUCE SPEED AND ALLOW GREATER DISTANCES FOR BRAKING WHEN HAULING CARGO Always load the cargo box with the load as far forward and as low as possible When operating over rough or hilly terrain reduce speed and cargo to maintain stable driving conditions Always operate the vehicle with extreme care when hauling or towing loads Slow down and drive in the lowest gear available SECURE ALL LOADS BEFORE OPERATING Unsecured loads can create unstable operating conditions which could result in loss of control of the vehicle OPERATE ONLY WITH STABLE AND SAFELY ARRANGED LOADS When handling off centered loads that cannot be centered securely fasten the load and operate with extra caution Always attach the tow load to the hitch point designated for your vehicle HEAVY LOADS CAN CAUSE BRAKING AND CONTROL PROBLEMS Use extreme caution when applying brakes with a loaded vehicle Avoid terrain or situations that may require backing downhill USE EXTREME CAUTION when operating with loads that extend over the rack sides Stability and maneuverability may be adversely affected causing a rollover DO NOT TRAVEL FASTER THAN THE RECOMMENDED SPEEDS Vehicle should never exceed 10 MPH 16 km h while towing a load on a level grass surface Vehicle speed should never exceed 5 MPH 8 km h when towing loads in rough terrain while cornering or while ascending or descending a hill The RANGER has been designed to carry or tow spec
16. operate at sustained idle 5 Perform regular checks on fluid levels controls and areas outlined on the daily pre ride inspection checklist See page 36 6 Pull only light loads 7 Check fluid levels of transmission and all gearcases after the first 25 hours of operation and every 100 hours thereafter 8 During the break in period change both the oil and the filter at 25 hours PVT Break in Clutches Belt A proper break in of the clutches and drive belt will ensure a longer life and better performance Break in the clutches and belt by operating at slower speeds during the break in period as recommended Pull only light loads Avoid aggressive acceleration and high speed operation during the break in period If a belt fails always clean any debris from the clutch air duct and from the clutch and engine compartments when replacing the belt See page 71 35 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 25 76 Brake fluid Ensure proper level 76 Park gear Ensure vehicle does not roll when in PARK Ensure PARK light illuminates Front suspension Inspect lubricate if necessary 61 Rear susp
17. operating the winch to prevent the battery from running low if winching for long periods 14 The winch motor may become hot during winch use If you winch for more than 45 seconds or if the winch stalls during operation stop winching and permit the winch to cool down for 10 minutes before using it again 15 After winching is complete especially if winching at an angle it may be necessary to re distribute the winch cable across the winch drum You will need an assistant to perform this task Release the clutch on the winch Feed out the winch cable that is unevenly bunched up in one area Re engage the winch clutch Have an assistant pull the winch cable tightly with about 100 Ibs 45 kg of tension using the hook strap Slowly winch the cable in while your assistant moves the end of the winch cable back and forth horizontally to evenly distribute the winch cable on the drum Doing this reduces the chances of the winch cable wedging itself between lower layers of winch cable m gom m 54 WINCH GUIDE Winch Cable Care For your safety always replace POLARIS winch parts including the cable with genuine POLARIS replacement parts available at your authorized POLARIS dealer WARNING Use of worn or damaged cable could lead to sudden failure and SEVERE INJURY 1 Always inspect your winch before each use Inspect for worn or loose parts including mounting hardware Never use the winch if any part needs repair or r
18. passenger in this vehicle All riders must be able to sit with backs against the seat both feet flat on the floor and both hands on the steering wheel if driving or on a passenger hand hold Never permit a guest to operate this vehicle unless the guest has read this manual and all product labels Always use the cab nets or doors while riding in this vehicle Always keep hands feet and all other body parts inside the vehicle at all times Always wear a helmet eye protection gloves long sleeve shirt long pants and over the ankle boots Never use this vehicle with drugs or alcohol as these conditions impair judgment and reduce operator reaction time INTRODUCTION Vehicle Identification Numbers Record your vehicle s identification numbers and key number in the spaces provided Remove the spare key and store it in a safe place An ignition key can be duplicated only by ordering a POLARIS key blank using your key number and mating it with one of your existing keys The ignition switch must be replaced if all keys are lost VIN stamped into main frame HHRH 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 is measured per prEN 15997 The operating conditions of the machinery during testing The vehicles were in like new condition Th
19. position Depress the brake pedal The brake light should come on after about 10mm 0 4 in of pedal travel If the light doesn t come on check the bulb 81 MAINTENANCE Battery AWARNING Battery electrolyte is poisonous It contains sulfuric acid Serious burns can result from contact with skin eyes or clothing Antidote External Flush with water Internal Drink large quantities of water or milk Follow with milk of magnesia beaten egg or vegetable oil Call physician immediately Eyes Flush with water for 15 minutes and get prompt medical attention Batteries produce explosive gases Keep sparks flame cigarettes etc away Ventilate when charging or using in an enclosed space Always shield eyes when working near batteries KEEP OUT OF REACH OF CHILDREN Your vehicle may have either a sealed battery which requires little maintenance or a con ventional battery A sealed battery can be identified by its flat covers on the top of the bat tery A conventional battery has six filler caps on the top of the battery Always keep battery terminals and connections free of corrosion If cleaning is necessary remove the corrosion with a stiff wire brush Wash with a solution of one tablespoon baking soda and one cup water Rinse well with tap water and dry off with clean shop towels Coat the terminals with dielectric grease or petroleum jelly Be careful not to allow cleaning solu tion or tap water into the battery Bat
20. product s warranty or service coverage if you have any questions This policy does not apply to products registered to government officials or military personnel on assignment outside the country of the selling dealer s authorized location This policy does not apply to Safety Bulletins 98 WARRANTY Notice If your product is registered outside of the country where it was purchased and you have not followed the procedure set above your product will no longer be eligible for warranty or service bulletin coverage of any kind other than safety bulletins Products registered to government officials or military personnel on assignment outside of the country where the product was purchased will continue to be covered by the Limited Warranty Please work with your dealer to resolve any warranty issues Should your dealer require any additional assistance they will contact the appropriate person at POLARIS This warranty gives you specific legal rights and you may also have other rights which vary from state to state or in different countries If any of the above terms are void because of federal state local law all other warranty terms will remain in effect For questions call POLARIS Customer Assistance United States amp Canada 1 800 POLARIS 1 800 765 2747 French 1 800 268 6334 U S A EPA Emissions Limited Warranty This emissions limited warranty is in addition to the POLARIS standard limited warranty for your vehicle POLARIS Ind
21. 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 Failure to follow the warnings contained in this manual can result in severe injury or death Your POLARIS RANGER is not a toy and can be hazardous to operate This vehicle handles differently than other vehicles such as cars trucks or other off road vehicles A collision or rollover can occur quickly even during routine maneuvers like turning or driving on hills or over obstacles if you fail to take proper precautions Read this owner s manual and review the safety DVD that came with your vehicle A free extra copy of the DVD can be obtained by contacting your local POLARIS dealer Understand all safety warnings precautions and operating procedures before operating the vehicle Keep this manual with the vehicle Review the safety DVD and take the free online Recreational Off Highway Vehicle Association ROHVA training course at www rohva org This vehicle is an ADULT VEHICLE ONLY You MUST be at least age 16 and have a valid driver s license to operate this vehicle No person under the age of 12 may ride as a
22. rollover Travel slowly and use extra caution when operating on unfamiliar terrain Always be alert to changing terrain conditions Improper Hill Climbing Climbing hills improperly can cause loss of control or vehicle rollover Always follow proper procedures for climbing hills as described in this owner s manual See page 40 Descending Hills Improperly Improperly descending a hill could cause loss of control or rollover Always follow proper procedures for traveling down hills as described in this owner s manual See page 40 Stalling While Climbing a Hill Stalling or rolling backwards while climbing a hill could cause a rollover Always maintain a steady speed when climbing a hill If all forward speed is lost Apply the brakes Place the transmission in reverse and slowly allow the vehicle to roll straight downhill while applying light brake pressure to control speed If you begin rolling downhill Never apply engine power Apply the brakes gradually until the vehicle is fully stopped Place the transmission in reverse and slowly allow the vehicle to roll straight downhill while applying light brake pressure to control speed 19 SAFETY Operator Safety Improper Tire Maintenance Operating this vehicle with improper tires or with improper or uneven tire pressure could cause loss of control or accident Always use the size and type of tires specified for your vehicle Always maintain proper tire pressure as desc
23. surfaces such as wet trails or loose gravel or during freezing weather follow these precautions 1 Do not operate on excessively rough slippery or loose terrain 2 Slow down before entering slippery areas 3 Maintain a high level of alertness reading the trail and avoiding quick sharp turns which can cause skids 4 Engage all wheel drive before wheels begin to lose traction NOTICE Severe damage to the drive train may occur if the AWD is engaged while the wheels are spinning Always allow the wheels to stop spinning before engaging AWD 5 Correct a skid by turning the steering wheel in the direction of the skid Never apply the brakes during a skid Sideways Turn in skid cra of Ski COeCo C C AX px C A 1 TQ Sys l l Coco Coemc BY x Coes Nd Driving Over Obstacles Follow these precautions when operating over obstacles 1 Always check for obstacles before operating in a new area 2 Look ahead and learn to read the terrain Be constantly alert for hazards such as logs rocks and low hanging branches 3 ravel slowly and use extra caution when operating on unfamiliar terrain Not all obstacles are immediately visible 4 Avoid operating over large obstacles such as large rocks and fallen trees If unavoidable use extreme caution and operate slowly 5 Always have all passengers dismount and move away from the vehicle before operating over an obstacle that could cause a rollover 39 O
24. than 45 seconds or if the winch stalls during operation stop winching and permit the winch to cool down for 10 minutes before using it again Never touch push pull or straddle the winch cable while winching a load Never let the winch cable run through your hands even if wearing heavy gloves Never release the clutch on the winch when the winch cable is under load at Never use the winch for lifting or transporting people 1 Never use the winch to hoist or suspend a vertical load Never immerse or submerse your winch in water Take your winch to your dealer for service if this occurs Always inspect your winch and winch cable before each use Never winch the hook fully into the winch This can cause damage to winch components Unplug the remote control from the vehicle when the winch is not in use to prevent inadvertent activation and use by unauthorized persons Never grease or oil the winch cable This will cause the winch cable to collect debris that will shorten the life of the cable WINCH GUIDE Winch Operation Read the Winch Safety Precautions in the preceding pages before using your winch Tip eal practicing the operation and use of your winch before you actually need to use it in the field AWARNING Improper winch use can result in SEVERE INJURY or DEATH Always follow all winch instructions and warnings in this manual Each winching situation is unique Take your time to think through the winchi
25. that can be released if the winch cable breaks This can result in SEVERE INJURY or DEATH See the Shock Loading section on page 56 B Never hook the winch cable back onto itself This will damage the winch cable and may result in winch cable failure WARNING Replace the winch cable at the first sign of damage to prevent SEVERE INJURY or DEATH in the event of failure For your safety always replace POLARIS winch parts including the cable with genuine POLARIS replacement parts available at your authorized POLARIS dealer C If possible keep the winch cable aligned with the centerline of the winching vehicle This will help the spooling of the winch cable and reduce the load on the fairlead D If freeing a stuck vehicle by attaching to a tree use an item such as a tow strap to avoid damaging the tree during winch operation Sharp cables and chains can damage and even kill trees Please remember to TreadLightly treadlightly org E Before operating the winch be sure that the safety latch on the winch cable hook is fully seated when the load is attached F Never operate your winch with a damaged hook or latch Always replace damaged parts before using the winch 5 Never remove the hook strap from the hook YES NO 6 Release the winch clutch and pull out the winch cable 7 Pulling out as much cable as possible maximizes the winch s pulling capacity Always be sure that at least five 5 full turns of winch cable are wrapped aro
26. to avoid fuel ignition due to electrical static discharge Do not smoke or allow open flames or sparks in or near the area where refueling is performed or where gasoline is stored Do not overfill the tank Do not fill the tank neck If gasoline spills on your skin or clothing immediately wash it off with soap and water and change clothing Exposure to Exhaust Engine exhaust fumes are poisonous and can cause loss of consciousness or death in a short time Never start the engine or let it run in an enclosed area The engine exhaust from this product contains chemicals known to cause cancer birth defects or other reproductive harm Operate this vehicle only outdoors or in well ventilated areas Operating a Damaged Vehicle Operating a damaged vehicle can result in an accident After any rollover or other accident have a qualified service dealer inspect the entire machine for possible damage including but not limited to seat belts rollover protection devices brakes throttle and steering systems Operating at Excessive Speeds Operating this vehicle at excessive speeds increases the operator s risk of losing control Always operate at a speed that s appropriate for the terrain the visibility and operating conditions your skills and experience and your passengers skills and experience Operating on Pavement This vehicle s tires are designed for off road use only not for use on pavement Operating this vehicle on paved su
27. water stream at the following items Wheel bearings Brakes Switches and controls Radiator Cab and body panels Electrical components and wiring Transmission seals Labels and 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 86 MAINTENANCE Cleaning and Storage Chrome Wheel Care if equipped Proper maintenance will protect chrome wheels from corrosion preserve wheel life and ensure a like new appearance for many years Chrome wheels exposed to road salt or salt in the air in coastal areas are more susceptible to corrosion if not properly cleaned Clean chrome wheels more often if they re exposed to salt or other corrosive elements 1 Wash chrome wheels frequently Use a mild detergent Never use abrasive cleaners on plated or painted surfaces 2 Rinse well with clear water Soap detergents salt dirt mud and other elements can cause corros
28. we recommend that the system be completely drained every five 5 years and fresh Antifreeze 50 50 Premix added Any time the cooling system has been drained for maintenance or repair replace the coolant with fresh Antifreeze 50 50 Premix If the recovery bottle has run dry the level in the radiator should be inspected Add coolant as needed Radiator and Cooling Fan Always check and clean the screen and radiator fins at the intervals outlined in the Periodic Maintenance Chart beginning on page 59 Do not obstruct or deflect air flow through the radiator by installing unauthorized accessories in front of the radiator or behind the cooling fan Interference with the radiator air flow can lead to overheating and consequent engine damage NOTICE Washing the vehicle with a high pressure hose could damage the radiator fins and impair the radiator s effectiveness Using a high pressure system is not recommended 69 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 59 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 2 Lift the hood View the coolant level in the overflow bottle 3 If the coolant level is below the safe operating range lift the hood and locate the overflow bottle lid Remove the cap and use a fun
29. 2c eee eee 67 Main Gearcase 66 Transmission s cuis ec 9E Ra 66 Fluid Check Coolant Overflow Bottle 70 Front Gearcase 00 67 Main Gearcase 00 66 Transmissie ece enai 66 Fluid Levels During Storage 88 Fluid Recommendations 61 Gearcase Fluid 61 66 El id Brake i e ERR eco Ga ld 76 Fogging the Engine s lesse esses 88 Fouled Plugs eee ese metra rhe 68 Front Gearcase censes rent rm eee ae 67 Fuel Stabilizer Fuel Tank Filler Cap Gap Spark Plug Gasoline Handling Gearcase Specification Chart Gearcase Front Gearcase Main Gears Shifting Hauling Cargo Headlight Beam Adjustment Headlight Lamp Replacement Ignition Switch Immersion of Vehicle Indicator Lamps Instrument Cluster Key Periodic Maintenance Chart Headlight Beam Adjustment Headlight Lamp Replacement Lubricants Gearcase Lubrication Recommendations Main Gearcase Maintenance Log Maintenance Periodic Metric Display Noise Emission Control System O ODStaClOS en o EE TOS ES 39 Oil Engine 570 0 6 2 cee eens 62 63 Engine HTX isset remet 64 65 Oil Change Engine Oil 570 62 63 Engine Oil ETX 64 65 Front Gearcase coser ees 67 Main Gearcase 00 0005 66 Transmission 0 00008 66 Oil Check Engine Oil 570 62 Engine Oil ETX
30. 32 FEATURES AND CONTROLS Instrument Cluster Rider Information Center Odometer Mode The odometer records and displays the distance traveled by the vehicle Trip Meter Mode The trip meter records the distance traveled by the vehicle if reset before each trip To reset select the trip meter mode Press and hold the MODE button until the meter resets to zero In the Rider Information Center the trip meter display contains a decimal point but the odome ter displays without a decimal point Hour Meter Mode This mode logs the total hours the engine has been in operation 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 Programmable Service Interval When the hours of engine operation equal the programmed service interval setting the wrench icon will flash for 5 seconds each time the engine is started When this feature is enabled it provides a convenient reminder to perform routine maintenance The service interval is programmed at 50 hours at the factory Use the following procedure to change the service interval 1 Press the MODE button until remaining service hours display 2 Press and hold the MODE button 3 When the service hours flash press and release the MODE button to advance the hours to the desired setting including OFF Press and hold the MODE button to set the new service hour int
31. 64 Front Gearcase s sent 67 Main Geatcase sese ee eges 66 Transmission llle 66 Oil Recommendation Gearcases 66 Operation on Public Lands 58 Operator Safety cess aoa Gace wes 13 20 Outlets Auxiliary iia ue eee Dh 22 P Parking on an Incline 00 42 Parking the Vehicle 00 0005 41 Periodic Maintenance Chart 59 61 Plug Gap cse ordre esee re Dreher Eire 68 Plug Torque ker er eR ER t Res 68 Plug ACCESsOry 2 oo rep coded eas a RECS 22 Plugs Fouled ee m mA 68 Polaris Products see en 92 Polishing the Vehicle 86 Power Steering sese nenii ed Ske beste reniet ias 26 Power Steering Unit Cleaning 79 Pre Ride Inspection 000005 36 PYT Break In i o toc tote re fenis 35 PVT Drying yis e repito oae omoes cer Rosie 73 PVT System ccekt m Ree 72 13 PVT System Operation 00 71 PVT Warning s ocs e RR Ree 71 73 PVT Cleaning Debris 71 72 R R diatOF oho aia an oh E erdt E 69 Registration Warranty 00 96 Removing the Vehicle from Storage 89 Reverse Operation 0 0 000000 41 Rider Information Center 31 34 Rading Gear erre bre eR erbe 8 9 Rollover Protective Structure 29 ROPS Cab Frame sos si 4p br had ee 29 103 INDEX S Safety Labels cocco rt boas 10 12 Safety Symbol
32. AL OR CONSEQUENTIAL DAMAGES OR ALLOW LIMITATIONS ON THE DURATION OF IMPLIED WARRANTIES SO THE ABOVE LIMITATIONS MAY NOT APPLY TO YOU IF INCONSISTENT WITH CONTROLLING STATE LAW 97 WARRANTY How To Obtain Warranty Service If your vehicle requires warranty service you must take it to a POLARIS Servicing Dealer When requesting warranty service you must present your copy of the Warranty Registration Form to the dealer THE COST OF TRANSPORTATION TO AND FROM THE DEALER IS YOUR RESPONSIBILITY POLARIS suggests that you use your original selling dealer however you may use any POLARIS Servicing Dealer to perform warranty service In the Country where your product was purchased Warranty or Service Bulletin repairs must be done by an authorized POLARIS dealer If you move or are traveling within the country where your product was purchased Warranty and Service Bulletin repairs may be requested from any authorized POLARIS dealer that sells the same line as your product Outside the Country where your product was purchased If you are traveling temporarily outside the country where your product was purchased you should take your product to an authorized POLARIS dealer You must show the dealer photo identification from the country of the selling dealer s authorized location as proof of residence Upon residence verification the servicing dealer will be authorized to perform the warranty repair If you move If you move to another country
33. ANGER may ee T cause the vehicle to float in deep or fast flowing water Le floorboard gt gt which could result in loss of control and lead to serious Qr ea injury or death Never cross deep or fast flowing water af ess with your RANGER 5 After leaving water always dry the brakes by applying light pressure to the pedal repeat edly until braking action is normal NOTICE After running your vehicle in water it s critical that you perform the services outlined in the Periodic Maintenance Chart beginning on page 59 Give special attention to engine oil transmission oil front and rear gearcases if equipped and all grease fittings Parking on an Incline Avoid parking on an incline if possible If it s unavoidable follow these precautions 1 Apply the brakes 2 Place the transmission in PARK 3 Turn the engine off 4 Block the rear wheels on the downhill side 42 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
34. Cleaning and Storage Washing the Vehicle Keeping your POLARIS vehicle clean will not only improve its appearance but it can also extend the life of various components NOTICE High water pressure may damage components POLARIS recommends washing the vehicle by hand or with a garden hose using mild soap NOTICE Certain products including insect repellents and chemicals will damage plastic surfaces Do not allow these types of products to contact the vehicle The best and safest way to clean your POLARIS vehicle is with a garden hose and a pail of mild soap and water 1 Use a professional type washing cloth cleaning the upper body first and the lower parts last 2 Rinse with clean water frequently 3 Dry surfaces with a chamois to prevent water spots Washing Tips Avoid the use of harsh cleaners which can scratch the finish Do not use a power washer to clean the vehicle Do not use medium to heavy duty compounds on the finish Always use clean cloths and pads for cleaning and polishing Old or reused cloths and pads may contain dirt particles that will scratch the finish Grease all zerk fittings immediately after washing Allow the engine to run for a while to evaporate any water that may have entered the engine or exhaust system If a high pressure water system is used for cleaning not recommended exercise extreme caution The water may damage components and could remove paint and labels Avoid directing the
35. E Cleaning and Storage Storage Tips Inspect and Lubricate Inspect all cables and lubricate all areas of the vehicle as recommended in the Periodic Maintenance Chart beginning on page 59 Battery Maintenance See pages 84 85 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 59 Front and rear gearcase fluid if equipped Transmission fluid Brake fluid change every two years and any time the fluid looks dark or contaminated Coolant test strength fill Fog the Engine 1 Treat the fuel system with POLARIS Carbon Clean Follow the instructions on the container Start the engine Allow it to idle for several minutes so the Carbon Clean reaches the injectors Stop the engine 2 Remove the spark plugs and add 2 3 tablespoons of engine oil To access the plug holes use a section of clear 1 4 hose and a small plastic squeeze bottle filled with the pre measured amount of oil Do this carefully If you miss the plug holes oil will drain from the spark plug cavities into the hole at the front of the cylinder head and appear to be an oil leak 3 Reinstall the spark plugs Torque to specification See page 68 4 Apply dielectric grease to the inside of each spark plug cap and reinstall the caps onto the plugs 5 Turn the engine over several times Oil will be forced in and around the piston rings and ring lan
36. ER ETX RANGER 570 570 EPS RANGER CREW 570 570 EPS Owner s Manual P N 9925356 TABLE OF CONTENTS IN FODUCUON suene heREERER RAE RRLRRPEREREEERREEREES 4 Safely A p Pr 8 Features and Controls ssssss 21 Operation usos siti ih MAREA ADR RIEN PREPARA TATE S 35 Wihch Olde ie sesaper rpt ieun a nea E E aa EAR EE E 49 Emission Control Systems sssss 58 Maintenance 5 6 eds ome tare ee eed dee sare te EN eke 59 SPCCHICANIONS ssi sereis srie tatkimi hne EERE ee WE 90 POLARIS Products eer o RRRERRR RE bias digas een cee 92 Troubleshoollnj sueexi ae un RERRERAR EE EE ERE REO 93 Warranty ziieerteesee t REERESEERRRE AERE EE RE ERU EA 96 Maintenance LOG 6 26065 iRRERSUSENREREOG EEERERESER 101 INGCX ocpraac rers eAEFREECEREAEWRCPRIGGATSEEREE 102 INTRODUCTION The RANGER is an off road vehicle Familiarize yourself with all laws and regulations con cerning the operation of this vehicle in your area The following signal words and symbols appear throughout this manual and on your vehicle Your safety is involved when these words and symbols are used Become familiar with their meanings before reading the manual A The safety alert symbol indicates a potential personal injury hazard DANGER A DANGER indicates a hazardous situation that if not avoided will result in death or serious injury WARNING A WARNING indicates a hazardous situation that if not avoided could
37. ER be in motion to shock load the winch cable in an attempt to move a second stuck vehicle See the Shock Loading section on page 56 For your safety always follow these guidelines when winching a vehicle free A Release the winch clutch and spool out the necessary length of winch cable B Align the winch cable as close as possible to the winching vehicle s centerline C Attach the winch cable hook to the anchor point or the stuck vehicle s frame following instructions in this manual D Re engage the clutch on the winch E Slowly winch in the slack in the winch cable F Select the proper vehicle gear to propel the stuck vehicle in the direction of winching G Shift to the lowest gear available on the stuck vehicle H Slowly and carefully apply vehicle throttle and winch together to free the vehicle l Stop inching as soon as the stuck vehicle is able to propel itself without the help of the winch J Detach the winch cable hook K Rewind the winch cable evenly back onto the winch drum following the instructions in this manual Never attempt to winch another stuck vehicle by attaching the winch cable to a suspension component brush guard bumper or cargo rack Vehicle damage may result Instead attach the winch to a strong portion of the vehicle frame or hitch 53 WINCH GUIDE Winch Operation 13 Extensive winching will run down the battery on the winching vehicle Let the winching vehicle s engine run while
38. Fuel Gauge The segments of the fuel gauge show the level of fuel in the fuel tank When the last segment clears a low fuel warning is activated All segments including the fuel icon will flash Refuel immediately If the fuel icon fails to display an open or short circuit has occurred in the fuel sensor circuit See your dealer Information Display Area This area displays odometer trip meter engine hour meter and programmable service hour interval Under Over Voltage This warning usually indicates that the vehicle is operating at an RPM too low to keep the battery charged It may also occur when the engine is at idle and high electrical load lights cooling fan accessories is applied Drive at a higher RPM or recharge the battery to clear the warning Clock The clock displays time in a 12 hour or 24 hour format See page 32 for resetting instructions 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 maintenance See page 32 for resetting instructions 4X4 Indicator This indicator illuminates when the 4X4 system is engaged switch is on 4X4 Turf Mode Indicator if equipped This indicator illuminates when the operator unlocks the differential See page 48 31 FEATURES AND CONTROLS Instrument Cluster Rider Information Center Use the MODE button to toggle through the information area option
39. LLOW ALL INSTRUCTIONS AND WARNINGS For your nearest Polaris dealer call 1 800 POLARIS 765 2747 or visit www polaris com Polaris Industries Inc POLRRIS 2100 Hwy 55 Medina MN 55340 Part No 9925356 Rev 01 Printed in USA
40. Lamp Replacement 1 Access the headlamp wiring harnesses through the front wheel wells Connector CAUTION Hot components can cause burns to skin Allow lamps to cool before servicing 2 Unplug the headlamp from the wiring harness Be sure to pull on the connector not on the wiring 3 Turn the lamp counter clockwise to remove it 4 Install the new lamp Tip Make sure the tab on the lamp locates properly in the housing 5 Reinstall the harness assembly into the headlight assembly 80 MAINTENANCE Lights Headlight Beam Adjustment 6 ihe Place the vehicle on a level surface with the headlight approximately 25 ft 7 6 m from a wall 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 Turn on the headlights ion crew 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 at the back of the headlight Loosen the screw adjust the headlight and tighten the Screw Repeat steps 4 6 until the lamp is properly adjusted Brake Lights When the brake pedal is depressed the brake light comes on Check the brake light before each ride 1 2 Turn the ignition switch to the ON
41. NING e p i IMPROPER TIRE PRESSURE OR OVERLOADING CAN m y CAUSE LOSS OF CONTROL RESULTING IN SERIOUS jiu wv qe we INJURY OR DEATH Ph gr 6 Reduce speed and allow greater distance for braking i 2 m m when carrying cargo x T Overloading or carrying tall off center or unsecured m d 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 Becareful if load extends over the side of the box RANGER MIDSIZE RANGER RANGER LSV EV MIDSIZE MIDSIZE CREW MAXIMUM CARGO BOX LOAD 500 Ibs 500 Ibs 500 Ibs 226 kg 226 kg 226 kg TIRE PRESSURE IN PSI KPa FRONT 10 69 FRONT 10 69 FRONT 20 138 REAR 10 69 REAR 14 96 REAR 20 138 MAXIMUM WEIGHT CAPACITY INCLUDES WEIGHT OF OPERATOR PASSENGER 1000 Ibs 1250 Ibs 1000 Ibs CARGO AND ACCESSORIES 454 kg 547 kg 454 kg Read Operation amp Maintenance Manual for more detailed loading information 7181056 Clutch Cover Warning WARNING Moving parts hazard under belt clutch guard To prevent serious injury do not operate vehicle with guard removed Do not modify engine or clutch Doing so can cause part failure possible imbalance and excessive engine RPM which can result in serious injury or death 12 7175488 Clutch Cover Warning SAFETY Operator Safety A WARNING Serious injury or death can result if you do not follow thes
42. PERATION Driving Uphill Whenever traveling uphill follow these precautions 1 Always travel straight uphill 2 Avoid excessively steep hills 3 Keep both feet on the floor 4 Always check the terrain carefully before ascending any hill Never climb hills with excessively slippery or loose surfaces 5 Proceed at a steady rate of speed and throttle opening Never open the throttle suddenly 6 Never go over the crest of a hill at high speed An obstacle a sharp drop or another vehicle or person could be on the other side of the hill Driving Downhill When driving downhill follow these precautions 1 Avoid excessively steep hills 2 Drive straight downhill Avoid descending a hill at an angle which would cause the vehicle to lean sharply to one side Travel straight downhill when possible 3 Slow down 4 Apply the brakes slightly to aid in slowing 40 OPERATION Driving on a Sidehill Sidehilling Driving on a sidehill is not recommended Improper procedure could cause loss of control or rollover Avoid crossing the side of any hill unless absolutely necessary If crossing a sidehill is unavoidable follow these precautions 1 2 Exercise extreme caution Slow down 3 Avoid crossing the side of a steep hill Driving in Reverse Follow these precautions when operating in reverse 1 Always check for obstacles or people behind the vehicle Always inspect left and right f
43. 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 accident or rollover which may result in serious injury or death Read and understand all safety warnings outlined in the safety section of this owner s manual Break In Period The break in period for your new POLARIS RANGER is the first twenty hours of operation or the time it takes to use the first two tanks full of gasoline No single action on your part is as important as a proper break in period Careful treatment of a new engine will result in more efficient performance and longer life for the engine Perform the following procedures carefully NOTICE Excessive heat build up during the first three hours of operation will damage close fitted engine parts Do not operate at full throttle or high speeds for extended periods during the first three hours of use Engine and Drivetrain Break in 1 Fill the fuel tank with gasoline Heed the gasoline warnings on page 18 2 Check the oil level See page 62 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 Vary throttle positions Do not
44. RANGER ETX RANGER 570 RANGER 570 EPS RANGER CREW 570 RANGER CREW 570 EPS 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 la u For videos and more information about a safe riding experience with your Polaris vehicle scan this QR code with your smartphone WELCOME Thank you for purchasing a POLARIS vehicle and welcome to our world wide family of POLARIS enthusiasts Be sure to visit us online at www polaris com for the latest news new product introductions upcoming events career opportunities and more Here at POLARIS we proudly produce an exciting line of utility and recreational products Snowmobiles e All terrain vehicles ATVs Low emission vehicles LEVs e RANGERQ utility vehicles RZR sport vehicles VICTORY motorcycles e GEMQ electric vehicles 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 m
45. S engine oil 2 Damage or failure resulting from the use of non recommended lubricants or fluids is not covered by this warranty This warranty provides no coverage for personal loss or expense including mileage transportation costs hotels meals shipping or handling fees product pick up or delivery replacement rentals loss of product use loss of profits or loss of vacation or personal time THE EXCLUSIVE REMEDY FOR BREACH OF THIS WARRANTY SHALL BE AT POLARIS OPTION REPAIR OR REPLACEMENT OF ANY DEFECTIVE MATERIALS COMPONENTS OR PRODUCTS THE REMEDIES SET FORTH IN THIS WARRANTY ARE THE ONLY REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF THIS WARRANTY POLARIS SHALL HAVE NO LIABILITY TO ANY PERSON FOR INCIDENTAL CONSEQUENTIAL OR SPECIAL DAMAGES OF ANY DESCRIPTION WHETHER ARISING OUT OF EXPRESS OR IMPLIED WARRANTY OR ANY OTHER CONTRACT NEGLIGENCE OR OTHER TORT OR OTHERWISE THIS EXCLUSION OF CONSEQUENTAL INCIDENTAL AND SPECIAL DAMAGES IS INDEPENDENT FROM AND SHALL SURVIVE ANY FINDING THAT THE EXCLUSIVE REMEDY FAILED OF ITS ESSENTIAL PURPOSE THE IMPLIED WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE IS EXCLUDED FROM THIS LIMITED WARRANTY ALL OTHER IMPLIED WARRANTIES INCLUDING BUT NOT LIMITED TO THE IMPLIED WARRANTY OF MERCHANTABILITY ARE LIMITED IN DURATION TO THE ABOVE SIX MONTH WARRANTY PERIOD POLARIS DISCLAIMS ALL EXPRESS WARRANTIES NOT STATED IN THIS WARRANTY SOME STATES DO NOT PERMIT THE EXCLUSION OR LIMITATION OF INCIDENT
46. Switch 23 46 Differential Lock Switch 23 Ignition Switch 22 Light Switch seeuuuuu 22 104 T Tachometer 4 2 Ive RE ERE REPORT 33 Throttle Pedal 2 mer Reeves 223 Tilt Steering ogc sods eee ayes meter sae 3 ns 23 Tires szesscesektexecieiche e aes s 78 79 Nut Totque imeem RR Rd 78 Tread Depth eer 78 Wheel Installation 79 Wheel Removal 79 Torque Spark Plug sses renser ianea enses 68 Towing Loads os cag cng cng ace eens peace 44 Towing Speed sose iad Oe dite e RUE 44 Trailer Hitch Bracket 2 2 een 29 Transmission aapinen Red see IND ces EE 66 Transmission Operation 71 73 Transmission System issues 72 73 Transmission Warming 71 73 Transmission Drying 00 73 Transporting the Vehicle 89 TURF Mode nett ath ok FR ees 48 V Vehicle Components 000005 21 Vehicle Identification Numbers 6 Vehicle Immersion 000004 73 Vehicle Transport 52222 rte 89 WwW Warning Symbols 0 0 00 eee eee 4 Warning Transmission Modification 71 73 Washing the Vehicle 00 86 Wheel Installation sepesi esac ee iiaea 79 Wheel Nut Torque c RR RR ER n 78 Wheel Removal 2 6 4 vh ec reme y 79 Winch Cable Cate isses reme 55 Winch Maintenance and Service Safety 57
47. Winch Operation 0000 51 54 Winch Safety Precautions 49 50 Winch Shock Loading lusus 56 AWARNING Improper vehicle use can result in SEVERE INJ URY or DEATH NEVER Operate If you are under age 16 and without a valid driver s license Without first viewing safety video and taking a ROHVA training course at www rohva org On excessively steep hills On public roads unless designated for off road use With a passenger who is not seated in a passenger seat or with passengers under age 12 or who cannot comfortably reach the floor and hand holds On paved surfaces pavement may seriously affect handling and control With non Polaris approved accessories they may seriously affect stability ALWAYS Wear your seat belt Vehicle rollover can cause severe injury or death Secure cab nets or doors and keep hands and feet inside vehicle atall times Wear a helmet eye protection gloves long sleeve shirt long pants and over the ankle boots Reduce speed and use extra caution when carrying passengers Avoid sharp turns orturns while applying heavy throttle Operate slowly in reverse avoid sharp turns or sudden braking Make sure passengers read and understand all safety labels ALL RIDERS MUST WEAR AN APPROVED HELMET AND PROTECTIVE GEAR ALL RIDERS MUST WEAR SEAT BELTS NEVER USE ON PUBLIC ROADS NEVER USE WITH DRUGS OR ALCOHOL READ OWNER S MANUAL FO
48. a Exhaust contains poisonous carbon monoxide gas that can cause loss of consciousness or death in a very short time Never operate without the spark arrestor Never go under the vehicle while it s inclined Use the following procedure to periodically purge accumulated carbon from the exhaust pipe 1 Remove the arrester clean out plug located on the bottom of the muffler 2 Place the transmission in PARK 3 Start the engine 4 Purge accumulated carbon from the system by momentarily revving the engine several times 5 If carbon is expelled cover or plug the exhaust outlet and rap on the pipe around the clean out plug while revving the engine several more times 6 Ifparticles are still suspected to be in the muffler elevate the rear of the vehicle one foot higher than the front Block the wheels Repeat steps 4 and 5 until no more particles are expelled when the engine is revved 8 Stop the engine Allow the arrester to cool 9 Reinstall the arrester plug and remove the outlet cover or plug 75 MAINTENANCE Brakes The front and rear brakes are hydraulic disc type brakes Press down on the brake pedal to engage the brakes See page 25 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
49. achine we ve ever produced For safe and enjoyable operation of your vehicle be sure to follow the instructions and rec ommendations in this owner s manual Your manual contains instructions for minor mainte nance but information about major repairs is outlined in the POLARIS Service Manual and should be performed only by a factory certified Master Service 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 POLARIS POLARIS RANGER and RANGER CREWO are trademarks of POLARIS Industries Inc Copyright 2014 POLARIS Industries Inc All information contained within this publication is based on the latest product information at the time of publication Due to constant improvements in the design and quality of production components some minor discrepancies may result between the actual vehicle and the information presented in this publication Depictions and or procedures in this publication are intended for reference use only No liability can be accepted for omissions or inaccuracies Any reprinting or reuse of the depictions and or procedures contained within whether whole or in part is expressly prohibited The original instructions for this vehicle are in English Other languages are provided as translations of the original instructions Printed in U S A 2015 RANG
50. age clutch WARNING Excessive throttle may cause loss of control and vehicle roll over 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 roll over Belt slippage from water or snow ingestion into the PVT system Dry out the PVT See page 73 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 fuel 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 35 and 71 93 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 Solution Out of fuel Refuel Clogged fuel
51. air or replacement of any defective materials components or products THE REMEDIES SET FORTH IN THIS LIMITED WARRANTY ARE THE ONLY REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF THIS WARRANTY POLARIS SHALL HAVE NO LIABILITY TO ANY PERSON FOR INCIDENTAL CONSEQUENTIAL OR SPECIAL DAMAGES OF ANY DESCRIPTION WHETHER ARISING OUT OF EXPRESS OR IMPLIED WARRANTY OR ANY OTHER CONTRACT NEGLIGENCE OR OTHER TORT OR OTHERWISE THIS EXCLUSION OF CONSEQUENTIAL INCIDENTAL AND SPECIAL DAMAGES IS INDEPENDENT FROM AND SHALL SURVIVE ANY FINDING THAT THE EXCLUSIVE REMEDY FAILED OF ITS ESSENTIAL PURPOSE ALL IMPLIED WARRANTIES INCLUDING BUT NOT LIMITED TO ANY IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE ARE LIMITED IN DURATION TO THE WARRANTY PERIOD DESCRIBED HEREIN POLARIS DISCLAIMS ALL EXPRESS WARRANTIES NOT STATED IN THIS WARRANTY Some states do not allow limitations on how long an implied warranty lasts so the above limitation may not apply if it is inconsistent with the controlling state law This limited warranty excludes failures not caused by a defect in material or workmanship This limited warranty does not cover damage due to accidents abuse or improper handling maintenance or use This limited warranty also does not cover any engine that has been structurally altered or when the vehicle has been used in racing competition This limited warranty also does not cover physical damage corrosion or defects caused by fire exp
52. amage Allow the engine to warm up for several minutes before operating the vehicle Stopping the Engine 1 Release the throttle pedal completely and brake to a complete stop 2 Turn the engine off 3 Place the transmission in PARK 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 2 Press on the brake pedal evenly and firmly 3 Practice starting and stopping using the brakes until you re familiar with the controls Tip When the throttle pedal is released completely and the engine speed drops near an idle the vehi cle has no engine braking 37 OPERATION Driving Procedure 1 Wear a helmet eye protection gloves long sleeve shirt long pants and over the ankle boots Sit in the driver s seat and fasten the seat belt Start the engine and allow it to warm up Always use the cab nets or doors while riding in this vehicle 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 depress the throttle with your right foot to begin driving Drive slowly Practice maneuvering and using the throttle and brakes on level surfaces Do not carry a passenger until you have at least two hours of driving experience with this vehicle Driving with a Passenger
53. be properly distributed and securely attached Reduce speed and follow the instructions in this manual for hauling cargo or pulling a trailer Allow a greater distance for braking Always place the transmission in PARK before getting out of the vehicle Always stop the engine before refueling Remove flammable material containers from the box before filling them with fuel Make sure the refueling area is well ventilated and free of any source of flame or sparks Gasoline is extremely flammable See page 18 for fuel safety warnings Always remove the ignition key when the vehicle is not in use to prevent unauthorized use by someone under the age of 16 or without a driver s license and proper training or accidental starting FOR MORE INFORMATION ABOUT SAFETY call POLARIS at 1 800 342 3764 Equipment Modifications Do not install any non POLARIS approved accessory or modify the vehicle for the purpose of increasing speed or power Any modifications or installation of non POLARIS approved accessories could create a substantial safety hazard and increase the risk of bodily injury The warranty on your POLARIS vehicle will be terminated if any non POLARIS approved equipment and or modifications have been added to the vehicle that increase speed or power The addition of certain accessories including but not limited to mowers blades tires sprayers or large racks may change the handling characteristics of the vehicle Use only POLARIS app
54. ce Chart beginning on page 59 Always use the recommended engine oil See page 61 NOTICE Allowing dirt or debris to enter the engine can result in serious engine damage Always clean away all dirt and debris from the dipstick area before removing the dipstick Oil Check The oil dipstick and fill tube is located on the engine Access the dipstick through the right rear wheel well 1 Position the vehicle on a level surface 2 Place the transmission in PARK 3 Always clean away all dirt and debris from the dipstick area before removing the dipstick Remove the dipstick Wipe it dry with a clean cloth 4 Reinstall and tighten the dipstick Remove the dipstick and check the oil level 6 Add the recommended fluid as needed Maintain the oil level in the safe range between the FULL and ADD marks Do not overfill 7 Reinstall and tighten the dipstick Oil and Filter Change Always check and change the oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 59 Always change the oil filter whenever changing oil eA Oil Filter Ms INP e Oy L SB Ly yy lj Oil Fill Q Cap ae Sealing Drain Plug Washer Full Add FULL TE ao N The engine drain plug is located on the bottom of the crankcase 1 Position the vehicle on a level surface Place the transmission in PARK Apply the brakes 2 Start the engine
55. cket with ratcheting wrench and extension 4 Pullthe bottom of the cover outward and over Step 3 the suspension to remove it 5 Make sure the cover gasket does not fall out of the groove when removing the cover 6 Squeeze the belt together so that it submarines further into the driven clutch creating slack in the belt between the clutches 7 Remove the belt by using the slack to pull part of the belt off the driven clutch 71 MAINTENANCE POLARIS Variable Transmission PVT System Belt Replacement Debris Removal 8 Rotate the driven clutch by hand until the belt is completely off Step 8 9 Slide the front of the belt out from between the drive clutch and inner clutch cover to completely remove it 10 Remove all debris wrapped in and around the PVT system 11 Remove all debris from the entire clutch air duct passage 12 Check for signs of damage to seals on the transmission and engine See your dealer promptly for service if any seals appear to 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 13 To install a belt place one end of the belt over the driving clutch Route the belt over the top of the driven clutch and down into the groove of the gt clutch to allow slack
56. d on the Vehicle The weight of both cargo and passengers impacts vehicle operation For your safety and the safety of others carefully consider how your vehicle is loaded and how to safely operate the vehicle Follow the instructions in this manual for loading tire pressure gear selection and speed Do not exceed vehicle weight capacities The vehicle s maximum weight capacity is listed in the specifications section of this manual and on a label on the vehicle When more passenger weight is added cargo weight may need to be reduced accordingly The recommended tire pressures are listed in the specifications section of this manual and on a label on the vehicle Always follow these guidelines Under ANY of these conditions Do ALL of these steps Passenger and or cargo exceeds half the maximum weight capacity 1 Slow down 2 Verify tire pressure 3 Use extra caution when Operating over obstacles operating Operating in rough terrain Climbing an incline Towing 17 SAFETY Operator Safety Handling Gasoline Gasoline is highly flammable and explosive under certain conditions Always exercise extreme caution whenever handling gasoline Always turn off the engine when refueling Always refuel outdoors or in a well ventilated area free of any source of flame or sparks Always use an approved gasoline container to store fuel and remove the container from the vehicle before filling
57. ds coating the cylinder with a protective film of fresh oil 6 If POLARIS fuel system additive is not used fuel tank fuel lines and injectors should be completely drained of gasoline Storage Area Covers Be sure the storage area is well ventilated Cover the vehicle with a genuine POLARIS cover Do not use plastic or coated materials They do not allow enough ventilation to prevent condensation and may promote corrosion and oxidation 88 MAINTENANCE Removal from Storage 1 A wR Check the battery electrolyte level and charge the battery if necessary Install it in the vehicle Make sure the battery vent hose is routed properly and that it s not pinched or restricted in any way 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 36 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 59 Transporting the RANGER Follow these procedures when transporting the vehicle 1 2 3 4 Apply the brakes Place the transmission in PARK Stop the engine Secure the fuel cap hood and cargo box Ensure that the seats are attached correctly and are not loose WARNING Cargo and other loose vehicle parts may fly off while transporting this vehicle Secure or remove all cargo and inspect the uni
58. e Check battery voltage each month during storage and recharge as needed to maintain a full charge See page 85 POLARIS recommends maintaining battery charge by using a POLARIS Battery Tender charger or by charging about once a month to make up for normal self discharge Battery Tender can be left connected during the storage period and will automatically charge the battery if the voltage drops below a pre determined point See page 92 for the part numbers of POLARIS products 84 MAINTENANCE Battery Battery Charging Conventional Battery 1 Remove the battery from the vehicle to prevent damage from leaking or spilled electrolyte during charging See page 83 2 Charge the battery with a charging output no larger than 1 10 of the battery s amp hr rating Charge as needed to raise the specific gravity to 1 270 or greater 3 Reinstall the battery See page 84 Make sure the positive terminal is toward the driver s side of the vehicle Battery Charging Sealed Battery The following battery charging instructions apply only to the installation of a sealed battery Read all instructions before proceeding with the installation of this battery The sealed battery is already filled with electrolyte and has been sealed and fully charged at the factory Never pry the sealing strip off or add any other fluid to this battery The single most important thing about maintaining a sealed battery is to keep it fully charged Since the batt
59. e chances of SEVERE INJURY or DEATH 57 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 engine design An electronic fuel injection EFI system controls fuel delivery The engine and EFI components are set at the factory for optimal performance and are not adjustable The emissions label is located under the hood Electromagnetic Interference This spark ignition system complies with Canadian ICES 002 Emissions Label under hood This vehicle complies with the EMC requi
60. e engine Inspect for leaks upper mark on the dipstick Dispose of used filter and oil properly MAINTENANCE Oil Filter Re check the oil level on the dipstick and add oil as necessary to bring the level to the 63 MAINTENANCE Engine Oil ETX Always check and change the oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 59 Always use the recommended engine oil See page 61 NOTICE Allowing dirt or debris to enter the engine can result in serious engine damage Always clean away all dirt and debris from the dipstick area before removing the dipstick Oil Check The oil dipstick is located on the lower engine behind the seat Access the dipstick through the right rear wheel well Remove the dipstick to check the oil level and to add oil An additional oil fill hole is located at the top of the engine Add oil through either the dipstick hole or the upper fill hole Access the upper fill hole cap through the cargo box access panel 1 Position the vehicle on a level surface 2 Place the transmission in PARK 3 Always clean away all dirt and debris from the dipstick area before removing the dipstick Remove the dipstick Wipe it dry with a clean cloth 4 Reinstall and tighten the dipstick 5 Remove the dipstick and check the oil level Maintain the oil level in the safe range between the FULL and ADD marks Do not overfill 6 Add the recommended fluid as needed 7 Re
61. e environment was controlled as indicated by the test procedure s The uncertainty of vibration exposure measurement is dependent on many factors including Instrument and calibration uncertainty Variations in the machine such as wear of components Variation of machine operators such as experience or physique Ability of the worker to reproduce typical work during measurements Environmental factors such as ambient noise or temperature SAFETY Safe Riding Gear The driver and all passengers must wear helmet eye protection gloves long sleeve shirt long pants over the ankle boots and seat belt at all times Protective gear reduces the chance of injury Long Sleeves Helmet Wearing a helmet can prevent a severe head injury Whenever riding this POLARIS vehicle always wear a helmet that meets or exceeds established safety standards Approved helmets in the USA and Canada bear a U S Department of Transportation DOT label Approved helmets in Europe Asia and Oceania bear the ECE 22 05 label The ECE mark consists of a circle surrounding the letter E fol lowed 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 SAFETY Safe Riding Gear Eye Protection Do not depend on eyeglasses or sunglasses for eye protection Whenever riding this POLARIS vehicle always wear shatterproof goggles or use
62. e instructions and procedures which are outlined in further detail within your owner s manual Read this entire manual and all labels carefully Follow the operating procedures described Never allow anyone under the age of 16 to operate this vehicle and never allow anyone without a valid driver s license to operate this vehicle Do not carry a passenger until you have at least two hours of driving experience with this vehicle No person under the age of 12 may ride as a passenger in this vehicle All riders must be able to sit with backs against the seat both feet flat on the floor and both hands on the steering wheel if driving or on a passenger hand hold The driver and all passengers must wear helmet eye protection gloves long sleeve shirt long pants over the ankle boots and seat belt at all times Always use the cab nets or doors while riding in this vehicle Always keep hands and feet inside the vehicle at all times Always keep both hands on the steering wheel and both feet on the floorboards of the vehicle during operation Never permit a guest to operate this vehicle unless the guest has read this manual and all product labels To reduce rollover risk be especially careful when encountering obstacles and slopes and when braking on hills or during turns This vehicle is for off road use only Never operate on public roads unless marked for off road use Always avoid paved surfaces Nev
63. ease lever Lift the front of the cargo box to dump the cargo Lower the cargo box and push down securely to latch Close the tailgate and secure both tailgate latches OPERATION Release a Lever WARNING Operating the vehicle while the cargo box is raised could result in severe injury The box could close unexpectedly and cause injury to the driver or passenger The rear tires will also catch the rear of a raised box damaging the vehicle and creating hazardous driving conditions Never operate this vehicle with the cargo box in the raised position 45 OPERATION All Wheel Drive AWD System For models equipped with a lockable rear differential refer to the All Wheel Drive Rear Differential section beginning on page 47 On models not equipped with a lockable rear differential the All Wheel Drive system is controlled by the AWD switch When the switch is on 2X4 the vehicle is in two wheel drive at all times When the switch is on AWD the vehicle is in all wheel drive and the 4X4 indicator in the instrument cluster will be on When in AWD the demand drive unit will automatically engage any time the rear wheels lose traction When the rear wheels regain traction the demand drive unit will automatically disengage There is no limit to the length of time the vehicle may remain in AWD Engaging Disengaging AWD The AWD switch may be turned on or off while the vehicle is moving Press the top of the rocker switch t
64. ension Inspect lubricate if necessary 61 Steering Ensure free operation 77 Tires Inspect condition and pressure 78 Wheels fasteners Inspect ensure fastener tightness 78 Frame nuts bolts fasteners Inspect ensure tightness Fuel and oil Ensure proper levels 25 62 Coolant level Ensure proper level 70 Coolant hoses Inspect for leaks Throttle Ensure proper operation 25 Indicator lights switches Ensure operation Air filter pre filter Inspect clean 74 Headlamp Check operation apply POLARIS dielectric grease 80 when lamp is replace Brake light tail lamp Check operation apply POLARIS dielectric grease 81 when lamp is replace Seat Belts Check length of belt for damage check latches for 27 proper operation Cab Nets Check for wear or damage ensure proper installation 28 36 OPERATION Starting Engine 1 Always start the engine outdoors or in a well ventilated area 2 Sitin the driver s seat and fasten the seat belt Secure the cab nets or doors 3 Apply the brakes Place the transmission in PARK 4 Do not press the throttle pedal while starting the engine Turn the ignition key past the ON RUN position to START Engage the starter for a maximum of five seconds Release the key when the engine starts 5 If the engine does not start within five seconds release the ignition switch and wait five seconds Repeat steps 4 and 5 until the engine starts NOTICE Operating the vehicle immediately after starting could cause engine d
65. ention 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 P Perform these operations more often for vehicles subjected to severe use E Enmission 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 59 MAINTENANCE Periodic Maintenance Chart Perform all services at whichever maintenance interval is reached first Item Maintenance Interval Remarks whichever comes first Hours Calendar Miles Km Steering Front suspension Rear suspension Tires Brake fluid l vel Pre Ride Make adjustments as needed Brake pedal travel See Pre Ride Checklist on page 36 Brake system Wheels fasteners Frame fasteners Engine oil level t Air filter pre filter Daily Inspect clean often replace as needed Coolant Daily Check level gt Power steering uni
66. eplacement 2 Always inspect your winch cable before each use Inspect for worn or kinked winch cable A Akinked winch cable made of wire rope is shown at right Even after being straightened out this cable has already been permanently and severely damaged Promptly discontinue use of a winch cable in this condition B Akinked winch cable made of wire rope that has been straightened out is shown at right Even though it may look usable the cable has been permanently and severely damaged It can no longer transmit the load that it could prior to kinking Promptly discontinue use of a winch cable in this condition C Awinch cable made of synthetic rope should be inspected for signs of fraying Replace the cable if fraying is observed shown at right Promptly discontinue use of a winch cable in this condition D Also replace the winch cable if there are fused or melted fibers Such an area of the synthetic rope will be stiff and appear smooth or glazed Promptly discontinue use of a winch cable in this condition 59 WINCH GUIDE Shock Loading WARNING Your winch cable is very strong but it is NOT designed for dynamic or shock loading Shock loading may tension a winch cable beyond its strength and cause the cable to break The end of a broken winch cable under such high loading can cause SEVERE INJURY or DEATH to you and other bystanders Winch cables are designed to NOT absorb energy This is true of bot
67. er consume alcohol or drugs before or while operating this vehicle Never operate at excessive speeds Always travel at a speed proper for the terrain visibility and operating conditions and your experience Never attempt jumps or other stunts Always inspect the vehicle before each use to make sure it s in safe operating condition Always follow the inspection procedures described in this manual S O 14 AFETY perator Safety Always travel slowly and use extra caution when operating on unfamiliar terrain Be alert to changing terrain Never operate on excessively rough slippery or loose terrain Always follow proper procedures for turning Practice turning at slow speeds before attempting to turn at faster speeds Never turn at excessive speeds Always have this vehicle checked by an authorized POLARIS dealer if it has been involved in an accident Never operate this vehicle on hills too steep for the vehicle or for your abilities Practice on smaller hills before attempting larger hills Always follow proper procedures for climbing hills as described in this manual See page 40 Check the terrain carefully before attempting to climb a hill Never climb hills with excessively slippery or loose surfaces Never apply throttle suddenly Never make sudden gear changes Never go over the top of a hill at high speed Always follow the proper procedures outlined in this manual for traveling downhill and for braking on hills
68. erval 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 Leave 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 33 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 Nan WwW 34 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
69. ery is sealed and the sealing strip cannot be removed you must use a voltmeter or multimeter to measure DC voltage WARNING An overheated battery may explode causing severe injury or death Always watch charging times carefully Stop charging if the battery becomes very warm to the touch Allow it to cool before resuming charging For a refresh charge follow all instructions carefully 1 Check the battery voltage with a voltmeter or multimeter A fully charged battery will register 12 8 V or higher If the voltage is less than 12 8 volts recharge the battery at 1 2 amps or less until battery voltage is 12 8 or greater 2 When using an automatic charger refer to the charger manufacturer s instructions for recharging When using a constant current charger use the guidelines below for recharging Always verify battery condition before and 1 2 hours after the end of charging 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 75 100 12 5 12 8 volts May need slight charge if no charge 3 6 hours given check in 3 months 50 75 12 0 12 5 volts Needs charge 5 11 hours 25 50 11 5 12 0 volts Needs charge At least 13 hours verify state of charge 0 25 11 5 volts or less Needs charge with desulfating charger At least 20 hours 85 MAINTENANCE
70. f purchase Upon receipt of this registration POLARIS will record the registration for warranty No verification of registration will be sent to the purchaser as the copy of the Warranty Registration Form will be your proof of warranty coverage If you have not signed the original registration and received the customer copy please contact your dealer immediately NO WARRANTY COVERAGE WILL BE ALLOWED UNLESS YOUR VEHICLE IS REGISTERED WITH POLARIS Initial dealer preparation and set up of your vehicle is very important in ensuring trouble free operation Purchasing a machine in the crate or without proper dealer set up will void your warranty coverage Warranty Coverage And Exclusions Limitations Of Warranties And Remedies This POLARIS limited warranty excludes any failures that are not caused by a defect in material or workmanship THIS WARRANTY DOES NOT COVER CLAIMS OF DEFECTIVE DESIGN This warranty also does not cover acts of God accidental damage normal wear and tear abuse or improper handling This warranty also does not cover any vehicle component or part that has been altered structurally modified neglected improperly maintained or used for racing competition or purposes other than for which it was designed This warranty excludes damages or failures resulting from improper lubrication improper engine timing improper fuel surface imperfections caused by external stress heat cold or contamination operator error or abuse imprope
71. filter See your POLARIS dealer 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 plug Inspect plug and replace if necessary No spark to spark plug Inspect plug 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 POLARIS dealer Engine Backfires Possible Cause Weak spark from spark plug Solution Inspect clean and or replace spark plug Incorrect spark plug gap or heat range Set gap to specs or replace plug Old or non recommended fuel Replace with fresh recommended fuel Incorrectly installed spark plug wires See your POLARIS dealer Incorrect ignition timing See your POLARIS dealer Mechanical failure See your POLARIS 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 ignition timing See your POLARIS dealer Incorrect spark plug gap or heat range Set gap to specs or replace plug TROUBLESHOOTING Engine Runs Irregularly Stalls or Misfires Possible Cause Solutio
72. gue Capacity 150 Ibs 68 kg 150 Ibs 68 kg Max Cargo Box Load 500 Ibs 227 kg 500 Ibs 227 kg Engine Dual overhead cam 4 valve 4 stroke single cylinder Displacement 567 cc 570 325 cc ETX Bore x Stroke mm 99mm x 73 6mm 570 78mm x 68mm ETX Alternator Output 460 W 3000 RPM Compression Ratio 10 1 570 11 5 1 ETX Starting System Electric Fuel System Electronic Fuel Injection Ignition Timing ECU Controlled 32 2 5000 RPM Spark Plug NGK MRTF 031 0 7 0 9 mm Lubrication System Wet Sump Cooling Liquid Front Suspension McPherson Strut w 8 in 20 3 cm of travel 570 McPherson Strut w 9 in 22 7 cm of travel ETX Rear Suspension Independent w 9 in 23 cm of travel 570 Dual A arm Anti Sway Bar w 10 in 25 4 cm of travel ETX Throttle Body Size 42 mm 570 36 mm ETX Ignition System Digital CDI 90 SPECIFICATIONS RANGER ETX RANGER 570 570 EPS RANGER CREW 570 570 EPS Driving System Type PVT PVT Shift Type Single Lever console Single Lever console Gear Reduction Low 28 84 1 28 84 1 Gear Reduction Reverse 25 83 1 25 83 1 Gear Reduction High 13 58 1 570 9 65 1 ETX 13 58 1 Drive Ratio Front 3 818 1 3 818 1 Tire Size Front 25x 8 12 25x 10 12 Tire Size Rear 25x 11 12 25x 10 12 Tire Pressure Front 10 psi 69 kPa 10 psi 69 kPa Tire Pressure Rear 10 psi 69 kPa 14 psi 96 kPa Brakes Front Rear Foot Activated 4 wheel
73. h wire rope and syn thetic rope winch cables 1 Never attempt to jerk a load with the winch For example never take up slack in the winch cable by moving the winching vehicle in an attempt to move an object This is a dangerous practice It generates high winch cable loads that may exceed the strength of the cable Even a slowly moving vehicle can create large shock loads in a winch cable WARNING SEVERE INJURY or DEATH can result from a broken winch cable 2 Never quickly turn the winch ON and OFF repeatedly jogging This puts extra load on the winch winch cable and generates excessive heat from the motor This is a form of shock loading 3 Never tow a vehicle or other object with your winch Towing an object with a winch produces shock loading of the cable even when towing at slow speeds Towing from a winch also positions the towing force high on the vehicle This can cause instability of the vehicle and possibly lead to an accident 4 Never use recovery straps with your winch Recovery straps are designed to stretch and can store energy This stored energy in the recovery strap is released if a winch cable fails making the event even more hazardous Similarly never use elastic bungie cords for winching 5 Never use the winch to tie down a vehicle to a trailer or other transportation vehicle This type of use also causes shock loading that can cause damage to the winch winch cable or vehicles used Your wi
74. have any questions regarding your warranty rights and responsibilities please contact POLARIS Customer Assistance United States amp Canada 1 800 POLARIS 1 800 765 2747 French 1 800 268 6334 100 MAINTENANCE LOG Use the following chart to record periodic maintenance DATE MILES KM OR HOURS TECHNICIAN SERVICE PERFORMED COMMENTS 101 INDEX A Accessory Outlets 0000000000 22 Adjustment Shock Spring TI Air Filter sensar ratane aeea a 74 Air Filter Cleaning 000 74 All Wheel Drive Disengaging AWD 46 47 Engaging AWD 46 47 Locking the Differential 48 Unlocking the Differential 48 All Wheel Drive Switch 0 23 All Wheel Drive System 46 All Wheel Drive Rear Differential System 47 48 Auxiliary Outlets eese ees 22 AW DiS witli scat oce tette po uere bo 23 46 AWD System isses se eR rer ssis 46 Axle Nut Torque is zu cassie sad cw race ete 78 B Baltery 55555 535 6 Sols overshadow e aes 82 85 Charging Conventional 85 Charging Sealed 85 Extreme Use 30 AH 29 Fluid Conventional 82 Installation 004 84 Removal es eet te Shoda 83 Storage ees exe dee e dea cau 84 Warnings cue ee pr NERA 82 Belt Burning c cos ead tne caters
75. he engine idling move e the lever to the desired gear Do not attempt to shift gears with engine speed above idle or while the vehicle is moving Tip Maintaining shift linkage adjustment is important to assure proper transmission function See your dealer if you experience any shifting problems NOTICE 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 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 24 FEATURES AND CONTROLS Brake Pedal Depress the brake pedal to slow or stop the vehicle Apply the brakes while starting the engine Throttle Pedal Push the pedal down to increase engine speed Spring pressure returns the pedal to the rest pangs position when released Always check that the throttle pedal returns normally before starting the engine This vehicle is equipped with a throttle release switch which is designed to reduce the risk of a frozen or stuck throttle If the throttle cable should stick in an open position when the operator releases the throttle pedal engine speed will be limited and power to the rear wheels will be Brake Throttle reduced Pedal Pedal Fuel Cap The fuel tank filler cap is located on the right SD n NAT US NS hand s
76. he seat belt is not secured SD The center of the seat is NOT equipped with a seat belt Never allow a passenger to ride between the operator and passenger seats WARNING Falling from a moving vehicle could result in serious injury or death Always fasten your seat belt securely before operating or riding in the RANGER To wear the seat belt properly follow this procedure 1 2 3 4 For 3 point belts pull the seat belt latch downward and across your chest toward the buckle at the inner edge of the seat The belt should fit snugly across your hips and diagonally across your chest Make sure the belt is not twisted Push the latch plate into the buckle until it clicks Release the strap it will self tighten 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 2 3 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 Pull each seat belt completely out and inspect the full length for any damage including cuts wear fraying or stiffness If any damage is found or if the seat belt does not operate properly have the seat belt system checked and or replaced by an authorized POLARIS dealer
77. hydraulic disc Foot Activated 4 wheel hydraulic disc Hood Headlights 2 single beam 50W quartz halogen 2 single beam SOW quartz halogen Taillights 10 L E D 28W 10 L E D 28W Brake Light 10 L E D 3 1W 10 L E D 3 1W Indicator Light 1 0 W 1 0 W Clutching See your POLARIS dealer for clutching specifications 91 POLARIS PRODUCTS Part Number Description Engine Lubricant 2870791 Fogging Oil 12 0z 355 ml Aerosol 2876244 PS 4 Full Synthetic 5W 50 4 Cycle Oil qt 95 1 2876245 PS 4 Full Synthetic 5W 50 4 Cycle Oil gal 3 8 1 2878920 PS 4 Extreme Duty Synthetic 10W 50 4 Cycle Oil qt 95 I 2878919 PS 4 Extreme Duty Synthetic 10W 50 4 Cycle Oil gal 3 8 I Gearcase Transmission Lubricants 2878068 AGL Full Synthetic Gearcase Lubricant amp Transmission Fluid qt 95 I 2878069 AGL Full Synthetic Gearcase Lubricant amp Transmission Fluid gal 3 8 1 2877922 Demand Drive Fluid qt 95 1 2877923 Demand Drive Fluid gal 3 8 I 2870465 Pump for Gallon 3 8 I Jug Coolant 2880514 Antifreeze 50 50 Premix qt 95 2880513 Antifreeze 50 50 Premix gal 3 8 Grease Specialized Lubricants 2871312 Grease Gun Kit All Season Grease 2871322 All Season Grease 3 0z 89 ml cartridge 2871423 All Season Grease 14 0z 414 ml cartridge 2876160 ATV Angle Drive Fluid qt 95 I 2872276
78. ide of the vehicle near the passenger seat NDA 7 Zz When refueling always use either leaded or SN i l AA Vrs unleaded gasoline with a minimum pump octane u NL B number of 87 R M 2 octane Do not use fuel with ESAn LN N2 v PA ethanol content greater than 10 percent such as MA RY 2 E 85 fuel NU us 9 25 FEATURES AND CONTROLS Seat Removal Pull up on the front of the seat and slide it toward the front of the vehicle Install the seat by sliding the tabs into the rear of the seat base Push down firmly on the front of the seat until the pins are fully seated into the grommets Electronic Power Steering EPS Electronic power steering if equipped engages when the ignition key is turned to the ON position EPS remains engaged whether the vehicle is moving or idle To conserve battery power the EPS will shut down 5 minutes after the engine is stopped if the key remains in the ON position The EPS warning indicator will illuminate to indicate the EPS has shut down Turn the key off and on to reset the unit See page 30 for EPS warning indicator information 26 FEATURES AND CONTROLS Seat Belts This POLARIS vehicle is equipped with three point lap and diagonal seat belts for the operator and passenger Always make sure the seat belts are secured for all riders before operating The driver s seat belt is equipped with a seat belt interlock d Vehicle speed will be limited to 15 MPH 24 km h ri if t
79. ields of vision before backing 2 Always avoid backing downhill 3 Back slowly 4 Apply the brakes lightly for stopping 5 Avoid turning at sharp angles 6 Never open the throttle suddenly 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 41 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 73 and take the vehicle to your dealer at the first opportunity Follow these procedures when operating through water 1 Determine water depths and current before entering water 2 Choose a crossing where both banks have gradual inclines 3 Proceed slowly avoiding rocks and obstacles 4 Avoid operating through deep or fast flowing water WARNING The large tires on your R
80. ific 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 Never exceed the following capacities Maximum Capacities Model Level Ground Cargo Box RANGER ETX 1000 Ibs 454 kg 500 Ibs 227 kg RANGER 570 570 EPS RANGER CREW 570 570 EPS 1250 Ibs 567 kg 500 Ibs 227 kg WARNING Driving with passengers in the cargo box can result in severe injury or death Never allow passengers to ride in the cargo box Passengers must always ride in the cab with seat belts fastened securely 43 OPERATION Towing Loads Towing improperly can alter vehicle handling and may cause loss of control or brake insta bility Always follow these precautions when towing 1 Never load more than 150 Ibs 68 1 kg tongue weight on the towing bracket 2 Always shift to low gear for towing 3 When towing a disabled RANGER vehicle place the disabled vehicle s transmission in neutral Do not operate the vehicle faster than 10 MPH 16 km h when towing 4 Do not operate the vehicle faster than 10 MPH 16 km h when towing See page 43 Towing a trailer increases braking distance 5 Do not tow more than the recommended weight for the vehicle See the towing capacity chart below and the specifications charts beginning on page 90 6 Attach a trailer
81. ignition key when the vehicle is not in use Hot Exhaust Systems Exhaust system components are very hot during and after use of the vehicle Hot components can cause burns and fire Do not touch hot exhaust system components Always keep combustible materials away from the exhaust system Use caution when traveling through tall grass especially dry grass to avoid debris build up around the exhaust system 20 FEATURES AND CONTROLS Vehicle Components Your vehicle is equipped with cab nets on both sides of the vehicle Cab nets or doors if equipped must be used by both operator and passengers at all times Any illustrations with out cab nets are only to allow component identification Always use the cab nets or doors Not all models come with all features Refer to the specifications section beginning on page 90 Seat Belts ROPS Cab Frame Y l v M Cargo Box Release Lever Hip Bars uia Muffler ku N _ 6park Arrester Electrical Compartment Compartment CREW CREW E MM Lu Fe ot 73 o 4o 1 3 ARE i e F NY pj Tailgate d S AY 7 Electrical Na ite BTA Compartment A INEA A ETX 570 570 EPS que D CUL Cargo Box Front Bumper Brush Guard Radiator Headlights 21 FEATURES AND CONTROLS Console Instrument Gear Selector Cluster MODE Shifter Button AWD Switch Steering Wheel j Ignition Light Storage ee Switch Tray 12V Auxiliary Compartment Outlet
82. install and tighten the dipstick Oil and Filter Change Upper Oil Fill Oil Dipstick Check Fill Full Add EE TE aon Always check and change the oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 59 Always change the oil filter whenever changing oil The engine drain plug is located on the bottom of the crankcase 1 Position the vehicle on a level surface Place the transmission in PARK Apply the brakes 2 Start the engine Allow it to idle for two to three minutes Stop the engine 64 Engine Oil ETX Oil and Filter Change 3 Clean the area around the drain plug CAUTION Hot oil can cause burns to skin Do not allow hot oil to contact skin 4 10 11 12 13 14 15 16 17 18 19 20 21 Place a drain pan beneath engine crankcase and remove the drain plug Allow the oil to drain completely Install a new sealing washer on the drain plug The sealing surfaces on drain plug and crankcase should be clean and free of burrs nicks or scratches Reinstall the drain plug Torque to 11 13 ft lbs 14 5 17 5 Nm Using a clean dry cloth clean the oil filter cover on the crankcase Place shop towels beneath the filter cover to catch oil drips Remove the cover screws and remove the cover to access the oil filter Remove the oil filter and spring retaining the spring for reinstallation
83. ion 3 Polish the clean chrome wheels periodically Use an automotive grade chrome polish 4 Routinely and liberally apply a weather resistant wax to each polished chrome wheel Choose a product suitable for chrome finishes Read and follow the product labels and instructions Removing Corrosion If light rust is found on the chrome finish use steel wool 0000 OTT grade to remove it Gently rub the affected areas with the steel wool until the corrosion has been removed Clean and polish the wheel as outlined above 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 86 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 62 Air Filter Air Box 1 Inspect and clean or replace the pre cleaner and air filter See page 74 2 Clean the air box 87 MAINTENANC
84. losions 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 POLARIS parts It is a potential violation of the Clean Air Act if a part supplied by an aftermarket parts manufacturer reduces the effectiveness of the vehicle s emission controls Tampering with emission controls is prohibited by federal law California Residents Certain POLARIS Off Road Vehicles are available in 49 state and 50 state versions Only the 50 state models are certified for sale in California The 50 state models available for sale in California are identified by the letter C in the model name e g R13UH88A C The POLARIS 50 state models are designed and built with features such as a reduced cargo box capacity Any modifications to these features may be a violation of the applicable California regulations and may void this limited emissions warranty offered by the manufacturer If you
85. lugs Spark Plug Recommendations Refer to the specifications section beginning on page 90 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 or Used Plug Torque RANGER ETX 031 7 9 mm 9 ft Ibs 12 Nm RANGER 570 570 EPS 031 7 9 mm 9 ft Ibs 12 Nm RANGER 031 7 9 mm 9 ft Ibs 12 Nm CREW 570 570 EPS 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 A hot exhaust system and engine can cause burns Wear protective gloves when removing a spark plug for inspection 1 Lift the cargo box to access the spark plugs 2 Remove the spark plug cap Using the spark plug wrench provided in the tool kit remove the plug by rotating it counter clockwise 3 Reverse the procedure for spark plug installation 4 Torque to specification Normal Plug The normal insulator tip is gray tan or light brown There will be few combustion deposits The electrodes are not burned or eroded This indicates the proper type and heat range for the engine and the service The
86. lure to comply with the instructions in this warning can result in severe injury or death Do not modify any component of the PVT system Doing so may reduce its strength so that a failure may occur at a high speed The PVT system has been precision balanced Any modification will cause the system to be out of balance creating vibration and additional loads on components The PVT system rotates at high speeds creating large amounts of force on clutch components As the owner you have the following responsibilities for your own safety and the safety of others Always follow all recommended maintenance procedures Always look for and remove debris inside and around the clutch and vent system when replacing the belt See your dealer as outlined in the owner s manual This PVT system is intended for use on POLARIS products only Do not install it in any other product Always make sure the PVT housing is securely in place during operation Belt Replacement Debris Removal If a belt fails always clean any debris from the clutch air duct and from the clutch and engine compartments when replacing the belt WARNING Failure to remove ALL debris when replacing the belt could result in vehicle damage loss of control and severe injury or death 1 Position the vehicle on a level surface Block the wheels to prevent vehicle movement Place the transmission in neutral 2 Liftthe cargo box 3 Remove the clutch cover screws using a 3 8 so
87. mains locked after following these instructions see your dealer for service 47 OPERATION All Wheel Drive Rear Differential System if equipped Locking the Differential Move the rocker switch to the center position to lock the differential and operate in two wheel drive 2WD Locking the differential in slippery or low traction conditions helps improve traction When the rear differential is locked both rear wheels rotate at the same speed Unlocking the Differential TURF Mode When operating in TURF mode the inside rear wheel will rotate independently from the outside wheel during turns Operate in TURF mode only as needed to protect smooth level surfaces from tire damage DO NOT operate in TURF mode when climbing or descending hills when sidehilling or when operating on uneven loose or slippery terrain such as sand gravel ice snow obstacles and water crossings Always operate in AWD on these types of terrain WARNING Operating in TURF mode if equipped when on sloped uneven or loose terrain could cause loss of control and result in serious injury or death One rear wheel may slip and lose traction or may lift up and grab when it touches the ground again Press the bottom of the switch to unlock the differential and allow the rear drive wheels to operate independently 1 WD When the rear differential is unlocked the rear wheels can rotate at different speeds Unlock the differential to make maneuvering easier and mi
88. moisture from the air The moisture causes the boiling temperature of the brake fluid to drop which can lead to early brake fade and the possibility of accident or severe injury Change the brake fluid every two years and any time the fluid becomes contaminated the fluid level is below the minimum or if the type and brand of the fluid in the reservoir are unknown See page 61 for fluid recommendations Position the vehicle on a level surface 2 View the brake fluid level at the reservoir in the driver s side wheel well The level should be between the upper MAX and lower MIN level lines 3 If the fluid level is lower than the upper level line open the hood and add brake fluid to the upper MAX line Brake Fluid Reservoir 4 Apply the brake forcefully for a few seconds and check for fluid leakage around the fittings Brake Inspection 1 Check the brake system for fluid leaks 2 Check the brake pedal for excessive travel or a spongy feel 3 Check the friction pads for wear damage and looseness 4 Check brake discs for signs of cracks excessive corrosion warping or other damage Clean any grease using an approved brake cleaner or alcohol WARNING Do not apply WD 40 or any petroleum product to brake discs These types of products are flammable and may also reduce the friction between the brake pad and caliper 5 Inspect the brake disc spline and pad wear surface for excessive wear Change pads when wo
89. n Fouled or defective spark plug Inspect clean and or replace spark plug Worn or defective spark plug wires See your POLARIS dealer Incorrect spark plug gap or heat range Set gap to specs or replace plug 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 Kinked or plugged fuel tank vent line Inspect and replace Incorrect fuel Replace with recommended fuel Clogged air filter Inspect and clean or replace Low fuel pressure See your POLARIS dealer Other mechanical failure Possible Lean Fuel Cause Low or contaminated fuel See your POLARIS dealer Solution Add or change fuel clean the fuel system Low octane fuel Replace with recommended fuel Clogged fuel filter Possible Rich Fuel Cause Fuel is very high octane See your POLARIS dealer Solution Replace with lower octane fuel Engine Stops or Loses Power Possible Cause Solution Out of fuel Refuel Kinked or plugged fuel vent line Inspect and replace Water is present in fuel Replace with new fuel Fouled or defective spark plug Inspect clean and or replace spark plug Worn or defective spark plug wires See your POLARIS dealer Incorrect spark plug gap or heat range Set gap to specs or replace plug Loose ignition con
90. nch cable is designed and tested to withstand the loads produced by the winch motor when operated from a stationary vehicle Always remember that the winch and winch cable are NOT designed for shock loading 56 WINCH GUIDE Winch Maintenance and Service Safety WARNING Improper or lack of winch maintenance and service could lead to SEVERE INJURY or DEATH Always follow all winch instructions and warnings in this manual 1 Always inspect your winch before each use Inspect for worn or kinked winch cable Also inspect for worn or loose parts including mounting hardware Permit your winch motor to cool down prior to servicing your winch 3 Never work on your winch without first disconnecting the battery connections to prevent accidental activation of the winch 4 For your safety always replace POLARIS winch parts including the cable with genuine POLARIS replacement parts available at your authorized POLARIS dealer 5 Some winch models use wire rope as the winch cable Other winches use a specially designed synthetic rope as the winch cable 6 Never replace a synthetic rope winch cable with a consumer grade polymer rope such as can be purchased in a hardware store Although they may look similar they are NOT alike A polymer rope not designed for winch use will stretch and store excessive energy when winching WARNING Failure of a stretched rope under winching conditions will release all of the stored energy This will increase th
91. nections 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 Other mechanical failure See your POLARIS dealer Overheated engine Clean radiator screen and core clean engine exterior see your POLARIS dealer 95 96 WARRANTY Limited Warranty POLARIS Industries Inc 2100 Highway 55 Medina MN 55340 POLARIS gives a SIX MONTH LIMITED WARRANTY on all components of your POLARIS vehicle against defects in material or workmanship POLARIS further warrants that the spark arrester in this product will meet the efficiency requirements of USFS standard 5100 1C for at least 1000 hours when subjected to normal use and when maintenance and installation are in accordance with POLARIS recommendations This warranty covers parts and labor charges for repair or replacement of defective parts and begins on the date of purchase by the original retail purchaser This warranty is transferable to another owner during the warranty period through a POLARIS dealer but any such transfer will not extend the original term of the warranty The duration of this warranty may vary by international region based upon local laws and regulations Registration At the time of sale the Warranty Registration Form must be completed by your dealer and submitted to POLARIS within ten days o
92. nel to add coolant through the filler opening Reinstall the cap Tip If coolant must be added often or if the overflow bottle runs completely dry there may be a leak in the system Overflow Radiator Have the cooling system inspected by your POLARIS Bottle Cap Cap dealer Radiator Coolant Level Always check and clean the screen and radiator fins at the intervals outlined in the Periodic Maintenance Chart beginning on page 59 Do not obstruct or deflect air flow through the radiator by installing unauthorized accessories in front of the radiator or behind the cooling fan Interference with the radiator air flow can lead to overheating and consequentially engine damage 1 Lift the hood CAUTION Escaping steam can cause burns Never remove the pressure cap while the engine is warm or hot Always allow the engine to cool before removing the pressure cap 2 Slowly remove the radiator cap 3 View the coolant level through the opening 4 Usea funnel and slowly add coolant as needed Tip This procedure is required only if the cooling system has been drained for maintenance and or repair But if the overflow bottle has run dry the level in the radiator should also be inspected 5 Reinstall the pressure cap Use of a non standard pressure cap will not allow the recovery system to function properly See your dealer for the correct replacement part 70 MAINTENANCE POLARIS Variable Transmission PVT System AWARNING Fai
93. ng unit to allow proper cooling Clean these areas thoroughly 79 MAINTENANCE Fuses If the engine stops or will not start or if you na experience other electrical failures a fuse may need EET petty emus EMR pear replacement Locate and correct any short circuits SPARE 5A SPARE 1A that may have caused the blown fuse then replace RES 2oa ce Zoa toa P PARR T hoa OPT S DPT GHTS RIVI ACCESSOR the fuse EPS PT LHT DRIVE ACCESSORY The fuse box is located in the electrical compartment under the left rearmost seat Spare fuses are provided in the fuse box If you suspect that a fuse or relay may not be working properly please see your POLARIS dealer Fuse Size Feature Supported 5A Brake Light 10A Drive System Fuel Pump 20A EFI Power Steering if equipped Lights Accessories 20A Circuit Fan Breaker Lights Poor lighting can result in reduced visibility when driving Headlight and taillight lenses become dirty during normal operation Clean lights frequently and replace burned out lamps promptly Do not operate this vehicle at night or in low light conditions until the headlight is replaced Always make sure lights are adjusted properly for best visibility When servicing a halogen lamp don t touch the lamp with bare fingers Oil from your skin leaves a residue causing a hot spot that will shorten the life of the lamp Headlight
94. ng you are about to do Proceed slowly and deliberately Never hurry or rush during winching Always pay attention to your surroundings You may need to change your winching strategy if it is not working Always remember that your winch is very powerful There are simply some situations that you and your winch will not be able to deal with Do not be afraid to ask others to help when this happens 1 Always inspect the vehicle winch winch cable and winch controls for any signs of dam age or parts in need of repair or replacement before each use Pay particular attention to the first 3 feet 1 meter of winch cable if the winch is being used or has been used for lifting an accessory plow assembly Promptly replace any worn or damaged cable 2 Never operate a winch or a vehicle in need of repair or service 3 Always apply your vehicle s park brake and or park mechanism to hold the vehicle in place during winching Use wheel chocks if needed Hook Strap ae NN LY Ca 51 WINCH GUIDE Winch Operation 4 Always use the hook strap when handling the hook WARNING Never put your fingers into the hook This could lead to SEVERE INJURY A Attach the hook itself onto the load or use a tow strap or NOT chain to secure the load to the winch cable Tip A tow strap is NOT intended to stretch A recovery strap is designed to stretch NO YES WARNING Never use a recovery strap when winching due to the excessive energy
95. nimize damage to turf NOTICE Damage to the differential can occur if it is engaged while the vehicle is traveling at high speeds or while the rear wheels are spinning Slow the vehicle to nearly stopped before engaging the differential 48 WINCH GUIDE These safety warnings and instructions apply if your vehicle came equipped with a winch or if you choose to add an accessory winch to your vehicle AWARNING Improper winch use can result in SEVERE INJURY or DEATH Always follow all winch instructions and warnings in this manual Your winch may have a cable made of either wire rope or specially designed synthetic rope The term winch cable will be used for either unless noted otherwise Winch Safety Precautions Gee we Nor o 10 11 12 Read all sections of this manual Never use alcohol or drugs before or while operating the winch Never allow children under 16 years of age to operate the winch Always wear eye protection and heavy gloves when operating the winch Always keep body hair clothing and jewelry clear of the winch cable fairlead and hook when operating winch Never attempt to jerk a load attached to the winch with a moving vehicle See the Shock Loading section on page 56 Always keep the area around the vehicle winch winch cable and load clear of people especially children and distractions while operating the winch Always
96. ntact your POLARIS dealer to purchase a replacement Replacement safety labels are provided by POLARIS at no charge The part number is printed on the label Seat Belt Drive Responsibly Warning Shift Caution Proper Use Warning Max Payload Warning Max Payload WARNING Warning RANGER Mid Size Never Exceed If Total Payload Exceeds ETX 35 mph 56 kph 700 Ibs 317 kg 570 570 EPS 35 mph 56 kph 850 Ibs 385 kg CREW 570 570 EPS 35 mph 56 kph 1000 Ibs 453 kg 7181296 Shift Caution CAUTION To avoid transmission damage shift only when vehicle is stationary and at idle APPLY BRAKE TO START When this vehicle is not in operation or unattended place shift in the park position 7181060 10 SAFETY Safety Labels and Locations Seat Belt Drive Responsibly Warning WARNING Improper vehicle use can result in SEVERE INJURY or DEATH Be Prepared Fasten seat belts Wear an approved helmet and protective gear ALWAYS use vehicle cab nets and or doors Each rider must be able to sit with back against seat feet flat on the floor and hands on steering wheel or hand holds Stay completely inside the vehicle Drive Responsibly Avoid loss of control and rollovers Avoid abrupt maneuvers sideways sliding skidding or fishtailing Followers have caused and never do donuts severe injuries and death Slow down before entering a turn even on flat open areas Avoid hard accele
97. o engage All Wheel Drive Press the bottom of the switch to operate in two wheel drive Initially the vehicle s electronic system will not enable the AWD until the engine RPM is below 3100 Once enabled the AWD remains enabled until the AWD switch is turned off If the switch is turned off while the demand drive unit is moving it will not disengage until the rear wheels regain traction Engage the AWD switch 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 or slipping may cause severe drive shaft and gearcase damage Always switch to AWD while the rear wheels have traction or are at rest 46 OPERATION All Wheel Drive Rear Differential System if equipped The 4X4 rear axle is equipped with a lockable differential that allows the operator to choose between an open differential or a closed differential For models that are not equipped with a lockable rear differential refer to the All Wheel Drive section beginning on page 46 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 When the AWD switch is on the front gearcase will automatically engage any time the rear wheels lose Differential Lock traction When the rear wheels regain traction the front
98. ock 1WD Turf Mode Differential Lock Press the top of the rocker switch to engage All Wheel Drive AWD See page 47 for AWD operating Differential Unlock instructions 2WD Move the rocker switch to the center position to lock the differential and operate in two wheel drive 2WD See page 48 for Differential Lock operating instructions Press the bottom of the switch to unlock the differential and allow the rear drive wheels to operate independently 1WD This mode of operation is well suited to turf driving or when active traction is not needed WARNING Never operate in TURF mode if equipped while operating on a hill or other irregular terrain Always move the AWD switch to AWD before ascending or descending a hill Adjustable Steering Wheel The steering wheel can be tilted upward or downward for rider preference Lift and hold the adjustment lever toward you while moving the steering wheel upward or downward Release the lever when the steering wheel is at the desired position 23 FEATURES AND CONTROLS Console Gear Selector Gear Shifter H High Gear L Low Gear N Neutral R Reverse P Park Low gear is the primary driving range for the RANGER High gear is intended for use on hard packed surfaces with light loads Whenever the vehicle is left unattended always place the transmission in PARK To change gears stop the vehicle and with t
99. ot lubricate the stud or the lug nut Nut Type Location Nut Torque Lug Nut Front and Rear 30 ft lbs 41 Nm Aluminum 90 1 4 Turn Wheels Nut and Washer Front and Rear 35 ft lbs 47 Nm Steel Wheels O Spindle Nut Front 70 ft Ibs 95 Nm Hub Retaining Nuts Rear 110 ft Ibs 150 Nm Front 80 ft Ibs 108 5 Nm 78 MAINTENANCE Tires Wheel Removal 1 Apply the brakes 2 Place the transmission in PARK 3 Stop the engine 4 Loosen the wheel nuts slightly 5 Elevate the side of the vehicle by placing a suitable stand under the frame 6 Remove the wheel nuts and washers Remove the wheel Wheel Installation 1 Place the transmission in PARK 2 Place the wheel in the correct position on the wheel hub Be sure the valve stem is toward the outside and rotation arrows on the tire point toward forward rotation WARNING Improperly installed wheels can adversely affect tire wear and vehicle handling which can result in serious injury or death Always ensure that all nuts are torqued to specification Do not service axle nuts that have a cotter pin installed See your POLARIS dealer 3 Attach the wheel nuts and washers and fin ger tighten 4 Carefully lower the vehicle to the ground 5 Torque the wheel nuts to specification See page 78 Power Steering Unit If your model is equipped with power steering frequently clean the areas around and on the power steeri
100. otective Structure ROPS The Rollover Protective Structure ROPS on this vehicle meets OSHA 1928 53 rollover a T ROPS performance requirements Always have your ffe 2 Label authorized POLARIS dealer thoroughly AS SES a inspect the ROPS if it ever becomes damaged ENT ROHVA in any way ea Label No device can assure occupant protection in Qu WWE 3 i if the event of a rollover Always follow all safe O M A JI operating practices outlined in this manual to mas Ph avoid vehicle rollover 3 x SW WARNING Vehicle rollover could cause severe i 8 injury or death Always avoid operating in a up manner that could result in vehicle rollover Storage Compartments A storage compartment is located under the driver s seat on CREW models Trailer Hitch Bracket This vehicle is equipped with a receiver hitch bracket for a trailer hitch Trailer towing equipment is not supplied with this vehicle To avoid injury and property damage always heed the warnings and towing capacities outlined on pages 43 44 Extreme Use 30 AH Battery Non EPS Models Only If your factory installed battery cannot maintain a charge because of operation in extreme cold or with multiple electrical accessories please see your POLARIS dealer to purchase a 30 AH battery To install this battery to your vehicle you will also need to purchase the 30 AH battery strap bracket See page 92 for the part numbers of POLARIS products 1 Fully charge the new batte
101. r component alignment tension adjustment or altitude compensation snow water dirt or other foreign substance ingestion contamination improper maintenance modified components use of aftermarket or unapproved components accessories or attachments unauthorized repairs or repairs made after the warranty period expires or by an unauthorized repair center WARRANTY Warranty Coverage And Exclusions Limitations Of Warranties And Remedies This warranty excludes damages or failures caused by abuse accident fire or any other cause other than a defect in materials or workmanship and provides no coverage for consumable components general wear items or any parts exposed to friction surfaces stresses environmental conditions and or contamination for which they were not designed or not intended including but not limited to the following items Finished and unfinished surfaces Carburetor Throttle body components Engine components Drive belts Hydraulic components and fluids Circuit breakers Fuses Wheels and tires Suspension components Brake components Seat components Clutches and components Steering components e c o o e o o o o Batteries Electronic components Light bulbs Sealed beam lamps Spark plugs Filters Sealants Lubricants Coolants Bushings Bearings Lubricants and Fluids 1 Mixing oil brands or using non recommended oil may cause engine damage We recommend the use of POLARI
102. ration when turning even from a stop Plan for hills rough terrain ruts and other changes in traction and terrain Avoid paved surfaces Avoid sidehilling riding across slopes Be Sure Riders Pay Attention and Plan Ahead If you think or feel the vehicle may tip or roll reduce your risk to injury Keep a firm grip on the steering wheel or hand holds and brace yourself Do not put any part of your body outside of the vehicle for any reason LOCATE AND READ OWNER S MANUAL FOLLOW ALL INSTRUCTIONS AND WARNINGS ALWAYS REVIEW SAFETY VIDEO AND TAKE ROHVA TRAINING rohva org 7181110 Proper Use Warning aS SN Require Proper Use of Your Vehicle PEANN Nn gt Do your part to prevent injuries e re C Do not allow careless or reckless driving Make sure operators are 16 or older with a valid driver s f M W i license j pa Do not let people drive or ride after using alcohol or drugs J TA Do not allow operation on public roads unless designated for off highway vehicle access collisions with cars and Proper Use Warning trucks can occur ETX 570 570 EPS Do not exceed seating capacity 2 occupants CREW 570 570 EPS Do not exceed seating capacity 4 occupants 11 SAFETY Safety Labels and Locations Passenger Tire Pressure Warning WARNING Passengers can be thrown off This can cause serious injury or death E Never carry passengers in cargo box WAR
103. rements 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 58 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 101 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 Vehicles subjected to heavy or severe use patterns must be inspected and serviced more fre quently 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 Short trip cold weather operation Pay special att
104. rfaces including sidewalks paths parking lots and driveways may adversely affect the handling of the vehicle and may increase the risk of loss of control and accident or rollover Avoid operating the vehicle on pavement If it s unavoidable travel slowly travel short distances and avoid sudden turns or stops 18 SAFETY Operator Safety Operating on Public Roads Operating this vehicle on public streets roads or highways could result in a collision with another vehicle Never operate this vehicle on any public street road or highway including dirt and gravel roads unless designated for off highway use In some areas it s unlawful to operate this vehicle on public streets roads and highways Turning Improperly Turning improperly could cause loss of traction loss of control accident or rollover Always follow proper procedures for turning as described in this owner s manual Never turn abruptly or at sharp angles Never turn at high speeds Practice turning at slow speeds before attempting to turn at faster speeds Jumps and Stunts Attempting wheelies jumps and other stunts increases the risk of an accident or rollover Never attempt wheelies jumps or other stunts Avoid exhibition driving Operating in Unfamiliar Terrain Failure to use extra caution when operating on unfamiliar terrain could result in an accident or rollover Unfamiliar terrain may contain hidden rocks bumps or holes that could cause loss of control or
105. ribed in the owner s manual and on safety labels Operating on Slippery Terrain Failure to use extra caution when operating on excessively rough slippery or loose terrain could cause loss of traction loss of control accident or rollover Do not operate on excessively slippery surfaces Always slow down and use additional caution when operating on slippery surfaces Skidding or sliding due to loss of traction can cause loss of control or rollover if tires regain traction unexpectedly Always follow proper procedures for operating on slippery surfaces as described in this owner s manual See page 39 Operating on Frozen Bodies of Water Severe injury or death can result if the vehicle and or the operator fall through the ice Never operate the vehicle on a frozen body of water unless you have first verified that the ice is sufficiently thick to support the weight and moving force of the vehicle you and your passengers and your cargo together with any other vehicles in your party Always check with local authorities and residents to confirm ice conditions and thickness over your entire route Vehicle operators assume all risk associated with ice conditions on frozen bodies of water Unauthorized Use of the Vehicle Leaving the keys in the ignition can lead to unauthorized use of the vehicle by someone under the age of 16 without a drivers license or without proper training This could result in an accident or rollover Always remove the
106. rn to 030 0 762 mm 030 0 762 mm 76 MAINTENANCE 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 59 1 Position the vehicle on a level surface 2 Lightly turn the steering wheel left and right 3 There should be 0 8 1 0 20 25 mm of freeplay 4 If there is excessive freeplay or strange noises or the steering feels rough or catchy have the steering system inspected by an authorized POLARIS dealer 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 77 MAINTENANCE Tires AWARNING Operating your vehicle with worn tires improperly inflated tires non standard tires or improperly installed tires will affect vehicle handling and could cause an accident resulting in serious injury or death Always follow all tire maintenance procedures as outlined in this manual and on the labels on the vehicle Always use POLARIS approved size and type of tires for this vehicle when replacing tires Tire Tread Depth i Always replace tires when tread depth is 1 8 3 mm worn to 1 8 3 mm or less Axle and Wheel Nut Torque GA ANS Specifications Inspect the following items occasionally for tightness and if they ve been loosened for main tenance service Do n
107. rom the boot then lift it straight upward and out of the air box 5 With the filter removed clean the intake boot and air box thoroughly and wipe well with a clean dry cloth NOTICE Dirt or debris in the intake boot could result in severe engine damage Always clean all dirt 6 and debris from the intake boot before installing the filter Reinstall the air filter if clean or install a new air filter if soiled Do not attempt to clean the air filter NOTICE Use of a non POLARIS approved air filter may cause engine damage Always use a T POLARIS approved replacement filter See page 92 for the part numbers of POLARIS products Make sure the filter is fully seated on the intake boot and that there is no gap between the filter and boot after installation Tighten the worm gear clamp to 24 in Ibs 2 7 Nm Reinstall the air box cover Make sure both hinges are fully inserted Secure the cover clips 74 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 service on the spark arrester while the system is hot Exhaust system temperatures can reach 1000 F Allow components to cool sufficiently before proceeding Remove any combustible materials from the area Wear eye protection and gloves Do not stand behind or in front of the vehicle while purging Never run the engine in an enclosed are
108. roved accessories and familiarize yourself with their function and effect on the vehicle SAFETY Operator Safety AWARNING Failure to operate the RANGER properly can result in a collision loss of control accident or rollover which may result in serious injury or death Heed all safety warnings outlined in this section of the owner s manual See the OPERATION section of the owner s manual for proper operating procedures Age Restrictions This vehicle is an ADULT VEHICLE ONLY NEVER operate this vehicle if you are under age 16 and NEVER operate without a valid driver s license Never operate with a passenger under the age of 12 All riders must be able to sit with backs against the seat both feet flat on the floor and both hands on the steering wheel if driving or on a passenger hand hold Operating Without Instruction Operating this vehicle without proper instruction increases the risk of an accident The operator must understand how to operate the vehicle properly in different situations and on different types of terrain All operators must read and understand the Owner s Manual and all warning and instruction labels before operating the vehicle All operators should review the safety DVD provided with this vehicle and take a ROHVA training course www rohva org Using Alcohol or Drugs Operating the vehicle after consuming alcohol or drugs could adversely affect operator judgment reaction time balance and percep
109. rs components whose failure increases the vehicle s regulated emissions and it covers components of systems whose only purpose is to control emissions Repairing or replacing other components not covered by this warranty is the responsibility of the vehicle owner This emissions limited warranty does not cover components whose failure does not increase the vehicle s regulated emissions For exhaust emissions emission related components include any engine parts related to the following systems Air induction system lgnition 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 99 WARRANTY U S A EPA Emissions Limited Warranty The following parts are considered emission related components for evaporative emissions Fuel Tank Vacuum Control Diaphragms Fuel Cap Control Cables Fuel Line Control Linkages Fuel Line Fittings Purge Valves Clamps Vapor Hoses Pressure Relief Valves Control Valves Control Solenoids Electronic Controls Liquid Vapor Separator Carbon Canister Canister Mounting Brackets Carburetor Purge Port Connector ee o o o o o e e o o o o o o o 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 rep
110. ry before installing it See page 85 2 To install the 30 AH battery remove the existing battery See page 83 3 Remove the plastic spacer at the bottom of the battery compartment Save the spacer for future use 4 Install the new battery See page 84 29 FEATURES AND CONTROLS Instrument Cluster High water pressure may damage components Wash the vehicle by hand or with a garden hose using 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 32 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 m EPS Warning This indicator illuminates briefly when the key is turned to the ON Z 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 po
111. s 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 Fahrenheit Celsius Time 12 Hour Clock 24 Hour Clock 1 Turn the key to the OFF position 2 Press and hold the MODE button while turning the key to the ON position 3 When the display flashes the distance setting tap the MODE button to advance to the desired setting 4 Press and hold the MODE button to save the setting and advance to the next display option 5 Repeat the procedure to change remaining display settings Clock Mode Tip The clock must be reset any time the battery has been disconnected or discharged 1 A the key to the ON position Use the MODE button to toggle to the odometer dis play 2 Press and hold the MODE button until the hour segment flashes Release the button 3 With the segment flashing tap the MODE button to advance to the desired setting 4 Press and hold the MODE button until the next segment flashes Release the button 5 Repeat steps 3 4 twice to set the 10 minute and 1 minute segments After completing the 1 minute segment step 4 will save the new settings and exit the clock mode 6 Turn the key to the OFF position
112. s cor rre rer ed 4 Safety Winch Maintenance 57 Seat Belt Inspection 00 27 Seat BES rnae eee eGel eek av cre 27 Seat Remoyal eere rr tmr 26 Severe Use Definition 59 Shifler e eesi otera ee kb ex moe Dee eae 24 Shifting Gears ess er Rr Rer Re qe 24 Shock Loading the Winch 56 Shock Spring Adjustment lusus 77 Signal Words Lc cuca eee Rep RE hae 4 Spark Arrester Warning 75 Spark Arrestor Cleaning 75 Spark Plug Gap isses essen 68 Spark Plug Inspection 4 68 Spark Plug Recommendations 68 Spark Plug Torque eee temm 68 Spark Plugs sese echercree RP RR cs RR 68 Spark Plugs Fouled 00 68 Specifications vele Rev ERE WES 90 91 Specifications Gearcase 04 66 Speed TOWNE s isch ry ER CR eR hne ees 44 Speedometer urere hor Tee t rene 30 Starting the Engine 00005 37 Steering Wheel Inspection TI Steering Wheel Adjustment 23 Stopping the Engine 4 37 DIOTAB ores he ee WA Go aR ehe ee ore 86 88 Storage ATO cv once sick e ROO ROT ee ec 88 Storage Compartments isle esse 29 Storage Tips eios pee PEU Ima M PRU S 87 Storage Battery sasni eeii 84 Storage COVeIS cce serre ree e memi 88 Storage Removal from 4 89 Switches AWD
113. sition High Beam This lamp illuminates when the headlamp switch is set to high beam Helmet Seat Belt This lamp is a reminder to the operator to ensure all riders are wearing helmets and seat belts before operating The driver s seat belt is equipped with a seat belt interlock Vehicle speed will be limited to 15 MPH 24 km h if the seat belt is not secured Check Engine This indicator appears if an EFI related fault occurs Do not operate the vehicle if this warning appears Serious engine damage could result See your dealer 30 FEATURES AND CONTROLS Instrument Cluster Rider Information Center The rider information center is located in the instrument cluster All segments will light up for one second at start up If the instrument WE ee RE F cluster fails to illuminate a battery Trip 1 PM over voltage may have occurred WW INA MAMA NAM MA and the instrument cluster may have VN shut off to protect the electronic speedometer If this occurs take the vehicle to your POLARIS dealer for VN ANTAN VANTAN EN proper diagnosis The information center is set to display standard units of measurement and a 12 hour clock at the factory To change to metric and or a 24 hour clock see page 32 1 Gear Indicator This indicator displays gear shifter position H High Gear L Low Gear N Neutral R Reverse Gear P Park Tip Gear Signal Error or shifter between gears
114. t if equipped Daily Inspect daily clean often Headlamp tail lamp Daily Check operation apply dielectric grease to electrical connections if replacing lamps E Air filter Weekly Inspect replace as needed Brake pad wear 10H Monthly Inspect periodically Battery 20H Monthly Check terminals clean test Fuel System 20H Monthly Inspect cycle key to pressurize fuel pump check lines and fittings for leaks and abrasion x Engine breather 25H 1M Inspect replace as needed gt Front Gearcase oil if equipped 25H 1M Perform a break in oil level check gt Middle Gearcase oil if equipped 25H 1M Perform a break in oil level check gt Rear gearcase oil if equipped 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 1M Ferom a break in oil change at one mon gt General lubrication 50 H 3M Lubricate all fittings pivots cables etc Shift Linkage 50 H 6M Inspect lubricate adjust D Steering 50 H 6M Lubricate gt Front Suspension 50 H 6M Lubricate gt Rear Suspension 50 H 6M Lubricate D Throttle cable Release switch 50 H 6M 500 800 Inspect adjust lubricate replace if E necessary E Throttle body air intake ducts 50 H 6M 500 800 Inspect duct for proper sealing air leaks ange Drive belt 50 H 6M 500 800 Inspect adjust replace as needed gt Perform these procedures more often for vehicles s
115. t for loose parts prior to transport 5 6 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 89 SPECIFICATIONS RANGER ETX RANGER 570 570 EPS RANGER CREW 570 570 EPS Maximum Weight Capacity 1000 Ibs 454 kg 1250 lbs 567 kg includes weight of operator passenger cargo accessories Dry Weight 1045 Ibs 474 kg ETX 1323 lbs 600 kg 570 1075 lbs 488 kg 570 1352 lbs 613 kg 570 EPS 1100 Ibs 499 kg 570 EPS Test GVW Rollover Protection 2750 Ibs 1247 kg per OSHA 29 2650 Ibs 1202 kg per OSHA 29 System ROPS CFR 1928 53 CFR 1928 53 Fuel Capacity 8 8 gal 33 3 1 8 8 gal 33 3 I Engine Oil Capacity 2 qts 1 9 1 570 2 qts 1 9 1 1 75 qts 1 6 1 ETX Coolant Capacity 120 oz 3 51 170 oz 51 Overall Length 110 in 279 4 cm 142 in 360 7 cm Overall Width 58 in 147 3 cm 60 in 152 4 cm Overall Height 73 in 185 cm 73 in 185 cm Wheelbase 73 in 185 cm 105 in 266 7 cm Cargo Box Dimensions Inside 32x42x11 5 in 81x107x29 cm 32x42x11 5 in 81x107x 9 cm Ground Clearance 10 in 25 4 cm 10 in 25 4 cm Min Turning Radius 150 in 381 cm 237 in 602 cm Towing Capacity 1500 Ibs 680 4 kg 1500 Ibs 680 4 kg Hitch Ton
116. tery Fluid Conventional Battery Lower Upper A poorly maintained battery will deteriorate rapidly Check Mark x the battery fluid level often Maintain the fluid level between the upper and lower level marks Add only distilled water Tap water contains minerals that are harmful to a battery 82 MAINTENANCE Battery Battery Removal AWARNING 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 Remove the seat rear seat on CREW 570 to access the battery compartment On conventional batteries remove the battery vent tube Disconnect the black battery cable first Disconnect the red battery cable last Remove the battery hold down strap Lift the battery out of the vehicle Be careful not to tip a conventional battery sideways which could spill electrolyte NOTICE If electrolyte spills immediately wash it off with a solution of one tablespoon baking soda and one cup water to prevent damage to the vehicle 83 MAINTENANCE Battery Battery Installation Using a new battery that has not been fully charged can damage the battery and result in a shorter life It can also hinder vehicle performance Follow the battery charging instructions on page 85 before installing the battery
117. tion Never drink alcohol or use drugs or medications before or while operating this vehicle Seat Belts Riding in this vehicle without wearing the seat belt increases the risk of serious injury in the event of rollover loss of control other accident or sudden stop Seat belts may reduce the severity of injury in these circumstances All riders must wear seat belts at all times Protective Apparel Riding in this vehicle without wearing an approved helmet and protective eyewear increases the risk of a serious injuries in the event of an accident Operator and all passengers must always wear an approved helmet that fits properly and eye protection goggles or face shield 16 SAFETY Operator Safety Cab Nets Riding in this vehicle without using the cab nets or doors if equipped increases the risk of serious injury or death in the event of an accident or rollover Always use the cab nets or doors while riding in this vehicle Always keep hands and feet inside the vehicle at all times Failure to Inspect Before Operating Failure to inspect and verify that the vehicle is in safe operating condition before operating increases the risk of an accident Always perform the pre ride inspection before each use of your RANGER to make sure it s in safe operating condition See page 36 Always follow all inspection and maintenance procedures and schedules described in this owner s manual See page 59 Operating With a Loa
118. 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 or incorrect throttle body adjustments 68 MAINTENANCE Cooling System The engine coolant level is controlled or maintained by the recovery system The recovery system components are the overflow bottle radiator filler neck radiator pressure cap and connecting hose As coolant operating temperature increases the expanding heated excess coolant is forced out of the radiator past the pressure cap and into the overflow bottle As engine coolant temperature decreases the contracting cooled coolant is drawn back up from the tank past the pressure cap and into the radiator Some coolant level drop on new vehicles is normal as the system is purging itself of trapped air Observe coolant levels and maintain as recommended by adding coolant to the overflow bottle Adding or Changing Coolant POLARIS recommends the use of POLARIS Antifreeze 50 50 Premix This antifreeze is already premixed and ready to use Do not dilute with water See page 92 for the part numbers of POLARIS products To ensure that the coolant maintains its ability to protect the engine
119. to the trailer hitch bracket only Do not attach a trailer to any other loca tion or you may lose control of the vehicle 7 Never tow a trailer on a grade steeper than 15 Model Total Towed Total Towed Total Hitch Maximum Load Weight Load Weight Vertical Towin Level Ground 15 grade Weight Spee RANGER ETX 1500 Ibs 680 4 kg 850 Ibs 386 kg 150 Ibs 68 1 kg 10 MPH 16 km h RANGER 570 570 EPS 1500 Ibs 680 4 kg 850 Ibs 386 kg 150 Ibs 68 1 kg 10 MPH 16 km h RANGER CREW 570 570 EPS 1500 Ibs 680 4 kg 850 Ibs 886 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 Dumping the Cargo Box 1 4 5 Select a level site to dump the cargo box Do not attempt to dump or unload the vehicle while parked on an incline Apply the brakes Place the transmission in PARK Dismount the vehicle Ensure that the cargo is positioned evenly or toward the front of the cargo box Release the tailgate latches WARNING If the weight distribution on the box is located toward the rear of the box when the release lever is pulled forward the box may dump unexpectedly and cause serious injury to the operator or bystanders Never operate the dump lever without ensuring that the load is positioned evenly or at the front of the box 6 T 8 Stand clear and pull up on the cargo box rel
120. turn the vehicle ignition power OFF when it and the winch are not being used Always be sure that at least five 5 full turns of winch cable are wrapped around the winch drum at all times The friction provided by this wrapped cable allows the drum to pull on the winch cable and move the load Always apply your vehicle s park brake and or park mechanism to hold the vehicle in place during winching Use wheel chocks if needed Always align the vehicle and winch with the load directly in front of the vehicle as much as possible Avoid winching with the winch cable at an angle to the winching vehicle s centerline whenever possible If winching at an angle is unavoidable follow these precautions A Lookat the winch drum occasionally Never let the winch cable stack or accumulate at one end of the winch drum Too much winch cable at one end of the winch drum can damage the winch and the winch cable B If stacking occurs stop winching Follow step 15 on page 54 to feed and rewind the cable evenly before continuing the winch operation 49 WINCH GUIDE Winch Safety Precautions 13 14 15 16 17 18 19 20 21 22 23 24 25 50 Never winch up or down at sharp angles This can destabilize the winching vehicle and possibly cause it to move without warning Never attempt to winch loads that weigh more than the winch s rated capacity The winch motor may become hot during winch use If you winch for more
121. ubjected to severe use E Emission Related Service D Have an authorized POLARIS dealer perform these services 60 Periodic Maintenance Chart MAINTENANCE Item Maintenance Interval Remarks whichever comes first Hours Calendar Miles Km Cooling system if applicable 50 H 6M Inspect coolant strength seasonally pressure test system yearly gt Oil lines fasteners 50 H 6M Inspect for leaks and loose fittings gt Engine oil and filter change 100 H 6M 1000 1600 Change oil and filter perform a break in oil change at one month gt Front Gearcase oil if equipped 100 H 6M Inspect level change yearly gt Middle Gearcase oil if equipped 100 H 6M Inspect level change yearly gt Rear gearcase oil if equipped 100 H 6M Inspect level change yearly gt Transmission oil 100 H 12M 1000 1600 Change fluid D Fuel system 100 H 12M 1000 1600 Cycle key to pressurize fuel pump E check for leaks at fill cap fuel lines rail and fuel pump replace lines every two years gt Radiator if applicable 100 H 12M Inspect clean external surfaces gt Cooling Hoses 100 H 12M Inspect for leaks gt Engine mounts 100 H 12M Inspect Exhaust muffler pipe 100 H 12M Inspect gt Spark plug 100 H 12M 1000 1600 Inspect replace as needed E D Ignition timing 100 H 12M Inspect gt Wiring 100 H 12M Inspect for
122. und the winch drum at all times The friction provided by this wrapped cable allows the drum to pull on the winch cable and move the load 52 WINCH GUIDE Winch Operation 8 10 11 12 Read and adhere to the following information for winch damping to ensure safe winch use A In order to absorb energy that could be released by a winch cable failure always place a damper on the winch cable A damper can be a heavy jacket tarp or other soft dense object A damper can absorb much of the energy released if a winch cable breaks when winching Even a tree limb can help as a damper if no other items are available to you B Lay the damper on top of the mid point of the winch cable length that is spooled out C On a long pull it may be necessary to stop winching so that the damper can be repositioned to the new mid point of the winch cable Always release the tension on the winch cable before repositioning the damper D Avoid being directly in line with the winch cable whenever possible Also never permit others to stand near or in line with the winch cable during winch operation Never hook the winch cable back onto itself This will damage the winch cable and may result in winch cable failure Never use straps chains or other rigging items that are damaged or worn The ONLY time a winch equipped vehicle should be moving when using the winch is when that vehicle itself is stuck The winch equipped vehicle should NEV
123. ur 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 Qux Uu od po p Move the vehicle to dry land or at the very least to water below the footrests Dry any water present in the air box Filter replacement is required if water is present Remove the spark plugs Turn the engine over several times using the electric start Dry the spark plugs and reinstall or replace with new plugs Attempt to start the engine If necessary repeat the drying procedure Take the vehicle to your dealer for service as soon as possible whether you succeed in starting it or not If water has been ingested into the PVT follow the procedure on page 73 for drying 73 MAINTENANCE Filter Systems Air Filter Always change the air filter at the intervals outlined in the Periodic Maintenance Chart beginning on page 59 1 Lift the cargo box 2 Clean all dirt and debris from the air box area 3 Unlatch the two 2 cover clips and carefully remove the air box cover Inspect the seal between the cover and air box to ensure the seal is not torn and has been maintaining a proper seal 4 Inspect the air filter and air box for dirt View of Under BOX Ans C over Clips debris oil or water If the filter needs to be P replaced remove the worm gear clamp from the filter neck with a flat blade screwdriver or 6mm socket Slide the filter rearward to remove it f
124. ustries Inc warrants that at the time it is first purchased this emissions certified vehicle is designed built and equipped so it conforms with applicable U S Environmental Protection Agency emission regulations POLARIS warrants that the vehicle is free from defects in materials and workmanship that would cause it to fail to meet these regulations The warranty period for off road vehicles 100cc or greater emissions certified vehicles starts on the date of purchase by original retail purchaser and continues for a period of 500 hours of engine operation 5000 kilometers 3100 miles of vehicle travel or 30 calendar months from the date of purchase whichever comes first The warranty period for ATVs less than 100cc emissions certified vehicles starts on the date of purchase by original retail purchaser and continues for a period of 250 hours of engine operation 2500 kilometers 1550 miles of vehicle travel or 30 calendar months from the date of purchase whichever comes first This EPA emissions warranty period is extended for at least as long as the standard factory warranty that Polaris provides on the vehicle as a whole The EPA emissions warranty period does not further extend if you purchase additional warranty coverage in the form of a service contract or other paid warranty extension but emission related parts may be covered subject to the terms of any such paid service contract or paid warranty extension This emissions limited warranty cove
125. ving Downhill 00000005 40 Driving in Reverse em 41 Driving on a Sidehill 000 41 Driving on Slippery Surfaces 39 Driving Over Obstacles 04 39 Driving Procedures secs ced dp Ru ao 38 Driving Through Water 0005 42 Driving Uphill zo orat repens 40 Driving with a Passenger 38 Driving After Driving in Water 73 Drying the Transmission 00 73 Dumping the Cargo Box 45 E Electronic Power Steering 26 Emissions Limited Warranty 99 100 Engaging AWD 2 e eee eee 46 47 Engine Break In 00 0 eee eee eee 35 Engine Fogging ose cere ee 88 Engine Oil 570 icr reme 62 63 Engine OI ETX creen cae ets rers 64 65 Engine Starting icine aah eas UE RR LR 37 Engine Stopping 0 0 000 e eee aT EPS renume gv paw yes EE UPRDEq ES e ES 26 Equipment Modifications 15 Error Codes Engine 000005 34 Exhaust Cleaning 2er 75 Exhaust Emission Control System 58 Exhaust System Warning seus 75 Extreme Use 30 AH Battery 29 Eye Prot ction 2 oe err REIR PECVET VS 9 F Filter Cleaning Air sleeese esses 74 Filter Systems 1 2 er eec ee 74 Filter Aib oor ree ee einer tirs 74 Fluid B ttety i es ere Re Rr UR 82 Fluid Change Front Gearcase 2 0 0
126. wear routing security apply dielectric grease to connectors sub jected to water mud etc D Clutches 100 H 12M 1000 1600 Inspect clean replace worn parts D Front wheel bearings 100 H 12M Inspect replace as needed D Brake fluid 200 H 24M Change every two years Spark arrester 300 H 36M Clean out gt Coolant 60M Replace coolant Valve clearance 500 H 5000 8000 Inspect adjust as needed Idle speed Adjust as needed 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 Lubrication Recommendations Check and lubricate all components at the intervals outlined in the Periodic Maintenance Chart beginning on page 59 or more often under severe use such as wet or dusty conditions Items not listed in the chart should be lubricated at the general lubrication interval Item Lube Method Engine Oil PS 4 5W 50 4 Cycle Oil See page 62 570 or page 64 ETX Brake Fluid DOT 4 Brake Fluid See page 76 Main Gearcase Oil AGL Gearcase Lubricant amp Transmission See page 66 Transmission Fluid Front Gearcase Oil Demand Drive Fluid See page 67 Front Prop Shaft Yoke U Joint Grease Locate fittings and grease 3 pumps maximum 61 MAINTENANCE Engine Oil 570 Always check and change the oil at the intervals outlined in the Periodic Maintenan
127. xen E Cue 93 Belt Lileto oes tese e AA as ee tiactadle ia us 44 Belt Replacement 34 rr EE e n ees 71 72 Belt Wedt orb b rg eS Ee 93 Brake Fluid 4 eie Rex hens 76 Brake Inspection er eee 76 Brake Lights inel ye eee Ease 81 Brake Pedal euer i aud maths 25 Brakes sede eoa suae Sad Brava aus Tee EUR 76 Braki g 2 ee EI ee EE 37 Break In Period 4 cromo 35 C Cab Frame ROPS 0000 e eee 29 Cab ING tS erin race ree roe ee UAR FRED 28 rc CETT 43 Cargo Box Dumping 45 Chart Periodic Maintenance 59 61 Check Engine Indicator 34 Chrome Wheel Care 004 87 Cleaning and Storage 86 88 Cleaning the Air Filter 0 74 Cleaning the Exhaust System 75 Cleaning the Spark Arrestor 75 Sirene Pr EC PR 9 Console ise e e ERR s 22 24 Coolant Level Overflow Bottle 70 Coolant Adding or Changing 69 Cooling Fan vice sen gard DR RES Re 69 Cooling System essess e nri ier is 69 70 Corrosion Removal Chrome 87 Crankcase Emission Control System 58 102 D Differential Locking Unlocking 48 Differential Lock Switch lusus 23 Disengaging AWD esses 46 47 Display Units Standard Metric 32 Drive Belt Wear eo cere dur Re ERREUR 93 Drivetrain Break In 00000 35 Dri

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