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Polaris 4X4 User's Manual

Contents

1. Engine Oil Polaris Premium 4 Add to proper level on dipstick Synthetic OW40 Brake Fluid DOT 3 or DOT 4 Maintain level between fill lines See page 82 Main Gearcase Oil Premium AGL Syn See page 64 Transmission thetic Gearcase Lube Front Gearcase Oil Premium Demand See page 66 Drive Hub Fluid Middle Gearcase Oil Premium ATV Angle See page 67 6X6 only Drive Fluid Rear Gearcase Oil Premium ATV Angle See page 68 Drive Fluid 1 Prop Shaft U joints Locate fittings and grease Front Prop Shaft Yoke Grease Locate fittings and grease 3 pumps maximum 2 Ball Joint gt xGrease Locate fitting back side of struts grease with grease gun 3 Swing Arm Grease Locate fittings on swing arm and Bushings grease with grease gun 58 MAINTENANCE AND LUBRICATION Lubrication Recommendations 59 MAINTENANCE AND LUBRICATION Engine Oil Always check and change the engine oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 53 Always change the oil filter whenever changing oil Premium 4 Synthetic Oil Polaris Premium 4 Season Synthetic engine oil has been specially formulated for use in Polaris 4 cycle engines It s a fully synthetic high performance multi viscosity oil designed to provide the ultimate in lubrication performance and protection See page 99 for the part numbers of Polaris products Premium 4 possesses unsurpassed film strength over the widest possible tem
2. Exhaust muffler 100 H 12M Inspect pipe His Spark plug 100 H Er EUN Inspect replace as needed LIE 100 H 12 NUM Inspect for wear routing security apply dielectric grease to connectors subjected to water mud etc drive 100 H Inspect clean replace worn Seen parts Front wheel 100 H Inspect replace as needed bearings m Brake fluid 200 H 24M Change every two years mw Genet Weser GS Toe adjustment Inspect periodically adjust when parts are replaced Auxiliary brake i daily adjust as equipped needed Headlight aim 7 Adjust as needed p Perform these procedures more often for vehicles subjected to severe use E Emission Control System Service 4 Cycle California m Have an authorized Polaris dealer perform these services 57 MAINTENANCE AND LUBRICATION Lubrication Recommendations Check and lubricate all components at the intervals outlined in the Periodic Maintenance Chart beginning on page 53 Items not listed in the chart should be lubricated at the General Lubrication interval Lubrication Chart Key p gt More often under severe use such as wet or dusty conditions Polaris Premium all Season Grease or grease conforming to NLGI No 2 such as Conoco Superlube M or Mobilegrease Special e Use Polaris Premium U Joint Lube every 500 miles before long periods of storage or after pressure washing or submerging wm o
3. 38 Driving Over Obstacles 42 Driving Procedures 37 Driving Safely 37 49 Driving Through Water 41 Driving Uphill 39 Dumping the Cargo Box 47 118 E Electromagnetic Interference 52 Emission Control Systems 52 Emissions Warranty 110 Engine O1 ire 60 63 Equipment Modifications 10 Exhaust Emission Control System 52 F Filter Systems 78 Front Gearcase 66 Fuel ees ie dee hes 27 Fuel Filtet rece Re 78 Fuel Gauge 27 Fuel Safety 22 G Gear 1 30 Gearcase Specification Chart 63 Gearcases 63 69 H Hauling 45 46 Headlight Beam Adjustment 89 High 75 1 Idle RPM 81 Ignition Switch 31 Indicator Lamp Replacement 90 Indicator Lights 26 L Light Switch 31 Lights RI 88 90 Low Range 75 Lubrication Recommendations 58 59 M Main Gearcase 64 65 Maintenance Chart 53 57 Maintenance Log 116 117 Middle Gearcase 67 Noise Emission Control System 52 Filter Change 62 63 Oil Check mk RR 61 Operator S
4. 2006 RANGER XP 4X4 700 EFI RANGER 6X6 700 EFI Owner s Manual for Maintenance and Safety Read this manual carefully It contains important safety information This is an adult vehicle only Operation is prohibited for those under 16 years of AWARNING Improper vehicle use can result in SEVERE INJURY or DEATH NEVER Operate on public roads A collision can occur with another vehicle Carry more than two passengers or passengers under age five e Use ALCOHOL or DRUGS before or while operating this vehicle Operate at speeds too fast for your skills or the conditions Operate this vehicle on HILLS steeper than 15 degrees 15 To prevent flipover in hilly terrain use throttle and brakes gradually ALWAYS e Avoid paved surfaces which may adversely affect handling and control Use proper RIDING TECHNIQUES to avoid vehicle overturns on hills and rough terrain and in turns Wear eye protection REVERSE operation be dangerous even at low speeds Steering becomes difficult To prevent flipover avoid sharp turns The park brake will supply increased braking but should be used as a parking brake only READ OWNER S MANUAL FOLLOW ALL INSTRUCTIONS AND WARNINGS THIS GENERAL PURPOSE OFF ROAD UTILITY VEHICLE DOES NOT MEET FEDERAL MOTOR VEHICLE SAFETY STANDARDS FOR ON ROAD VEHICLES LU e For your nearest Polaris dealer C PGLQHHBAIS call 1 800 POLARIS The Way Out aan or visit
5. MAINTENANCE AND LUBRICATION Gearcases Middle Gearcase RANGER 6X6 Always check and change the middle gearcase oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 53 Maintain the oil level even with the bottom thread of the fill plug hole Refer to the Gearcase Specifications Chart on page 63 for recommended lubricants capacities and torque specifications See page 99 for the part numbers of Polaris products The middle gearcase fill plug 1 is located on the side of the gearcase Oil Check 1 Position the vehicle on a level surface 2 Remove the fill plug Check the oil level 3 Add the recommended oil as a needed 4 Reinstall the fill plug Torque to E specification Oil Change 1 Remove the fill plug 2 Remove the drain plug 2 from the bottom of the gearcase Drain the oil into a drain pan Discard used oil properly Clean and reinstall the drain plug Torque to specification Add the recommended fluid Reinstall the fill plug Torque to specification Check for leaks OY Ux RU 67 MAINTENANCE AND LUBRICATION Gearcases Rear Gearcase Always check and change the rear gearcase oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 53 Refer to the Gearcase Specifications Chart on page 63 for recommended lubricants capacities and torque specifications See page 99 for the p
6. miliar terrain Be alert to changing terrain Never operate on excessively rough slippery or loose terrain SAFETY Operator Safety Always follow proper procedures for turning as described in this manual Practice turning at slow speeds before attempting to turn at faster speeds Never turn at excessive speeds Always have this vehicle checked by an authorized Polaris dealer if it has been involved in an accident Never operate this vehicle on hills too steep for the vehicle or for your abilities Practice on smaller hills before attempting larger hills Always follow proper procedures for climbing hills as described in this manual Check the terrain carefully before attempting to climb a hill Never climb hills with excessively slippery or loose surfaces Never open the throttle suddenly or make sudden gear changes Never go over the top of a hill at high speed Always follow the proper procedures outlined in this manual for traveling downhill and for braking on hills Check the terrain care fully 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 pos sible Always check for obstacles before operating in a new area Never attempt to operate over large obstacles such as rocks or fallen trees Always follow the proper procedures outlined in this manual when operating over obstacles Always
7. 1 2 3 38 Slow down when entering slippery areas Maintain a high level of alertness reading the trail and avoiding quick sharp turns which can cause skids Correct a skid by turning the steering wheel in the direction of the skid Drive with AWD engaged if equipped to assist in controlling the vehicle CAUTION 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 WARNING Failure to exercise care when operating on slippery surfaces can result in loss of tire traction and cause loss of control accident and serious injury or death Never apply the brakes during a skid Do not operate on excessively slippery surfaces Always reduce speed and use additional caution when operating on slippery surfaces OPERATION Driving Safely Driving Uphill Whenever traveling uphill follow these precautions 1 Always travel straight uphill 2 Avoid steep hills 15 maximum 3 Keep both feet on the floor 4 Proceed at a steady rate of speed and throttle opening 4 WARNING Climbing hills improperly can cause loss of control or vehicle overturn Always check the terrain carefully before climbing a hill Braking and handling are greatly affected when operating in hilly terrain Improper procedure could cause loss of control or overturn and result in serious injury or death Avoid climbing steep hills 15
8. Remove the wheel Wheel Installation 1 2 3 Place the amp transmission in gear Engage the park brake Place the wheel in the correct position on the wheel hub Be sure the valve stem is toward the outside and rotation arrows on the tire point toward forward rotation Attach the wheel nuts and washers and finger tighten Carefully lower the vehicle to the ground Torque the wheel nuts to specification See page 86 87 MAINTENANCE AND LUBRICATION Lights 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 4 WARNING Poor lighting while driving can result in severe injury or death Headlight and taillight lenses become dirty during normal operation Wash the headlights frequently to maintain lighting quality Hot components can cause serious burns to skin Do not service the headlamps until they ve cooled sufficiently dioe Mg Lamp Replacement Open the hood s Unplug the headlamp from the wiring harness 1 Be sure to pull on the connector not on the wiring 3 Turn the lamp counterclockwise to remove it 4 Install the new lamp NOTE Make sure the tab on the lamp locates properly in the housing 5 Reinstall the harness assembly into the headlight assembly 88 MAINTENANCE AND LUBRICATION Lights Beam Adjustment Place the vehicle on a level surface with th
9. This warranty period begins on the date which the LSI engine is delivered to the origi nal retail purchaser and ends two years after that date During this two year period PO LARIS warrants to the original retail purchaser and each subsequent purchaser that the LSI engine is free from defect in material and workmanship that can cause the failure of a warranted emission related part What is Covered Under This Warranty Repair and or replacement of any warranted emission related part will be performed at no charge provided the work is performed at an authorized dealer There will also be no charge for any diagnostic labor performed at an authorized dealer which leads to the determination that a warranted emission related part is defective Any warranted part which is not scheduled for replacement as required maintenance or which is scheduled only for regular inspection to the effect of repair or replace as necessary shall be warranted for the warranty period Any warranted part which is scheduled for replacement as required maintenance shall be warranted for the period of time up to the first scheduled replacement of that part This warranty shall apply only towards the repair replacement and or adjustment of the component parts listed below 112 WARRANTY California Emission Control Warranty Statement Emission Related Parts Covered Under This Warranty 1 Fuel Metering System i Carburetor and internal parts and or pressure regula
10. 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 Battery Storage When the vehicle is placed in storage for three months or more the battery should be removed stored out of the sun in a cool dry place and tested monthly Before reusing take the battery to your dealer for testing and recharging 94 MAINTENANCE AND LUBRICATION Cleaning and Storage See page 99 for the part numbers of Polaris products Cleaning the RANGER Keeping your RANGER clean will not only improve its appearance but it can also extend the life of various components With a few precautions your RANGER can be cleaned much like an automobile Washing the RANGER The best and safest way to clean your RANGER is with a garden hose and a pail of mild soap and water Use a professional type washing mitten cleaning the upper body first and the lower parts last Rinse with water frequently and dry with a chamois to prevent water spots NOTE If warning and safety labels are damaged contact your a Polaris dealer for free replacement CAUTION High water pressure may damage vehicle components Polaris recommends washing the vehicle by hand or with a garden hose using mild soap Certain products including insect repellants and chemicals will damage plastic surfaces Do not allow these types of products to come into contact with the vehicle If a high pressure w
11. 4X4 Box Load 1000 Ibs Maximum 6X6 Box Load 1200 Ibs IMPROPER TIRE PRESSURE OR OVERLOADING can cause loss of control resulting in SEVERE INJURY OR DEATH TIRE PRESSURE PSI RANGER 2x4 and 4 4 FRONT 10 REAR 10 RANGER 6x6 FRONT 10 CENTER 10 REAR 10 MAXIMUM WEIGHT CAPACITY Gross Vehicle Weight INCLUDING MACHINE DRIVER AND CARGO RANGER 2X4 and 4X4 is 2750 LBS RANGER 6X6 is 2900 LBS Reduce speed and allow greater distance for braking when carrying cargo Overloading or carrying tall off center or unsecured loads will increase your risk of losing control Loads should be centered and carried as low as possible in box For stability on rough or hilly terrain reduce speed and cargo Be careful if load extends over the side of the box Read Owner s Manual for more detailed loading information 19 SAFETY Safety Decals and Locations MANUFACTURED BY POLARIS IND INC DATE VIN THIS VEHICLE IS A GENERAL PURPOSE OFF ROAD UTILITY VEHICLE AND IS NOT INTENDED FOR USE ON PUBLIC ROADS CE V HICULE USAGE G N RAL V HICULE UTILITAIRE POUR SERVICE HORS ROUTE QUI N EST PAS DESTIN TRE UTILIS SUR LES CHEMINS PUBLICS 7078472 Location 5 under hood ATTENTION e Operation of this vehicle without the air filter element will severely damage the engine Clean pre filter element often more frequent cleaning required in dusty conditions Do not operate vehicle witho
12. 75 in 190 5 cm Ground Clearance 11 5 in 29 cm Engine 4 valve 4 stroke twin cylinder with counter balance 100 SPECIFICATIONS RANGER 4X4 XP Lubrication System Pressurized Wet Sump Engine Oil 0W 40 lockable differential 4 wheel hydraulic disc NOTE See your Polaris dealer for clutching specifications 101 SPECIFICATIONS RANGER 6X6 EFI 147 x 122 x 25 4 cm with counter balance ECU Lubrication System Pressurized Wet Sump Engine Oil 0W 40 102 SPECIFICATIONS RANGER 6X6 EFI Front Suspension MacPherson strut w 6 25 in 15 9 cm of travel Center Suspension Independent w 5 25 in 13 3 cm of travel Rear Suspension Swing arm w dual shocks w 6 25 in 15 9 cm of travel Driving System Shift Type Single Lever console Gear Reduction Low 8 71 1 Gear Reduction High 3 14 1 Tire Pressure Center Rear 8 12 psi Brakes Front Rear Foot Activated 4 wheel hydraulic disc Tire Size Center Rear 25x11 12 12 NOTE See your Polaris dealer for clutching specifications Drive Ratio Final 3 70 1 103 TROUBLESHOOTING Contact your Polaris dealer for service if you re unable to identify solutions using the following charts Engine Doesn t Turn Over Possible Cause Solution Low battery voltage Recharge battery to 12 5 VDC Loose battery connections Check all connections and tighten Loose solenoid connections Check all connections and tighten Loose electronic cont
13. CONTROLS Console Cup Holder Indicator Lights Shift Lever Light Switch AWD Differential Switch if equipped Hour Meter Glove Box with Lid 12V Accessory Plug 9 Storage Tray 10 Ignition Switch 11 Storage Box Qo cM QN UY Pe QS 29 FEATURES AND CONTROLS Gear Selector H High Gear H L Low Gear L N Neutral N R Reverse NOTE Low gear is the primary driving range for the RANGER XP High gear is intended for use on hard packed surfaces with light loads To change gears stop the vehicle and with the engine idling move the lever to the desired gear Do not attempt to shift gears with engine speed above idle or while the vehicle is moving CAUTION Do not attempt to shift the transmission while the vehicle is moving or damage to the transmission could result Always shift when the vehicle is stationary and the engine is at idle Always place the transmission in gear engage the park brake and turn the engine off whenever the vehicle is left unattended Maintaining shift linkage adjustment is important to assure proper transmission function See your dealer if you experience any shifting problems 30 FEATURES AND CONTROLS Switches Ignition Switch 1 The ignition switch is a three position key operated switch The key can be removed from the switch when it is in the OFF position OFF Engine off All electrical circuits are off except Acc 12V ON RUN Electrical cir
14. and filter Air Filter Air Box Breather Filter Inspect and clean or replace the pre cleaner and air filter Clean the air box and drain the sediment tube Fluid Levels Inspect the following fluid levels and change if necessary front and rear gearcases transmission and brake fluid change every two years or as required if fluid looks dark or contaminated Inspect and Lubricate Inspect all cables and lubricate Follow lubrication guidelines in the Maintenance Section of the service or owner s manual to completely grease and lubricate the entire vehicle with Polaris Premium All Season Grease 96 MAINTENANCE AND LUBRICATION Cleaning and Storage Storage Tips Fog the Engine 1 Treat the fuel system with Polaris Carbon Clean following the instructions on the can Run the engine for several minutes so the Carbon Clean reaches the injectors Turn the engine off 2 Remove the spark plugs and add 2 3 tablespoons of Premium 4 Synthetic 0W40 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 NOTE 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 70 4 Apply dielectric grease to the inside of each spark plug cap and reinstall the caps onto th
15. been ingested into the PVT follow the procedure on page 77 for drying 91 MAINTENANCE AND LUBRICATION Battery Keep the battery terminals and connections free of corrosion If cleaning is necessary remove the corrosion with a stiff wire brush Wash with a solution of one tablespoon baking soda and one cup water Rinse well with tap water and dry off with clean shop towels Coat the terminals with dielectric grease or petroleum jelly Be careful not to allow cleaning solution or tap water into the battery 4 WARNING Battery electrolyte is poisonous It contains sulfuric acid Serious burns can result from contact with skin eyes or clothing Antidote External Flush with water Internal Drink large quantities of water or milk Follow with milk of magnesia beaten egg or vegetable oil Call physician immediately Eyes Flush with water for 15 minutes and get prompt medical attention Batteries produce explosive gases Keep sparks flame cigarettes etc away Ventilate when charging or using in an enclosed space Always shield eyes when working near batteries KEEP OUT OF REACH OF CHILDREN 92 MAINTENANCE AND LUBRICATION Battery Replenishing Battery Fluid Conventional Battery A poorly maintained battery will deteriorate rapidly Check the battery fluid level often The fluid level should be kept between the upper and lower level marks 1 To refill use only distilled water Tap water contains minerals that ar
16. limited warranty is in addition to the Polaris standard limited warranty for this vehicle Polaris warrants that this vehicle is 1 designed built and equipped to conform at the time of initial sale with the requirements of 40 CFR 1051 and 2 free from defects in materials and workmanship that may keep it from meeting these requirements The emissions warranty period for this vehicle begins on the date the vehicle is delivered to the original retail purchaser and ends 30 months 2 5 years after that date or after 5000 km 3100 miles whichever comes first This emission related warranty covers components whose failure would increase an en gine s emissions including electronic controls fuel injection exhaust gas recirculation aftertreatment or any other system utilized in this vehicle to control emissions Replac ing or repairing other components not covered by this emissions warranty or the standard warranty is the responsibility of the owner including the parts labor and other costs associated with recommended maintenance The exclusive remedy for breach of this limited warranty shall be at the exclusive option of Polaris repair or replacement of any defective materials components or products THE REMEDIES SET FORTH IN THIS LIMITED WARRANTY ARE THE ONLY REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF THIS WARRANTY POLARIS SHALL HAVE NO LIABILITY TO ANY PERSON FOR INCIDENTAL CONSEQUENTIAL OR SPECIAL DAMAGES OF ANY DESCRIPTION
17. maximum protection 7172676 Location 2 A WARNING A WARNING ON Passengers can be thrown off CR i This can cause serious injury 7 metum or death Vo mm Never carry passengers in F cargo box Max 2x 4 Box Load 850 lbs Remove flammable material containers from box before filling A WARNING Max 4x 4 Box Load 1000 Ibs Max 6x6 Box Load 1200 Ibs A WARNING IMPROPER TIRE PRESSURE OR OVERLOADING can cause loss of Reduce speed and allow greater distance for braking when carrying control resulting in SEVERE INJURY OR DEATH cargo Overloading or carrying tall off center or unsecured loads TIRE PRESSURE PSI will increase your risk of losing control Loads should be centered RANGER 2x 4and 4x4 FRONT 10 REAR 10 and carried as low as possible in box For stability on rough or hilly RANGER 6x6 FRONT 10 CENTER 10 REAR 10 terrain reduce speed and cargo Be careful if load extends over the MAXIMUM WEIGHT CAPACITY Gross Vehicle Weight side of the box INCLUDING MACHINE DRIVER AND CARGO Read Owner s Manual for more detailed loading information RANGER 2 X 4 and 4 x 4is 2750 LBS RANGER 6 X 6 is 2900 LBS 7173023 Location 3 inside front of box Container Passenger Tire Pressure Warning Decal Text Remove flammable material containers from box before filling Passengers can be thrown off This can cause serious injury or death Never carry passengers in cargo box Maximum 2X4 Box Load 850 Ibs Maximum
18. on page 100 Attach a trailer to the trailer hitch bracket only Do not attacha trailer to any other location or you may lose control of the vehicle Never tow a trailer on a grade steeper than 15 Maximum Towing Capacities Level Ground Total Towed Total Towed Total Hitch Maximum Load Weight Load Weight Vertical level ground 15 grade Weight RANGER 1500 lbs 850 Ibs 150 1 5 10 mph 4x4 XP 681 kg 886 kg 68 1 kg 16 kph RANGER 1750 Ibs 1000 Ibs 150 Ibs 10 mph 6X6 EFI 794 kg 454 kg 68 1 kg 16 kph Belt Life To extend belt life use the lowest gear possible when hauling or towing heavy cargo 48 OPERATION Driving Safely Parking the RANGER 4 WARNING A rolling vehicle can cause property damage and serious injury Always engage the park brake after stopping the engine 1 Stop the vehicle on a level surface 2 Turn the engine off 3 Engage the park brake 4 Remove the ignition switch key to prevent unauthorized use 4 WARNING Gasoline is extremely flammable and can be explosive under certain conditions When parking inside a garage or other structure be sure that the structure is well ventilated and that the vehicle is not close to any source of flame or sparks including any appliance with pilot lights 49 OPERATION Differential Lock 4X4 The 4X4 rear axle is equipped with a lockable differential that allows the operator to choose between an open differentia
19. on the pipe around the clean out plugs while revving the engine several more times If particles are still suspected to be in the muffler elevate the rear of the vehicle one foot higher than the front Engage the park brake Block the wheels Make sure the transmission is in neutral and repeat steps 3 and 4 until no more particles are expelled when the engine is revved Stop the engine Allow the arrestor to cool Reinstall the arrestor plugs and remove the outlet cover or plug 79 MAINTENANCE AND LUBRICATION Throttle System 4 amp WARNING Failure to check or maintain proper operation of the throttle system can result in an accident and lead to serious injury or death if the throttle pedal sticks during operation Never start or operate this vehicle if it has a sticking or improperly operating throttle pedal Immediately contact your dealer for service if throttle problems arise Always check the pedal for free movement and return before starting the engine and occasionally during operation Throttle Freeplay If the throttle pedal 1 has excessive play due to cable stretch or misadjustment it will cause a delay in throttle response especially at low engine speed The throttle may also not open fully If the throttle pedal has no freeplay the throttle may be hard to control and the idle speed may be erratic Check the throttle pedal freeplay at the intervals outlined in the Periodic Maintenance Chart beginning o
20. poisonous carbon monoxide and can cause loss of consciousness or death Never run an engine in an enclosed area Transporting the RANGER Follow these procedures when transporting the vehicle 1 Turn off the engine and remove the key to prevent loss during transporting 2 Place the transmission in gear Engage the park brake 3 Be sure the fuel cap oil cap and seat are installed securely 4 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 98 POLARIS PRODUCTS Part No Description Engine Lubricant 2870791 Fogging Oil 12 oz Aerosol 2871281 Premium 4 Synthetic OW 40 4 Cycle Engine Oil qt 2871844 Premium 4 Synthetic OW 40 4 Cycle Engine Oil gal 2873602 2873603 2871653 2872276 2870465 2671654 2872277 2871322 2871423 2871460 2871515 2871551 2871312 2871329 2872073 2872348 2871323 60 40 Coolant gal 2871534 60 40 Coolant qt 99 SPECIFICATIONS RANGER 4X4 XP Overall Width tires 58 in 147 3 cm Wheelbase 76 in 193 cm Cargo Box 58 x 42 x 10 in L x W x H 147 x 106 7 x 25 4 cm Min Turning Radius 132 in 335 3 cm Max Cargo Box Load 1000 Ibs 454 kg Overall Length 113 in 282 cm Front Suspension MacPherson strut w 8 in 20 3 cm of travel Rear Suspension Independent w 9 0 in 22 9 cm of travel Overall Width box 60 in 152 4 cm Overall Height
21. when the vehicle is not in use WARNING After any overturn or accident have a qualified service dealer inspect the entire vehicle for possible damage including but not limited to brakes throttle and steering systems CAUTION Always keep combustible materials away from the exhaust system Exposure to the hot components could result in a fire 17 SAFETY Safety Decals and Locations Warning decals have been placed on the RANGER for your protection Read and follow the instructions of the decals on the RANGER carefully If any of the decals depicted in this manual differ from the decals on your RANGER always read and follow the instructions of the decals on the RANGER If any decal becomes illegible or comes off contact your Polaris dealer to purchase a replacement Replacement safety decals are provided by Polaris at no charge The part number is printed on the decal AWARNING 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 NO STEP Location 1 18 SAFETY Safety Decals and Locations AWARNING VEHICLE ROLLOVER could cause severe injury or death This cab frame is not designed or intended to provide rollover protection ALWAYS WEAR YOUR SEAT BELT for
22. 0 Battery under hood 11 Storage Box under hood 23 FEATURES AND CONTROLS Component Locations 12 Headlights 13 Radiator if equipped 14 Front Bumper Brush Guard 15 Hood Hold Down Strap 24 FEATURES AND CONTROLS Component Locations 16 Taillights 17 Tailgate 18 Tailgate Latch Release 19 Muffler Spark Arrester 20 CV Boot Rear Caliper 21 Air Box 22 Receiver Hitch 25 FEATURES AND CONTROLS Indicator Lights 1 High Gear 2 Low Gear 3 Neutral Gear 4 Reverse Gear 5 High Temperature 6 Park Brake 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 page 48 Auxiliary Outlet The 12 volt receptacle 7 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 26 FEATURES AND CONTROLS Fuel Cap Fuel Gauge The fuel tank filler cap 8 is located on the right hand side of the vehicle near the passenger seat It has a built in f
23. 81 for throttle pedal adjustment procedures Park Brake Pedal 3 Engage the park brake when parking the vehicle to help prevent the vehicle from rolling To engage the park brake apply the brakes then push the park brake pedal down firmly and fully with your foot Park Brake Release 4 Always apply the service brakes before releasing the park brake To release the park brake pull the park brake release handle Make sure the park brake pedal is functioning properly before each operation 32 OPERATION Vehicle 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 CAUTION 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 Use of any oils other than those recommended by Polaris may cause serious engine damage We recommend the use of Polaris Premium 4 Synthetic Oil for your 4 cycle engine 1 the fuel tank with gasoline Heed the gasoline warnings on page 22 2 Check the oil level on the dipstick See page 61 Add Pola
24. D UTILITY VEHICLE DOES NOT MEET FEDERAL MOTOR VEHICLE SAFETY STANDARDS FOR ON ROAD VEHICLES 7172675 AVERTISSEMENT L usage incorrect du v hicule peut entrainer des BLESSURES GRAVES ou MORTELLES NE JAMAIS conduire ce v hicule sur les voies publiques Une collision avec un autre v hicule pourrait se produire transporter plus de deux passagers ou des passagers g s de moins de cinq ans CONSOMMER D ALCOOL ni prendre des MEDICAMENTS ou DROGUES avant ou pendant la conduite de ce v hicule conduire des vitesses excessives pour ses propres comp tences ou l tat de la route conduire ce v hicule sur des PENTES plus de 15 degr s 15 Pour viter un retournement sur les pentes uliliser les freins et l acc l rateur graduellement TOUJOURS e viter de conduire sur des surfaces pav es car cela pourrait s rieusement affecter la tenue de route et le contr le utiliser les bonnes TECHNIQUES DE CONDUITE sur les pentes en terrain accident et dans les virages afin d viter un retoum ement du v hicule porter une protection oculaire La conduite en MARCHE ARRIERE peut tre dangereuse m me basse vitesse Le braquage est plus difficile Pour viter un retournement ne pas prendre de virages trop serr s Le frein de stationnement de secours augmente la puissance de freinage mais ne doit s utiliser que pour le stationnement ou en cas d urgence LIRE LE MANUEL D UTILISATION SUIVRE TOUTES LES INSTRUCT
25. ION 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 Your key can be duplicated only by mating a Polaris key blank with one of your existing keys so if both keys are lost the ignition switch must be replaced Vehicle Model Number behind left front wheel Frame VIN 1 under hood Engine Serial Number 2 right front side of engine crankcase Key Number 3 SAFETY Operator Safety 4 amp WARNING Failure to follow the warnings contained in this manual can result in severe injury or death A Polaris RANGER is not a toy and can be hazardous to operate This vehicle handles differently than other vehicles such as motorcycles and cars A collision or rollover can occur quickly even during routine maneuvers like turning or driving on hills or over obstacles if you fail to take proper precautions Read and understand your owner s manual and all warnings before operating the vehicle Age Restrictions This vehicle is an ADULT VEHICLE ONLY Operation is prohibited for anyone under 16 years of age No person under the age of 5 may ride as a passenger in this vehicle Know Your Vehicle As the operator of the vehicle you are responsible for your personal safety the safety of others and the protection of our environment Read and understand your owner s manual which includes valuable information about all aspe
26. IONS ET AVERTISSEMENTS SI LE MANUEL D UTILISATION EST MANQUANT CONTACTER UN CONCESSIONNAIRE POLARIS POUR OBTENIR UN NOUVEL EXEMPLAIRE CE V HICULE UTILITAIRE UNIVERSEL POUR SERVICE HORS ROUTE N EST PAS CONFORME AUX R GLEMENTATIONS AM RICAINES POUR LA CONDUITE SUR VOIES PUBLIQUES 7172675 F 21 SAFETY Fuel Safety WARNING 22 Gasoline is highly flammable and is explosive under certain _ conditions Always exercise extreme caution whenever handling gasoline Always stop the engine when refueling Always refuel outdoors or in a well ventilated area Do not smoke or allow open flames or sparks in or near the refueling area or where gasoline is stored Do not over fill 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 Never start the engine or let it run in an enclosed area Gasoline powered engine exhaust fumes are poisonous and can cause loss of consciousness and death in a short time FEATURES AND CONTROLS Some Polaris vehicles are equipped with special features such as the cab frame Not all models come with all features Refer to the specifications section beginning on page 100 Component Locations Bagg D D Hg a Cab Frame if equipped Hip Bar Console Steering Wheel Seat Storage Box under driver s seat Cargo Box Seat Belts Fuel Tank Cap Fuel Gauge 1
27. Ibs 6X6 Drive Fluid 200 ml 19 4 Nm 19 4 Nm Rear Gearcase Premium ATV Angle 18 oz 40 50 ft Ibs 30 45 in Ibs 4X4 Drive Fluid 532 ml 64 68 Nm 3 5 Nm Rear Gearcase Premium ATV Angle 10 oz 14 ft Ibs 14 ft Ibs 6X6 Drive Fluid 300 ml 19 4 Nm 19 4 Nm 63 MAINTENANCE AND LUBRICATION Gearcases Transmission Main Gearcase Always check and change the transmission oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 53 Maintain the oil level even with the bottom of the fill plug hole The fill plug 1 is located at the rear of the vehicle Refer to the Gearcase Specifications Chart on page 63 for recommended lubricants capacities and torque specifications See page 99 for the part numbers of Polaris products Oil Check 1 Position the vehicle on a level surface 2 Remove the fill plug 3 Check the oil level 4 Add the recommended oil as needed 5 Reinstall the fill plug Torque to specification 64 MAINTENANCE AND LUBRICATION Gearcases Transmission Main Gearcase Oil Change The drain plug 2 is located on the bottom of the transmission Access the drain plug through the drain hole in the skid plate 1 2 gt Remove the fill plug Place a drain pan under the drain plug Remove the drain plug Drain the oil Dispose of used oil properly Wipe the magnetic end of the drain plug clean to remove accumulated metalli
28. NCE AND LUBRICATION Seat Belts Inspect all three seat belts for proper operation before each use of the vehicle 1 Push the latch plate into the buckle until it clicks The latch plate must slide smoothly into the buckle A click indicates that it s securely latched 2 Push the red button in the middle of the buckle to make sure it releases freely 3 Check the belt webbing for wear cuts or damage If any irregularities are found have the seat belt system checked and or replaced by an authorized Polaris dealer The RANGER seat belt is adjustable and should be adjusted for both the operator and passengers before driving Although having the belt at 30 is typical for many people it will not accommodate all body 1 sizes and shapes Make sure the seat belt is adjusted to the lowest possible lap position before riding 1 To adjust loosen the bolts 1 2 Reposition both the buckle and retractor Tighten the bolts NOTE The center belt does not self adjust Before riding pull on the strap to secure the belt on the lap of the center passenger 4 WARNING Failure to follow the age recommendations for this vehicle could result in serious injury or death No one under the age of 16 may operate this vehicle No one under the age of 5 may ride as a passenger in this vehicle 85 MAINTENANCE AND LUBRICATION Tires 4 amp WARNING Operating your vehicle with worn tires will increase the possibility of skidding loss of
29. Replace with new fuel Low battery voltage Recharge battery to 12 5 VDC Kinked or plugged fuel vent line Inspect and replace Incorrect fuel Replace with recommended fuel Clogged air filter Inspect and clean or replace Other mechanical failure See your Polaris dealer Possible Lean Fuel Mixture Cause Solution Low or contaminated fuel Add or change fuel clean the fuel system Low octane fuel Replace with recommended fuel Clogged fuel filter Replace filter Possible Rich Fuel Mixture Cause Solution Fuel is very high octane Replace with lower octane fuel 105 TROUBLESHOOTING Engine Stops or Loses Power Possible Cause Solution Kinked or plugged fuel vent line Water present in fuel Fouled or defective spark plugs Worn or defective spark plug wires Incorrect spark plug gap or heat range Loose ignition connections Low battery voltage Clogged air filter Other mechanical failure Overheated engine Clean radiator screen and core if equipped Clean engine exterior See your Polaris dealer 106 WARRANTY LIMITED WARRANTY Polaris Sales Inc 2100 Highway 55 Medina MN 55340 gives a SIX MONTH LIM ITED WARRANTY on all components of the Polaris RANGER against defects in mate rial or workmanship This warranty covers the parts and labor charges for repair or replacement of defective parts which are covered by this warranty This warranty begins on the date of purchase This warranty is transferrable to another consumer duri
30. There may be some instances when water is accidently ingested into the PVT system Use the following instructions to dry it out before operating Loosen the bottom screws that secure the clutch cover Allow the water to drain Tighten the screws Apply the brakes Start the engine Engage the park brake Shift the transmission to neutral Apply varying throttle for 10 15 seconds to expel the moisture and air dry the belt and clutches Do not hold the throttle wide open for more than 10 seconds 8 Allow the engine RPM to settle to idle speed Apply the service brakes Release the park brake and shift the transmission to the lowest available range 9 Test for belt slippage If the belt slips repeat the process 10 Take the vehicle to your dealer for service as soon as possible STON Ur Roc 77 MAINTENANCE AND LUBRICATION Filter Systems Air Filter Always change the air filter at the intervals outlined in the Periodic Maintenance Chart beginning on page 53 1 Liftthe cargo box to access the air box 2 Remove the air box cover and inspect the gasket It should adhere tightly to the cover and seal all the way around 3 Remove the air filter 1 4 Do not attempt to clean the main element Install a new air filter NOTE Apply a small amount of general purpose grease to the sealing edges of the filter before installing 5 Inspect the air box for oil or water deposits If present drain them into a suitable co
31. To Use Low Range vs High Range Following is a guideline for when to use low range and high range Low Range When basic operation is at speeds less than 7 MPH 11 KPH For heavy pulling When operating in rough terrain swamps mountains etc at low ground speeds High Range When basic operation is at speeds greater than 7 MPH 11 KPH When operating at high ground speeds 75 MAINTENANCE AND LUBRICATION PVT System WARNING 76 Failure to comply with the instructions in this warning can result in severe injury or death Do not modify any component of the PVT system Doing so may reduce its strength so that a failure may occur at a high speed The PVT system has been precision balanced Any modification will cause the system to be out of balance creating vibration and additional loads on components The PVT system rotates at high speeds creating large amounts of force on clutch components Extensive engineering and testing has been conducted to ensure the safety of this product However as the owner you have the following responsibilities to make sure this system remains safe Always follow all recommended maintenance procedures See your dealer as outlined in the owner s manual This PVT system is intended for use on Polaris products only Do not install it in any other product Always make sure the PVT housing is securely in place during operation MAINTENANCE AND LUBRICATION PVT System PVT Drying
32. WHETHER ARISING OUT OF EXPRESS OR IMPLIED WARRANTY OR ANY OTHER CON TRACT NEGLIGENCE OR OTHER TORT OR OTHERWISE ALL IMPLIED WARRANTIES INCLUDING BUT NOT LIMITED TO ANY IM PLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICU LAR 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 workman ship 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 any engine that has been used in racing competition This limited warranty also does not cover physical damage corrosion or defects caused by fire explosions or other similar causes beyond the control of Polaris If you have any questions regarding your warranty rights and responsibilities you should contact the Polaris Warranty Department at 1 763 417 8650 110 WARRANTY California Emission Control Warranty Statement The Air Index of this Engine is 3 1111 0 2 4 6 8 10 Most Clean Least Clean Note The lower the Air Index the less pollution This engine is certified to be emission compl
33. adjustment procedures have a qualified dealer perform these operations Maintenance intervals in the following chart are based upon average riding conditions and an average vehicle speed of approximately 10 miles per hour Vehicles subjected to severe use must be inspected and serviced more frequently Severe Use Definition Frequent immersion in mud water or sand Racing or race style high RPM use Prolonged low speed heavy load operation Extended idle Short trip cold weather operation Pay special attention to the oil level A rise in oil level during cold weather can indicate contaminants collecting in the oil sump or crankcase Change oil immediately if the oil level begins to rise Monitor the oil level and if it continues to rise discontinue use and determine the cause or see your dealer 53 MAINTENANCE AND LUBRICATION Periodic Maintenance Chart Maintenance Chart Key p gt Perform these procedures more frequently for vehicles subjected to severe use E Emission Control System Service 4 Cycle California m Have an authorized Polaris dealer perform these services 4 WARNING Improperly performing the procedures marked with a m could result in component failure and lead to serious injury or death Have an authorized Polaris dealer perform these services 54 MAINTENANCE AND LUBRICATION Periodic Maintenance Chart Perform all services at whichever maintenance interval is reached first Maintenance Int
34. afety 5 17 P Park Brake Adjustment 83 Park Brake Inspection 83 Park Brake Pedal 32 Park Brake Release 32 Parking on an Incline 44 Parking the RANGER 49 Periodic Maintenance Chart 53 57 Polaris Products 99 Pre Ride Inspection 34 Premium 4 Synthetic Oil 60 PVT Drying 77 PVT SYSTEM 75 PVT System me 76 77 R Radiator and Cooling Fan 73 Radiator Coolant Level 74 Rear Gearcase 68 69 Rear Spring Adjustment 84 Removalfrom Storage 98 S Seat Belts 28 85 Seat Removal 27 Sidehilling 40 Spark 79 Spark Plug Removal 71 INDEX S Spark 70 71 Specifications 100 103 Starting the Engine 35 Steering Wheel Inspection 84 Stopping the Engine 36 Storage cha eed pr ees 95 97 Storage Tips 96 97 Suspension Adjustment 84 Switches 2 eee rye 31 T Throttle Body 81 Throttle 80 Throttle Pedal 32 Throttle System 80 81 Tire Tread Depth 86 Tires eremo eee 86 87 Tool Kits 90 Torq
35. art numbers of Polaris products The rear gearcase fill plug 1 is on the driver s side of the rear gearcase Oil Check 6X6 The easiest way to check for adequate oil in the 6X6 is to drain and refill the gearcase to capacity see page 63 Perform the oil change as outlined on page 69 Oil Check 4X4 Maintain the oil level 3 4 of an inch 19 mm below the bottom thread of the fill plug hole Use a light colored non absorbent measuring instrument such as a white cable tie to measure the depth 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 68 MAINTENANCE AND LUBRICATION Gearcases Rear Gearcase Oil Change 1 Remove the fill plug 2 Place a drain pan under the drain plug 2 Remove the drain plug 3 Drainthe oil Dispose of used oil properly 4 Clean the drain plug Reinstall the drain plug Torque to specification 5 Add the recommended oil 6 Reinstall the fill plug Torque to specification 7 Check for leaks 69 MAINTENANCE AND LUBRICATION Spark Plugs CAUTION Using non recommended spark plugs can result in serious engine damage Always use Polaris recommended spark plugs Refer to the specifications section beginning on page 100 Spark Plug Gap Torque Mode Electrode Gap New Plug Torque Used Plug Torque RANGER 18 f
36. ater system is used exercise extreme caution to avoid damaging wheel bearings radiator transmission seals body panels brakes and warning labels Grease all zerk fittings immediately after washing and allow the vehicle to run for a while to evaporate any water that may have entered the engine or exhaust system Waxing the RANGER Your RANGER can be waxed with any non abrasive automotive paste wax Avoid the use of harsh cleaners since they can scratch the body finish 95 MAINTENANCE AND LUBRICATION Cleaning and Storage Storage Tips CAUTION 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 necessary repairs and then clean the vehicle thoroughly with mild soap and warm water to remove all dirt and grime Don t use harsh detergents or high pressure washers Some detergents deteriorate rubber parts Use dish soap type cleaners only High pressure washers may force water past seals Stabilize the Fuel Fill the fuel tank Add Polaris Carbon Clean Fuel Treatment or Polaris Fuel Stabilizer Follow the instructions on the container for the recommended amount Carbon clean will also reduce the possibility of bacterial growth in the fuel system Allow 15 20 minutes of operation for the stabilizer to disperse through the fuel in the tank Oil and Filter Warm the engine and change the oil
37. ating instructions specified in the Owner s Manual including a Improper or inadequate maintenance of any warranted emission related part b Improper installation adjustment or repair of the LSI engine or any warranted emis sion related part unless performed by an authorized dealer c Failure to use recommended fuel as specified in the Owner s Manual d Repairs and diagnosis performed outside of an authorized dealer e Use of parts which are not authorized by POLARIS Maintenance Schedule The LSI engine owner is responsible for having all scheduled inspection and maintenance services performed at the intervals specified in the Owner s Manual and to retain records of these services as having been performed These records should be transferred to each subsequent owner of the LSI engine POLARIS cannot deny a claim solely because there are no records of scheduled maintenance however a warranty claim may be denied if the failure to perform the scheduled maintenance and inspection resulted in the failure of a warranted emission related part As a minimum the LSI engine owner is responsible for the scheduled inspection and maintenance described below which are based on the procedures described in the Owner s Manual 114 WARRANTY Maintenance Schedule Key p Perform these procedures more often for vehicles subjected to severe use E Emission Control System Service California m Have an authorized Polaris dealer perform these servic
38. be careful of skidding or sliding On slippery surfaces such as ice travel slowly and exercise caution to reduce the chance of skidding or sliding out of control Never operate your vehicle in fast flowing water or in water deeper than that specified in this manual Wet brakes may have reduced stopping ability Test your brakes after leaving water If necessary apply them lightly several times to let friction dry out the pads Always be sure there are no obstacles or people behind your vehicle when operating in reverse When it s safe to proceed in reverse move slowly Avoid turning at sharp angles in reverse Always use the proper size and type of tires specified in this manual Always maintain proper tire pressure as specified on page 19 SAFETY Operator Safety Never modify this vehicle through improper installation or use of accessories Never exceed the stated load capacity for this vehicle Cargo should be properly distributed and securely attached Reduce speed and follow the instructions in this manual for hauling cargo or pulling a trailer Allow a greater distance for braking Always wear the seat belts when operating this vehicle Seat belts reduce the severity of injury in case of a sudden stop or collision Always keep arms and legs inside the cab frame while the vehicle is in motion Always engage the park brake before getting out of the vehicle See page 32 Always apply the service brakes before releasing the park b
39. c filings After the oil has drained completely install a new sealing washer Reinstall the drain plug Torque to specification Add the recommended oil as needed Do not overfill Reinstall the fill plug Torque to specification Check for leaks 65 MAINTENANCE AND LUBRICATION Gearcases Front Gearcase Always check and change the front gearcase oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 53 Maintain the oil level even with the bottom thread of the fill plug hole The front gearcase fill plug 1 is located on the right side of the front gearcase Refer to the Gearcase Specifications Chart on page 63 for recommended lubricants capacities and torque specifications See page 99 for the part numbers of Polaris products Oil Check 1 Position the vehicle on a level surface 2 Remove the fill plug Check the oll level 3 Add the recommended oil as needed 4 Reinstall the fill plug Torque to specification Oil Change Ge 1 Support the vehicle securely with a jackstand 2 Remove the front tire on the driver s side 3 Remove the fill plug 4 Place a drain pan under the drain plug 2 on the bottom right hand side Remove the drain plug Drain the oil Discard used oil properly Clean the drain plug Reinstall the drain plug Torque to specification 7 Add the recommended oil Reinstall the fill plug Torque to specification 9 Check for leaks EA 90 66
40. cks or scratches 7 Reinstall the drain plug Torque to 20 ft Ibs 27 Nm 8 Place shop towels beneath the oil filter Using an oil filter wrench turn the filter counterclockwise to remove 9 Using a clean dry cloth clean the filter sealing surface on the crankcase 10 Lubricate the o ring on the new filter with a film of fresh engine oil Check to make sure the o ring is in good condition 11 Install the new filter and turn by hand until the filter gasket contacts the sealing surface then turn and additional 1 2 turn 62 MAINTENANCE AND LUBRICATION Engine Oil Oil and Filter Change 12 Remove the dipstick and fill the sump with two quarts 1 9 1 of recommended oil 13 Shift the transmission to neutral 14 Engage the park brake 15 Apply the brakes Start the engine Allow it to idle for one to two minutes 16 Stop the engine Inspect for leaks 17 Re check the oil level on the dipstick and add oil as necessary to bring the level to the upper mark on the dipstick 18 Dispose of used filter and oil properly Gearcases Gearcase Specification Chart Gearcase Lubricant Capacity Fill Plug Drain Plug Torque Torque Main Gearcase Premium AGL 15 2 oz 14 ft Ibs 14 ft Ibs Transmission Synthetic Gearcase 450 ml 19 4 Nm 19 4 Nm Lube Front Gearcase Premium Demand 5 oz 8 10 ft Ibs 11 ft Ibs Drive Hub Fluid 150 ml 11 13 6 Nm 15 Nm Middle Gearcase Premium ATV Angle 6 75 oz 14 ft Ibs 14 ft
41. control and an accident which could result in serious injury or death Always replace tires when the tread depth measures 1 8 3 mm or less Improper tire inflation or the use of non standard size or type of tires may adversely affect vehicle handling which could result in vehicle damage or personal injury Always maintain proper tire pressure When replacing tires always use original equipment size and type Tire Tread Depth Always replace tires when tread depth is worn to 1 8 3 mm or less 1 8 3 mm Axle and Wheel Nut Torque Specifications Inspect the following items occasionally for tightness and if they ve been loosened for maintenance service Location Specification Front Wheel Nuts 35 ft Ibs 47 Nm Rear Wheel Nuts 35 ft Ibs 47 Nm Front Spindle Nut 70 ft Ibs 95 Nm Center and Rear Hub 110 ft Ibs 150 Nm Retaining Nuts 86 MAINTENANCE AND LUBRICATION Tires amp 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 Wheel Removal 1 2 3 4 Stop the engine Place the transmission in gear Engage the park brake Loosen the wheel nuts slightly Elevate the side of the vehicle by placing a suitable stand under the frame Remove the wheel nuts and washers
42. cts of your vehicle including safe operating procedures The RANGER is an off road vehicle Familiarize yourself with all laws and regulations concerning the operation of this vehicle in your area We strongly advise you to strictly follow the recommended maintenance program outlined in your owner s manual This preventive maintenance program is designed to ensure that all critical components on your vehicle are thoroughly inspected at specific intervals SAFETY Operator Safety The following signal words and symbols appear throughout this manual and on your RANGER Your safety is involved when these words and symbols are used Become familiar with their meanings before reading the manual A A The safety alert symbol on your vehicle or in this manual alerts you to the potential for personal injury WARNING The safety alert warning indicates a potential hazard that may result in serious injury or death CAUTION The safety alert caution indicates a potential hazard that may result in minor personal injury or damage to the vehicle CAUTION A caution indicates a situation that may result in damage to the vehicle NOTE A note will alert you to important information or instructions SAFETY Operator Safety 4 WARNING Serious injury or death can result if you do not follow these instructions and procedures which are outlined in further detail within your owner s manual Read this manual and all labels care
43. cuits are on Electrical equipment can be used START Electric starter is engaged by holding ignition switch key in this position Upon release the key will return to the ON RUN position 4 amp WARNING Leaving the keys in the ignition can lead to unauthorized use of the vehicle resulting in serious injury or death Always remove the ignition key when the vehicle is not in use Light Switch 2 The ignition switch key must be in the ON RUN position to operate the headlights The switch has three positions A High Beam B Low Beam C Off AWD Differential Lock Switch 3 The AWD Differential Switch has three positions D AWD E Differential Lock WD Off IWD Press the top of the rocker switch to engage AWD See page 51 for AWD operating instructions Move the rocker switch to the center position to lock the differential and return to 2WD See page 50 for Differential Lock operating instructions Press the bottom of the switch to unlock the differential and return to 1WD 31 FEATURES AND CONTROLS Brake Pedal 1 Depress the brake pedal to slow or stop the vehicle Apply the brakes while starting the engine Throttle Pedal 2 Push the pedal down to increase engine speed Spring pressure returns the pedal to the rest position when released Always 1 check that the throttle pedal returns normally before starting the engine Make sure there s adequate throttle pedal freeplay 2 See page
44. e a substantial safety hazard and increase the risk of bodily injury The warranty on your Polaris RANGER is terminated if any equipment has been added to the vehicle or if any modifications have been made to the vehicle that increase its speed or power NOTE The addition of certain accessories including but not limited to mowers blades tires sprayers or large racks may change the handling characteristics of the vehicle Use only Polaris approved accessories and familiarize yourself with their function and effect on the vehicle 10 SAFETY Operator Safety 4 WARNING POTENTIAL HAZARD Stalling rolling backwards while climbing a hill WHAT CAN HAPPEN Vehicle overturn HOW TO AVOID THE HAZARD Maintain a steady speed when climbing a hill If you lose all forward speed Apply the brakes Engage the park brake after fully stopped If you begin rolling backwards Never apply engine power Apply the brakes gradually When fully stopped engage the park brake In the event of an accident have a qualified service dealer check the complete vehicle for possible damage including but not limited to brakes throttle and steering 11 SAFETY Operator Safety 4 amp WARNING 12 POTENTIAL HAZARD Operating this vehicle on paved surfaces WHAT CAN HAPPEN Loss of control HOW TO AVOID THE HAZARD This vehicle s tires are designed for off road use only not for use on pavement Paved surfaces may seriousl
45. e harmful to a battery 4 WARNING Improperly connecting or disconnecting battery cables can result in an explosion and cause serious injury or death When removing the battery always disconnect the negative black cable first When reinstalling the battery always connect the negative black cable last Battery Removal 1 Open the hood 2 Remove the battery vent tube from the battery 3 Disconnect the black negative battery cable first 4 Disconnect the red positive battery cable next 5 Lift the battery out of the vehicle being careful not to tip it sideways and spill any electrolyte 4 CAUTION 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 93 MAINTENANCE AND LUBRICATION Battery Battery Installation 1 Setthe battery in its holder 2 Install the battery vent tube It must be free from obstructions and securely installed If not battery gases could accumulate and cause an explosion The tube should be routed away from the frame and body to prevent corrosion Avoid skin contact with electrolyte as severe burns could result 3 First connect and tighten the red positive cable 4 Second connect and tighten the black negative cable 5 Verify that cables are properly routed NOTE Wheninstalling a new battery make sure it s fully charged prior to its initial use
46. e headlight approximately 25 ft 7 6 m from a wall 2 Measure the distance from the floor to the center of the headlight and make a mark on the wall at the same height 3 Apply the brakes Start the engine Turn on the headlights 4 Observe the headlight aim The most intense part of the headlight beam should be aimed 8 20 3 cm below the mark placed on the wall in step 2 NOTE Include the weight of a rider on the seat while performing this step 5 Adjust the beam to the desired position by turning the adjustment screw 1 Brake Lights When the brake pedal is depressed the console brake light comes on Check the brake light before each ride 1 Turn the ignition switch to the ON position 2 Depress the brake pedal The brake light should come on after about 10mm 0 4 in of pedal travel If the light doesn t come on check the bulb 89 MAINTENANCE AND LUBRICATION Lights Indicator Lamp Replacement 1 Liftthe hood 2 Reach in behind the console panel and lift the release 1 to unplug the light from the harness 3 Using a flathead screwdriver press on the tab 2 on the top of the light to remove the indicator light assembly from the console panel 4 Using a screwdriver turn the light that needs to be replaced 1 4 turn counterclockwise 5 Grip the light with a needle nose plier and remove the light from the assembly 6 Install the new light and use a small flat head screwdriver to seat i
47. e owner you are responsible for the performance of the required maintenance listed in your Owner s Safety and Maintenance Manual herein Own er s Manual POLARIS recommends that you retain all receipts covering mainten ance on your LSI engine but POLARIS cannot deny warranty solely for the lack of receipts or for your failure to ensure the performance of all scheduled maintenance Asthe LSI engine owner you should however be aware that POLARIS may deny you warranty coverage if your LSI engine or a part has failed due to abuse neglect improper maintenance or unapproved modifications You are responsible for presenting your LSI engine to a dealer authorized by PO LARIS as soon as a problem exists The warranty repairs should be completed in a reasonable amount of time not to exceed 30 days If you have any questions regarding your warranty rights and responsibilities you should contact the Polaris Warranty Department at 1 763 417 8650 Limited Warranty California Only POLARIS warrants to the owner of the LSI engine installed in their Polaris vehicle that the LSI engine 1 has been designed built and equipped at the time of manufacture so as to conform with the applicable regulations of the California Air Resources Board and 2 is free from defects in materials and workmanship which may cause it to fail to con form with those regulations as applicable according to the terms and conditions stated below Warranty Period
48. e plugs 5 Turn the engine over several times Oil will be forced in and around the piston rings and ring lands coating the cylinder with a protective film of fresh oil 6 If Polaris fuel system additive is not used fuel tank fuel lines and injectors should be completely drained of gasoline Battery Maintenance Remove the battery and recharge it fully Store the battery in a cool dry place Engine Anti Freeze Test engine coolant strength and change if necessary Coolant should be replaced every two years Storage Area Covers Be sure the storage area is well ventilated and cover the machine with a genuine Polaris cover NOTE Do not use plastic or coated materials They do not allow enough ventilation to prevent condensation and may promote corrosion and oxidation 97 MAINTENANCE AND LUBRICATION Removal from Storage 1 Check the battery electrolyte level and charge the battery if necessary Install it in the vehicle Make sure the battery vent hose is routed properly and that it s not pinched or restricted in any way 2 Make sure the spark plug is tight Fill the fuel tank with fuel 4 Check all the points listed in the Daily Pre Ride Inspection section on page 34 NOTE Tightness of the bolts nuts and other fasteners should be checked by an authorized Polaris dealer 5 Lubricate at the intervals outlined in the Periodic Maintenance Chart beginning on page 53 4 WARNING Engine exhaust contains
49. e verification the servicing dealer will be authorized to per form the warranty repair If You Move If you move to another country be sure to contact Polaris Customer Assistance and the customs department of the destination country before you move Vehicles importation rules vary considerably from country to country You may be required to present docu mentation of your move to Polaris Industries in order to continue your warranty cover age You may also be required to obtain documentation from Polaris Industries in order to register your vehicle in your new country How to Get Service If Purchased From A Private Party If you purchase a Polaris product from a private citizen outside of the country in which the vehicle was originally purchased all warranty coverage will be denied Notice If your vehicle is registered outside of the country where it was purchased and you have not followed the procedure set out above your vehicle will no longer be eligible for war ranty or service bulletin coverage of any kind Vehicles registered to Government officials or military personnel on assignment outside of the country where the vehicle was purchased will continue to be covered by the basic warranty For questions call Polaris Customer Assistance United States 1 763 417 8650 Canada 1 204 925 7100 109 WARRANTY U S A EPA Emissions Limited Warranty This Terrain Vehicle or Off Road Utility Vehicle ORUV emissions
50. edal completely 2 Press on the brake pedal evenly and firmly NOTE Practice starting and stopping using the brakes until you re familiar with the controls NOTE When the throttle pedal is released completely and the engine speed drops near an idle the vehicle has no engine braking 4 WARNING Failure to allow for increased braking distance when hauling cargo or towing a trailer may result in accident and injury Always slow down and allow additional braking distance when towing or hauling cargo 36 OPERATION Driving Safely Driving Procedures REN Sit in the driver s seat and fasten the seat belt 2 After starting the engine and allowing it to warm up apply the service brakes and shift the transmission into gear Check your surroundings and determine your path of travel Release the park brake Keeping both hands on the steering wheel slowly release the brakes and depress the throttle with your right foot to begin driving 6 Drive slowly Practice maneuvering and using the throttle and brakes on level surfaces DA ROO NOTE Low gear is the primary range for operating the RANGER XP High gear is intended for use on hard packed surfaces with light loads 37 OPERATION Driving Safely Driving On Slippery Surfaces When driving on slippery surfaces such as wet trails loose gravel or ice be alert for the possibility of skidding and sliding Under these conditions follow these precautions
51. er if equipped Engine oil change 2 1M Perform a break in oil break in change at one month General 5 3M Lubricate all fittings pivots lubrication cables etc Shift Linkage Inspect lubricate adjust Soong Front suspension Rear suspension 5H 5H OH Throttle Cable 50 H ETC Switch Throttle body air 50 H intake ducts flange 0 H Inspect adjust lubricate replace if necessary Inspect ducts for proper sealing air leaks Drive belt Cooling system 5 if applicable Engine oil change 100 H Inspect adjust replace as needed Inspect coolant strength seasonally pressure test system yearly Perform a break in oil change at 25 hours one month Oil filter change 100 H Replace with oil change p Perform these procedures more often for vehicles subjected to severe use E Emission Control System Service 4 Cycle California m Have an authorized Polaris dealer perform these services 56 MAINTENANCE AND LUBRICATION Periodic Maintenance Chart Maintenance Interval whichever comes first ener Miles Km Fuel system 100 ps Check for leaks at tank cap lines fuel valve filter pump throttle body replace lines every two years m Fuel fiter filter 100H H 12 12M yearly eee 100 12 NUM NENNLLT r clean external if applicable surfaces Cooling hoses 100 H Inspect for leaks if applicable gt Enaine mauris xw met
52. erval whichever comes first Calendar Miles Km Pre Ride O Make adjustments as need Fars nene n e Die meme 7 p gt Broke pedal revel menm mwemwme meme weesmemes menemmes meme gt mene 7 Air filter pre filter E 0 Inspect clean often Air box sediment Daily Drain deposits when visible tube Coolant Daily Check level daily change if applicable coolant every 2 years Headlamp tail Daily Check operation apply lamp dielectric grease if replacing Air filter Weekly Inspect replace as needed main element E Brake pad wear Monthly Inspect periodically 20H Monthly sew Check terminals clean test Front gearcase oil 25 H Monthly Inspect level change yearly if equipped Middle gearcase 25H Monthly Inspect level change yearly oil if equipped Rear gearcase oil 25H Monthly Inspect level change yearly if equipped gt Transmission n Monthy inspectievel change year p Perform these procedures more often for vehicles subjected to severe use E Emission Control System Service 4 Cycle California m Have an authorized Polaris dealer perform these services 55 MAINTENANCE AND LUBRICATION Periodic Maintenance Chart Maintenance Interval whichever comes first Calendar Miles Km Engine breather 2 Monthly Inspect replace if necessary filt
53. es Maintenance Interval whichever comes first Calendar Miles Km Air filter pre filter fiero Inspect clean often Air box sediment Daily Drain deposits when visible tube Air filter Weekly Inspect replace as needed main element Engine breather Monthly ERE Inspect replace if necessary Inspect adjust lubricate re place if necessary Inspect ducts for proper sealing air leaks filter if equipped Throttle Cable 50H ETC Switch li Throttle body air intake ducts flange Fuel system 100 H 12M Check for leaks at tank cap lines fuel valve filter pump throttle body replace lines every two years H Spark plug 100 H l Inspect replace as needed Repair and Replacement of Emission Related Parts It is recommended that only LSI engine replacement parts which have been authorized and approved by POLARIS should be used in the performance of any warranty maintenance or repairs of emission related parts These replacement parts will be provided at no charge if the part is still under warranty Inspect adjust How to File a Warranty Claim Where to Get Warranty Ser vice All repairs qualifying under this Limited Warranty must be performed by a dealer who sold you the LSI engine or a dealer authorized by POLARIS In the event that any emission related part is found to be defective during the warranty period you must notify the Polaris Warranty Department at 1 763 417 8650 and you will be advised of
54. es not cover physical damage to paint or finish stress cracks tearing or puncturing of upholstery material corrosion or defects in parts com ponents or the vehicle caused by fire explosions or any other cause beyond Polaris con trol This warranty does not cover the use of unauthorized lubricants chemicals or fuels that are not compatible with the vehicle The exclusive remedy for breach of this warranty shall be at Polaris exclusive option repair or replacement of any defective materials or components or products THE REMEDIES SET FORTH IN THIS WARRANTY ARE THE ONLY REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF THIS WARRANTY POLARIS SHALL HAVE NO LIABILITY TO ANY PERSON FOR INCIDENTAL CONSEQUENTIAL OR SPECIAL DAMAGES OF ANY DE SCRIPTION WHETHER ARISING OUT OF EXPRESS OR IMPLIED WARRANTY OR ANY OTHER CONTRACT NEGLIGENCE OR OTHER TORT OR OTHER WISE Some states do not permit the exclusion or limitation of incidental or consequen tial damages or implied warranties so the above limitations or exclusions may not apply to you if inconsistent with controlling state law 107 WARRANTY LIMITATIONS OF WARRANTIES AND REMEDIES ALL IMPLIED WARRANTIES INCLUDING BUT NOT LIMITED TO THE IM PLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICU LAR PURPOSE ARE LIMITED IN DURATION TO THE ABOVE SIX MONTH WARRANTY PERIOD POLARIS FURTHER DISCLAIMS ALL EXPRESS WAR RANTIES NOT STATED IN THIS WARRANTY Some states do not allow l
55. fully Follow the operating pro cedures described Never allow anyone without a valid driver s license to operate this vehicle Minimum age recommendation for passengers is five years old Pas sengers under five years of age require special restraints which are not available with this vehicle Driver and passenger should wear their seat belts at all times Never permit a guest to operate this vehicle unless the guest has read this manual and all product labels To reduce tipover risk be especially careful when encountering ob stacles and slopes and when braking on hills or during turns This vehicle is for off road use only Never operate on public roads Always avoid paved surfaces Helmets are recommended whenever driving this vehicle in an aggressive manner Eye protection is recommended at all times Never consume alcohol or drugs before or while operating this ve hicle Never operate at excessive speeds Always travel at a speed proper for the terrain visibility and operating conditions and your experi ence Never attempt wheelies jumps or other stunts Always inspect your vehicle each time you use it to make sure it s in safe operating condition Always follow the inspection and mainte nance procedures and schedules described in this manual Always keep both hands on the steering wheel and both feet on the floorboards of the vehicle during operation Always travel slowly and use extra caution when operating on unfa
56. iant for 1000 hours of use Your Warranty Rights and Obligations The California Air Resources Board and Polaris Industries Inc 2100 Highway 55 Me dina Minnesota 55340 herein POLARIS are pleased to explain the emission control system warranty on your Large Spark Ignition Engine herein LSI engine The Cali fornia Air Resources Board has designated this engine for this vehicle as an LSI engine which produces 25 and greater horsepower and the vehicle has a six 6 or four 4 wheel drive and or a round steering wheel In California this LSI engine must be designed built and equipped to meet the state s stringent anti smog standards Polaris must warrant the emission control system on your LSI engine for the period of time described below provided there has been no abuse neglect or improper maintenance of your LSI engine Your emission control system includes parts such as the carburetor and the ignition sys tem Also included may be hoses connectors and other emission related assemblies Where a warrantable condition exists POLARIS will repair your LSI engine at no cost to you including diagnosis parts and labor Manufacturer s Warranty Coverage LSI engines are warranted for two 2 years If any emission related part on your LSI engine is defective the part will be repaired or replaced by POLARIS 111 WARRANTY California Emission Control Warranty Statement Owner s Warranty Responsibilities Asthe LSI engin
57. if it becomes contaminated if the fluid level is below the minimum or if the type and brand of the fluid in the reservoir are unknown 1 Position the vehicle on a level surface 2 View the brake fluid level at the reservoir 1 under the hood The level should be between the upper MAX and lower MIN level lines 3 Ifthe fluid level is lower than the lower level line add brake fluid to the upper MAX line 4 Apply the brake forcefully for a few seconds and check for fluid leakage around the fittings 4 WARNING After opening a bottle of brake fluid always discard any unused portion Never store or use a partial bottle Brake fluid is hygroscopic meaning it rapidly absorbs moisture from the air The moisture causes the boiling temperature of the brake fluid to drop which can lead to early brake fade and the possibility of accident or severe injury 82 MAINTENANCE AND LUBRICATION Brakes Brake Inspection 3 6 7 8 9 Check the brake system for fluid leaks Check the brake pedal for excessive travel or a spongy feel Check the friction pads for wear damage and looseness Inspect the brake disc spline and pad wear surface for excessive wear Change pads when worn to 3 64 1 mm Park Brake Inspection 1 2 Slowly push the park brake pedal down with your foot After 8 to 12 clicks of pedal travel check the vehicle for movement The vehicle should not rol
58. imitations on how long an implied warranty lasts so the above limitation may not apply to you if inconsistent with controlling state law HOW TO OBTAIN WARRANTY SERVICE If your vehicle requires warranty service you must take it to a Polaris Servicing Dealer When requesting warranty service you must present your copy of the Warranty Registra tion form to the dealer THE COST OF TRANSPORTATION TO AND FROM THE DEALER IS YOUR RESPONSIBILITY Polaris suggests that you use your original selling dealer however you may use any Polaris Servicing Dealer to perform warranty service Please work with your dealer to resolve any warranty issues Should your dealer require any additional assistance they will contact the appropriate person at Polaris This warranty gives you specific legal rights and you may also have other rights which vary from state to state If any of the above terms are void because of state or federal law all other warranty terms will remain in effect Lubricants 1 Mixing oil brands or using non recommended oil may cause engine damage We recommend the use of Polaris engine oil 2 Damage resulting from the use of non recommended lubricants may not be covered by warranty SPARK ARRESTOR Polaris warrants that the spark arrestor in this vehicle will meet the efficiency requirements of 43 CFR 8343 1 c for at least 1000 hours when subjected to normal use and when mainte nance and installation are in accordance with Pola
59. instead Operating the vehicle while the park brake is engaged could cause loss of control and result in serious injury or death Always disengage the park brake before operating the vehicle 44 OPERATION Driving Safely Hauling Cargo 4 WARNING Hauling cargo improperly can alter vehicle handling and may cause loss of control or brake instability which can result in serious injury or death Always follow these precautions when hauling cargo 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 arive 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
60. l or a closed differential It s beneficial to lock the differential in low traction situations Move the AWD Differential Lock rocker switch to the center position A to lock the differential and return to 2WD Press the bottom of the switch B to unlock the differential and return to 1WD CAUTION 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 50 OPERATION All Wheel Drive AWD The illuminated amber AWD switch 1 indicates that the vehicle is in AWD When the AWD switch is on the front wheels will automatically engage any time the rear wheels lose traction When the rear wheels regain traction the front wheels will automatically disengage There is no limit to the length of time the vehicle may remain in AWD When the RANGER 6X6 AWD switch is off the vehicle is in two wheel drive at all times When the RANGER 4X4 AWD switch is off the vehicle is in one wheel drive at all times See page 50 for 4X4 two wheel drive differential lock operation The AWD switch may be turned on or off while the vehicle is moving If the switch is turned off while the front hubs are driving they will not release until the rear wheels regain traction CAUTION Switching to AWD while the rear wheels are spinning may cause severe drive shaft and clutch damage Always s
61. l while parked If the vehicle moves adjustment is necessary Park Brake Adjustment 1 2 3 Position the vehicle on a level surface Shift the transmission to neutral Loosen or tighten the nuts on the pedal end of the park brake cable as needed 83 MAINTENANCE AND LUBRICATION Steering Wheel Inspection Check the steering wheel for specified freeplay and smooth operation at the intervals outlined in the Periodic Maintenance Chart beginning on page 53 1 Position the vehicle on level ground 2 Lightly turn the steering wheel left and right 3 There should be 0 8 1 0 in 20 25 mm of free play 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 Suspension Adjustment 4X4 The 4X4 rear suspension may be adjusted to provide a stiffer suspension if necessary The shocks are mounted to the inside mounting holes A at the factory but they may be relocated to the outside mounting holes B 1 Remove the top shock mounting bolts A 2 Reposition the shocks to the outside mounting holes B 3 Reinstall the shock mounting bolts Torque to 30 ft 165 40 Nm Rear Spring Adjustment The rear shock absorber springs are adjusted by rotating the adjustment cam C either clockwise or counterclockwise to increase or decrease spring tension 84 MAINTENA
62. laced Brake light tail lamp Check operation apply Polaris dielec tric grease when lamp is replaced 34 OPERATION Starting the Engine 4 WARNING SUUS ES Engine exhaust contains poisonous carbon monoxide and can cause loss of consciousness resulting in severe injury or death Never run an engine in an enclosed area Sit in the driver s seat and fasten the seat belt Engage the park brake Shift the transmission to neutral Apply the brakes while starting the engine NOTE Do not press the throttle pedal while starting the engine 5 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 If the engine does not start within five seconds release the ignition switch and wait five seconds Repeat steps 5 and 6 until the engine starts Vary the engine RPM slightly with the throttle to aid in warm up until the engine idles smoothly CAUTION Operating the vehicle immediately after starting could cause engine damage Allow the engine to warm up for several minutes before operating the vehicle 35 OPERATION Stopping the Engine 1 Release the throttle pedal completely and brake to a complete stop 2 Turn the engine off 3 Engage the park brake 4 WARNING A rolling vehicle can cause property damage and serious injury Always engage the park brake after stopping the engine Braking 1 Release the throttle p
63. lete line of apparel parts and accessories available through our online store at www purepolaris com Have your accessories and clothing delivered right to your door POLARIS The Way Out Copyright 2005 Polaris Sales Inc All information contained within this publication is based on the latest product information at the time of publication Due to constant improvements in the design and quality of production components some minor discrepancies may result between the actual vehicle and the information presented in this publication Depictions and or procedures in this publication are intended for reference use only No liability can be accepted for omissions or inaccuracies Any reprinting or reuse of the depictions and or procedures contained within whether whole or in part is expressly prohibited Printed in U S A 2006 RANGER XP 4X4 700 EFI RANGER 6X6 700 EFI Owner s Manual P N 9920220 2 TABLE OF CONTENTS VEHICLE IDENTIFICATION NUMBERS 4 SAFETY sew dieu Rae tux az Dabo ecd et e 5 FEATURES AND CONTROLS 23 OPERATION aotem cunt ahead Gromer Rau 33 EMISSION CONTROL SYSTEMS 52 MAINTENANCE AND LUBRICATION 53 POLARIS 5 99 SPECIFICATIONS 100 TROUBLESHOOTING 104 WARRANT Yes asus dea OD ae es 107 MAINTENANCE LOG 116 INDE acu o ti ob e ane ine 118 VEHICLE IDENTIFICAT
64. loads that extend over the rack sides Stability and maneuverability may be adversely affected causing the vehicle to overturn DO NOT TRAVEL FASTER THAN THE RECOMMENDED SPEEDS Vehicle should never exceed 10 mph 16 kph while towing a load on a level grass surface Vehicle speed should never exceed 5 mph 8 kph when towing loads in rough terrain while cornering or while ascending or descending a hill 45 OPERATION Driving Safely Hauling Cargo The RANGER has been designed to carry or tow specific capacities Always read and understand the load distribution warnings listed on the warning labels Never exceed the following capacities Maximum Capacities Cargo Box Level Ground RANGER 4X4 XP 1500 Ibs 681 kg 1000 Ibs 454 kg RANGER 6X6 EFI 1750 Ibs 794 kg 1250 Ibs 567 kg 4 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 46 OPERATION Driving Safely Dumping the Cargo Box 4 WARNING BOUM 6 7 8 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 bo
65. logs rocks and low hanging branches 4 amp WARNING Severe injury or death can result if your vehicle suddenly comes in contact with a hidden obstacle Not all obstacles are immediately visible Reduce speed and travel with caution in unfamiliar terrain 42 OPERATION Driving Safely Driving in Reverse Follow these guidelines when operating in reverse 1 Back slowly 2 Apply the brakes lightly for stopping 3 Avoid turning at sharp angles 4 Always avoid backing downhill 5 Never open the throttle suddenly while backing 6 Always inspect left and right fields of vision before backing 4 WARNING Failure to use caution when operating in reverse can result in serious injury or death Before shifting into reverse always check for obstacles or people behind the vehicle and follow the reverse operation procedures outlined in this manual Always back slowly 43 OPERATION Driving Safely Parking on an Incline Avoid parking on an incline if possible If it s unavoidable follow these precautions 1 Place the transmission in gear 2 Engage the park brake 3 Turn the engine off 4 Block the rear wheels on the downhill side 4 WARNING A rolling vehicle can cause property damage and serious injury Always engage the park brake after stopping the engine Always block the downhill side of the wheels if leaving the vehicle on a hill or park the vehicle in a sidehill position
66. maximum Use extreme caution when operating on hills and follow proper operating procedures outlined in the owner s manual Never climb hills with excessively slippery or loose surfaces Never open the throttle suddenly 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 39 OPERATION Driving Safely Sidehilling 4 WARNING Crossing hillsides or turning on hills can result in loss of control or vehicle overturn resulting in severe injury or death Avoid crossing the side of a hill when possible When unavoidable exercise extreme caution Avoid operating on steep hills 15 maximum Driving Downhill Whenever descending a hill follow these precautions 1 Proceed directly downhill 2 Slow down 3 Apply the brakes slightly to aid in slowing 4 WARNING 40 Traveling downhill improperly could cause loss of control or vehicle overturn Always check the terrain carefully before descending a hill Never descend a hill at high speed Excessive speed may result in loss of vehicle control and lead to serious injury or death Always operate slowly when traveling downhill Avoid descending a hill at an angle which would cause the vehicle to lean sharply to one side Travel straight downhill when possible OPERATION Driving Safely Driving Through Water 4 WARNING The large tires on your RANGER may cause the vehicle to fl
67. n page 53 Adjust the freeplay if necessary Throttle Freeplay Inspection 1 Engage the park brake 2 Shift the transmission to neutral 2 Apply the brakes Start the engine Allow it to warm up thoroughly 3 Measure the distance the throttle pedal moves before the engine begins to pick up speed Freeplay should be 1 16 to 1 8 inches 1 6 3 2 mm 80 MAINTENANCE AND LUBRICATION Throttle System Throttle Freeplay Adjustment 1 Slide the boots 1 off the inline cable adjuster sleeve 2 Loosen the adjuster locknut 3 2 Turn the adjuster until 1 16 to 1 8 inch freeplay is achieved NOTE While adjusting flip the throttle lever back and forth 3 Tighten the locknut and slide the boots over the cable adjuster until they touch at the midpoint of adjuster 1 2 3 fm Throttle Body Idle RPM Idle RPM is preset by the manufacturer If the engine idle speed is not satisfactory please see your Polaris dealer for adjustment 81 MAINTENANCE AND LUBRICATION Brakes The front and rear brakes are hydraulic disc type brakes and are activated by the brake pedal See page 32 Brake Fluid Routine inspections are recommended to keep the brake system in good operating condition Inspect the level of the brake fluid before each operation Change the brake fluid at the intervals outlined in the Periodic Maintenance Chart beginning on page 53 The brake fluid should also be changed
68. ng the warranty period through a Polaris dealer REGISTRATION At the time of sale the Warranty Registration Form must be completed by your dealer and submitted to Polaris within ten days Upon receipt of this registration Polaris will record the registration for warranty No verification of registration will be sent to the purchaser as the copy of the Warranty Registration Form will be the warranty entitle ment If you have not signed the original registration and received the customer copy please contact your dealer immediately NO WARRANTY COVERAGE WILL BE ALLOWED UNLESS YOUR VEHICLE IS REGISTERED WITH POLARIS Initial dealer preparation and set up of your vehicle is very important in ensuring trouble free operation Purchasing a machine in the crate or without proper dealer set up will void your warranty coverage WARRANTY COVERAGE AND EXCLUSIONS LIMITATIONS OF WARRANTIES AND REMEDIES The Polaris limited warranty excludes any failures that are not caused by a defect in ma terial or workmanship This warranty does not cover accidental damage normal wear and tear abuse or improper handling This warranty also does not cover any vehicle that has been altered structurally neglected improperly maintained used for racing or used for purposes other than for which it was manufactured or for any damages which occur during trailer transit or as a result of unauthorized service or the use of unauthorized parts In addition this warranty do
69. ning Reinstall the cap NOTE f coolant must be added often or if the overflow bottle runs completely dry there may be a leak in the system Have the cooling system inspected by your Polaris dealer 73 MAINTENANCE AND LUBRICATION Cooling System Radiator Coolant Level Always check and change the coolant at the intervals outlined in the Periodic Maintenance Chart beginning on page 53 4 WARNING Escaping steam can cause severe burns Never remove the pressure cap while the engine is warm or hot Always allow the engine to cool before removing the pressure cap 1 Liftthe hood and slowly remove the radiator cap 1 2 View the coolant level through the opening 3 Use a funnel and slowly add coolant as needed NOTE 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 1 the radiator should also be inspected NOTE Use of a non standard pressure cap will not allow the recovery system to function properly See your dealer for the correct replacement part 74 MAINTENANCE AND LUBRICATION Polaris Variable Transmission PVT System 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 When
70. ntainer NOTE Service the air filter more frequently if the vehicle is operated in wet conditions or at high throttle openings for extended periods Fuel Filter Your Polaris vehicle is equipped with an in line fuel filter Have your dealer replace it after every 100 hours of operation Do not attempt to clean the fuel filter 78 MAINTENANCE AND LUBRICATION Spark Arrestor 4 amp WARNING Failure to heed the following warnings while servicing the spark arrestor could result in serious injury or death Do not perform service on the spark arrestor while the system is hot Exhaust system temperatures can reach 1000 F Allow components to cool sufficiently before proceeding Remove any combustible materials from the area Wear eye protection and gloves Do not stand behind or in front of the vehicle while purging Never run the engine in an enclosed area Exhaust contains poisonous carbon monoxide gas that can cause loss of consciousness or death in a very short time Never go under the vehicle while it s inclined Use the following procedure to periodically purge accumulated carbon from the exhaust pipe 1 Remove the arrestor clean out plugs 1 located on the bottom of the muffler Shift the transmission to neutral Apply the brakes Start the engine Purge accumulated carbon from the system by momentarily revving the engine several times If carbon is expelled cover or plug the exhaust outlet 2 and rap
71. oat in deep or fast flowing water which could result in loss of control and lead to serious injury or death Never cross deep or fast flowing water with your RANGER Your Polaris RANGER can operate through water up to a maximum recommended depth equal to the floorboards 1 Follow these procedures when operating through water 1 Always determine water depths and current before entering 2 Choosea crossing where both banks have gradual inclines 3 Proceed slowly avoiding rocks and obstacles 4 After leaving water always dry the brakes by applying light pressure to the pedal repeatedly until braking action is normal NOTE After running your vehicle in water it s critical that you perform the services outlined in the Periodic Maintenance Chart beginning on page 53 Give special attention to engine transmission oil front and rear gearcases and all grease ittings CAUTION 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 91 and take the vehicle to your dealer at the first opportunity 41 OPERATION Driving Safely Driving Over Obstacles SM wrk ee Be alert Look ahead and learn to read the terrain you re traveling on Watch for hazards such as
72. on required in your area Any time the cooling system has been drained for maintenance or repair replace the coolant If the recovery bottle has run dry the level in the radiator should be inspected Add coolant as needed 72 MAINTENANCE AND LUBRICATION Cooling System Radiator and Cooling Fan Always check and clean the screen and radiator fins at the intervals outlined in the Periodic Maintenance Chart beginning on page 53 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 CAUTION Washing the vehicle with a high pressure hose could damage the radiator fins and impair the radiator s effectiveness Exercise caution if a high pressure system is used for washing the vehicle Coolant Level Always check and change the coolant at the intervals outlined in the Periodic Maintenance Chart beginning on page 53 Maintain the coolant level between the minimum and maximum marks on the bottle when the fluid is cool The overflow bottle 1 is located in front of the right front wheel 1 Position the vehicle on level ground 2 View the coolant level in the overflow bottle 3 Ifthe coolant level is below the safe operating range lift the hood and locate the overflow bottle lid Remove the lid and use a funnel to add coolant through the filler ope
73. perature range It resists viscosity and frictional breakdown in ambient temperatures from 40 F to 120 F Its exceptional frictional properties result in more efficient operation more power output and lower fuel consumption Although Polaris Premium 4 is the only oil recommended for use in this engine use of any API certified SH oil is allowable as long as it s 0W 40 Oil may need to be changed more frequently if Polaris Premium 4 is not used Follow the manufacturer s recommendations for ambient temperature operation CAUTION Mixing brands or using a non recommended oil may cause serious engine damage We recommend the use of Polaris Premium 4 All Season synthetic oil or API certified SH oil OW 40 Never substitute or mix oil brands Use only OW 40 4 WARNING Vehicle operation with insufficient deteriorated or contaminated engine oil will cause accelerated wear and may result in engine seizure accident and injury Always perform the maintenance procedures as outlined in the Periodic Maintenance Chart 60 MAINTENANCE AND LUBRICATION Engine Oil Always check and change the oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 53 We recommend the use of Polaris Premium 4 Season Synthetic engine oil Oil Check The oil dipstick and fill tube 1 is located on the engine 1 2 NOTE Due to the dipstick entry 6 Position the vehicle on a level surface Apply the brakes S
74. rain WHAT CAN HAPPEN Loss of control vehicle overturn HOW TO AVOID THE HAZARD Travel slowly and use extra caution when operating on unfamiliar terrain Always be alert to changing terrain conditions when operating the vehicle You may come upon hidden rocks bumps or holes suddenly without enough time to react 15 SAFETY Operator Safety 4 amp WARNING 16 POTENTIAL HAZARD Failure to follow the minimum age recommendations for this vehicle WHAT CAN HAPPEN Serious injury or death the child or others HOW TO AVOID THE HAZARD Only persons with a valid driver s license should operate a Polaris RANGER Even though a child may be within the age group for which some vehicles are recommended he or she may not have the skills abilities or judgment needed to operate the vehicle safely and may be involved in a serious accident WARNING POTENTIAL HAZARD Operating this vehicle with improper tires or with improper or uneven tire pressure WHAT CAN HAPPEN Loss of control accident and or overturn HOW TO AVOID THE HAZARD Always use the size and type of tires specified in the Owner s Manual for this vehicle See page 19 Always maintain proper tire pressure as described on the decal and in the Owner s Manual See page 19 SAFETY Operator Safety A A WARNING Leaving the keys in the ignition can lead to unauthorized use of the vehicle resulting in serious injury or death Always remove the ignition key
75. rake Always turn off the engine before refueling Make sure the refueling area is well ventilated and free of any source of flame or sparks Gasoline is extremely flammable See page 22 for refueling instruc tions Always remove the ignition key when the vehicle is not in use to prevent unauthorized use or accidental starting FOR MORE INFORMATION ABOUT SAFETY call Polaris at 1 800 342 3764 SAFETY Operator Safety 4 amp WARNING Make sure your RANGER is in excellent operating condition at all times We strongly recommend that the operator check all safety components before each ride Polaris RANGERs are designed to provide safe operation when used as directed Failure of critical machine components may result from operation with any modifications especially those that increase speed or power The RANGER may become aerodynamically unstable at speeds higher than those for which it is designed Loss of control may occur at higher speeds Modifications may also create a safety hazard and lead to bodily injury Do not make any modifications to your RANGER Equipment Modifications We are concerned for the safety of our customers and for the general public Therefore we strongly recommend that consumers do not install on a Polaris RANGER any equipment that may increase the speed or power of the vehicle or make any other modifications to the vehicle for these purposes Any modifications to the original equipment of the vehicle creat
76. ris Premium 4 Synthetic Oil if necessary to maintain the oil level in the normal safe operating range 3 Drive slowly at first Select an open area that allows room to familiarize yourself with vehicle operation and handling 4 Vary throttle positions Do not operate at sustained idle 5 Perform regular checks on fluid levels controls and areas outlined on the daily pre ride inspection checklist See page 34 6 Pull only light loads 7 During the break in period change both the oil and the filter at 25 hours 33 OPERATION Pre Ride Inspection 4 amp WARNING If a proper inspection is not done before each use severe injury or death could result Always inspect the vehicle before each use to ensure it s in proper operating condition Pre Ride Checklist Brake system lever travel Ensure proper operation Brake fluid Ensure proper level Inspect lubricate if necessary Inspect lubricate if necessary Front suspension Rear suspension Steering Ensure free operation Wheels fasteners Frame nuts bolts fasteners Inspect ensure tightness nspect condition and pressure nspect ensure fastener tightness Ensure proper levels Ensure proper level Inspect for leaks Ensure proper operation Indicator lights switches Ensure operation Air filter pre filter Inspect clean Air box sediment tube Drain deposits whenever visible Headlamp Check operation apply Polaris dielec tric grease when lamp is rep
77. ris recommendations 108 WARRANTY Exported Vehicles EXCEPT WHERE SPECIFICALLY REQUIRED BY LAW THERE IS NO WARRANTY OR SERVICE BULLETIN COVERAGE ON THIS VEHICLE IF IT IS SOLD OUTSIDE THE COUNTRY OF THE SELLING DEALER S AUTHORIZED LOCATION This policy does not apply to vehicles that have received authorization for export from Polaris Industries Dealers may not give authorization for export You should consult an authorized dealer to determine this vehicle s warranty or service bulletin coverage if you have any questions This policy does not apply to vehicles registered to government officials or military per sonnel on assignment outside the country of the selling dealer s authorized location This policy does not apply to Safety Recalls How to Get Service In the Country where your vehicle was purchased Warranty or Service Bulletin repairs must be done by an authorized Polaris dealer If you move or are traveling within the country where your vehicle was purchased Warranty or Service Bulletin repairs may be requested from any authorized Polaris dealer who sells the same line as your vehicle Outside the Country where your vehicle was purchased If you are traveling temporarily outside the country where your vehicle was purchased you should take your vehicle to an authorized Polaris dealer You must show the dealer photo identification from the country of the selling dealer s authorized location as proof of residence Upon residenc
78. rocedure for spark plug installation Torque to specification See page 70 71 MAINTENANCE AND LUBRICATION Cooling System Operation 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 NOTE Some coolant level drop on new vehicles is normal as the System is purging itself of trapped air Observe coolant levels and maintain as recommended by adding coolant to the overflow bottle Adding or Changing Coolant To ensure that the coolant maintains its ability to protect the engine we recommend that the system be completely drained every two years and a fresh mixture of antifreeze and water added Polaris recommends the use of Polaris Premium 60 40 anti freeze coolant or a 50 50 mixture of high quality aluminum compatible anti freeze coolant and distilled water Polaris Premium 60 40 is already premixed and ready to use Do not dilute with water See page 99 for the part numbers of Polaris products NOTE Always follow the manufacturer s mixing recommendations for the freeze protecti
79. rol box connections Inspect clean reinstall connectors Engine Turns Over Fails to Start Possible Cause Solution Inspect and clean or replace Drain the fuel system and refuel Replace with new fuel Inspect plug s replace if necessary Inspect plug s replace if necessary Immediately see your Polaris dealer Replace the filter Recharge battery to 12 5 VDC Mechanical failure See your Polaris dealer Engine Pings or Knocks Possible Cause Solution Poor quality or low octane fuel Replace with recommended fuel Incorrect ignition timing See your Polaris dealer Incorrect spark plug gap or heat range Set gap to specs or replace plugs 104 TROUBLESHOOTING Engine Backfires Possible Cause Solution Weak spark from spark plugs Inspect clean and or replace spark plugs Incorrect spark plug gap or heat range Set gap to specs or replace plugs Old or non recommended fuel Replace with new fuel Incorrectly installed spark plug wires See your Polaris dealer Incorrect ignition timing See your Polaris dealer Mechanical failure See your Polaris dealer Engine Runs Irregularly Stalls or Misfires Possible Weak Spark Cause Solution Fouled or defective spark plugs Inspect clean and or replace spark plugs Worn or defective spark plug wires See your Polaris dealer Incorrect spark plug gap or heat range Set gap to specs or replace plugs Loose ignition connections Check all connections and tighten Water present in fuel
80. t Ibs 18 ft Ibs goer temm Qm em RANGER 035 9 mm 18 ft Ibs 18 ft Ibs 6X6 EFI 24 Nm 24 Nm 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 4 WARNING A hot exhaust system and engine can cause serious burns Wear protective gloves when removing a spark plug for inspection 1 Normal 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 NOTE The tip should not be white A white insulator tip indicates overheating caused by use of an improper spark plug or incorrect throttle body adjustments 70 MAINTENANCE AND LUBRICATION Spark Plugs 2 Wet Fouled The wet fouled insulator tip is black A damp oil film covers the firing end There may be a carbon layer over the entire nose Generally the electrodes are not worn General causes of fouling are excessive oil use of non recommended injection oil or incorrect throttle body adjustments Spark Plug Removal and Replacement 1 Remove the seat to access the engine compartment 2 Remove the spark plug cap Using the spark plug wrench provided in the tool kit remove the plug by rotating it counterclockwise 3 Reverse the p
81. t into place 1 4 turn clockwise 7 Snap the assembly back into the console panel and reconnect the harness 8 Close the hood Tool Kit To help you perform routine maintenance a tool kit is provided with your vehicle Items included in the kit are A screwdriver An open end wrench 8 10 mm An open end wrench 12 14 mm A tire pressure gauge A spark plug wrench and handle A spanner wrench for shock adjustment NOTE Additional tools will be necessary to perform routine maintenance 90 MAINTENANCE AND LUBRICATION Vehicle Immersion CAUTION If your vehicle becomes immersed major engine damage can result if the vehicle is not thoroughly inspected Take the vehicle to your dealer before starting the engine If it s impossible to take your RANGER to a dealer before starting it follow the steps outlined below 1 Move the vehicle to dry land or at the very least to water below the footrests 2 Dry any water present in the air box NOTE Filter replacement is required if water is present Thoroughly dry the air pre cleaner located under the hood 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 SA wx Ropa Attempt to start the engine If necessary repeat the drying procedure 8 Take the vehicle to your dealer for service as soon as possible whether you succeed in starting it or not NOTE f water has
82. tart the engine and let it idle for 20 30 seconds then stop the engine Lift the lever lock 2 to remove the dipstick Wipe it dry with a clean cloth Reinstall the dipstick completely but do not lock it The dipstick must be screwed completely in to keep the angle and depth of the stick consistent 22 SAFE ADR ene Remove the dipstick ps 3 and check the oil level Maintain the oil level in the safe range 3 Do not overfill angle into the crankcase the oil level will read higher on the bottom side of the dipstick Always read the level on the upper surface 4 of the dipstick After reinstalling the dipstick be sure to seat the lever lock 61 MAINTENANCE AND LUBRICATION Engine Oil Oil and Filter Change 4 CAUTION Hot oil can cause serious burns to skin Do not allow hot oil to come into contact with skin Always change the oil and filter at the intervals outlined in the Periodic Maintenance Chart beginning on page 53 Always change the oil filter whenever changing oil 1 Position the vehicle on a level surface 2 Run the engine for two to three minutes until warm Stop the engine 3 Clean the area around the drain plug 4 Place a drain pan beneath engine crankcase and remove the drain plug 5 Allow the oil to drain completely 6 Reinstall the sealing washer on the drain plug NOTE The sealing surfaces on drain plug and crankcase should be clean and free of burrs ni
83. the appropriate dealer where the warranty repair is to be performed 115 MAINTENANCE LOG Periodic Maintenance Record Use the following chart to record periodic maintenance DATE MILES KM TECHNICIAN SERVICE PERFORMED COMMENTS 116 MAINTENANCE LOG DATE MILES KM TECHNICIAN SERVICE PERFORMED COMMENTS 117 INDEX A Age Restrictions 5 Air Filter lx ees 78 All Wheel Drive AWD 51 Auxiliary Outlet 26 AWD 5 31 B ei de 92 94 Battery 93 Battery Installation 94 Battery Removal 93 Battery Storage 94 Brake Fluid 82 Brake Inspection 83 Brake Lights 89 Brake Pedal 32 Brakes erui MERITOS 82 83 Braking 36 C Cleaning 95 97 Component Locations 23 25 Console eres ERE Peete end 29 Coolant cP dI PART eS 72 Coolant 1 73 Cooling System 72 74 Cooling System Operation 72 Crankcase Emission Control System 52 D Decals and Locations 18 21 Differential Lock 50 Differential Lock Switch 31 Disengaging AWD 51 Driving Downhill 40 Driving in Reverse 43 Driving On Slippery Surfaces
84. the combustion chamber by the intake system 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 Engine idle speed is the only adjustment Polaris recommends that the operator perform Any other adjustments should be performed by an authorized Polaris dealer Emissions labels are located on either the recoil cover the stator housing or the left side of the engine near the clutch cover Electromagnetic Interference This spark ignition system complies with Canadian ICES 002 This vehicle complies with European directives 97 24 EC and 89 336 EEC 52 MAINTENANCE AND LUBRICATION Periodic Maintenance Chart Careful periodic maintenance will help keep your vehicle in the safest most reliable condition Inspection adjustment and lubrication of important components are explained in the periodic maintenance chart Inspect clean lubricate adjust and replace parts as necessary When inspection reveals the need for replacement parts use genuine Polaris parts available from your Polaris dealer Record maintenance and service in the Maintenance Log beginning on page 116 NOTE Service and adjustments are important for proper vehicle operation If you re not familiar with safe service and
85. tor or fuel injection system ii Air fuel ratio feedback and control system if applicable iii Cold start enrichment system if applicable iv Regulator assy gaseous fuel if applicable 2 Air Induction System i Intake manifold if applicable ii Air filter 3 Ignition System i Spark plugs ii Magneto or electronic ignition system iii Spark advance retard system if applicable 4 Exhaust manifold if applicable 5 Miscellaneous Items Used in Above Systems i Electronic controls if applicable ii Hoses belts connectors and assemblies iii Filter lock assy gaseous fuel if applicable If an authorized dealer determines that other LSI engine components have been damaged due to the failure of a warranted emission related part during the warranty period PO LARIS will repair and or replace the necessary components 113 WARRANTY What is Not Covered Under This Warranty This warranty does not cover any emission related part which malfunctions fails or is damaged due to alterations and or modifications such as changing adding or removing parts When the LSI engine is being serviced under warranty POLARIS and any of its authorized dealers shall not be liable for any loss of use of the LSI engine for any damage to goods or loss of time or inconvenience This limited warranty also does not apply to any emission related part which malfunctions fails or is damaged due to failure to follow the maintenance and oper
86. ue Specifications 86 Towing Capacities 48 Towing Loads 48 Trailer Hitch Bracket 26 Transmission 64 65 Transporting the RANGER 98 Troubleshooting 104 106 V Vehicle Break In Period 33 Vehicle Identification Numbers 4 Vehicle Immersion 91 Warranty vue ru eee 107 115 Wheel Installation 87 Wheel Removal 87 119
87. uel gauge that indicates the amount of fuel remaining in the tank ey When the indicator needle nears the E empty mark refuel at the earliest opportunity When refueling always use either leaded or unleaded gasoline with a minimum pump octane number of 87 M 2 octane 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 27 FEATURES AND CONTROLS Seat Belts The RANGER is equipped with lap style seat belts for the operator and passenger 4 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 Passengers under five years of age require special restraints which are not available with this vehicle No person under the age of five years may ride in the RANGER To wear the seat belt properly follow this procedure 1 Place the belt across your lap as low on your hips as possible taking care that the belt is not twisted 2 Push the latch plate into the buckle until it clicks 3 Release the strap it will self tighten NOTE The center belt must be tightened manually by pulling on the strap To unfasten press the square red button in the buckle s center 28 FEATURES AND
88. ut pre filter 7172921 Location 6 CAUTION To avoid transmission Pour ne pas endommager la bo te de vitesses ne changer de vitesse que lorsque le v hicule est damage shift only when vehicle is stationary and at idle l arr t ou au ralenti 7472674 Location 7 20 SAFETY Safety Decals and Locations Discretionary Warning Decal WARNING Improper vehicle use can result in SEVERE INJURY or DEATH NEVER Operate on public roads A collision can occur with another vehicle Carry more than two passengers or passengers under age five USE ALCOHOL or DRUGS before or while operating this vehicle Operate at speeds too fast for your skills or the conditions Operate this vehicle on HILLS steeper than 15 degrees 15 To prevent flipover on hilly terrain use throttle and brakes gradually ALWAYS Avoid paved surfaces which may adversely affect handling and control Use proper RIDING TECHNIQUES to avoid vehicle overturns on hills and rough terrain and in tums Wear eye protection REVERSE operation can be dangerous even at low speeds Steering becomes difficult To prevent flipover avoid sharp turns The park emergency brake lever will supply increased braking but should be used as an emergency or parking brake only READ OWNER S MANUAL FOLLOW ALL INSTRUCTIONS AND WARNINGS IF OWNER S MANUAL IS MISSING CONTACT A POLARIS DEALER FOR A REPLACEMENT THIS GENERAL PURPOSE OFF ROA
89. witch to AWD while the rear wheels have traction or are at rest Disengaging AWD Under certain conditions it may be possible for the front gearcase to remain locked unnecessarily This condition causes increased steering effort and some vehicle speed restriction Take the following steps to disengage the AWD system l Stop the vehicle 2 Shift to reverse and back up a minimum of 10 feet 3 Stop completely 4 Shift into low gear and drive forward If the front gearcase remains locked after following these instructions return the vehicle to your dealer for service 51 EMISSION CONTROL SYSTEMS Noise Emission Control System Do not modify the engine intake or exhaust components as doing so may affect compliance with U S A EPA noise control requirements 40 CFR 205 and local noise level requirements Operation on Public Lands in the U S A Your Polaris vehicle has a spark arrestor that was tested and qualified to be in accordance with the USDA Forest Service Standard 5100 1C Federal law requires that this spark arrestor be installed and functional when the vehicle is operated on public lands Operation of off road vehicles on public lands in the U S A is regulated by 43 CFR 8343 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
90. www polarisindustries com Polaris Sales Inc 2100 Hwy 55 Medina MN 55340 Phone 763 417 8650 Fax 763 542 0599 Part No 9920220 Rev 01 Printed in USA AWARNING The engine exhaust from this product contains chemicals known to cause cancer birth defects or other reproductive harm WELCOME Thank you for purchasing a Polaris vehicle and welcome to our world wide family of Polaris owners We proudly produce an exciting line of utility and recreational products Snowmobiles All terrain vehicles ATVs RANGER utility vehicles Victory motorcycles We believe Polaris sets a standard of excellence for all utility and recreational vehicles manufactured in the world today Many years of experience have gone into the engineering design and development of your Polaris vehicle making it the finest machine we ve ever produced For safe and enjoyable operation of your vehicle be sure to follow the instructions and recommendations in this owner s manual Your manual contains instructions for minor maintenance but information about major repairs is outlined in the Polaris Service Manual and should be performed only by a Factory Certified Master Service Dealer MSD Technician Your Polaris dealer knows your vehicle best and is interested in your total satisfaction Be sure to return to your dealership for all of your service needs during and after the warranty period We also take great pride in our comp
91. x in the raised position Select a level site to dump the cargo box Do not attempt to dump or unload the vehicle while parked on an incline Engage the park brake Dismount the vehicle Ensure that the cargo is positioned evenly or toward the front of the cargo box Release the tailgate by pulling up on the tailgate latch Stand clear and pull up on the cargo box release lever 1 Lift the front of the cargo box to dump the cargo Lower the cargo box and push down securely to latch eue XY awe 4 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 47 OPERATION Driving Safely Towing Loads 4 WARNING Towing 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 towing Never load more than 150 Ibs 68 1 kg tongue weight on the towing bracket Do not operate the vehicle faster than 10 mph 16 km h when towing See page 45 Towing a trailer increases braking distance Do not tow more than the recommended weight for the vehicle See the towing capacity chart below and the specifications charts beginning
92. y will reduce your alertness and slow your reaction time In most states and provinces it s prohibited by law to drive while intoxicated or under the influence of drugs 13 SAFETY Operator Safety 4 amp WARNING 14 POTENTIAL HAZARD Operating this vehicle at excessive speeds WHAT CAN HAPPEN Loss of control accident HOW TO AVOID THE HAZARD Always travel at a speed proper for the terrain visibility and operating conditions and your experience WARNING POTENTIAL HAZARD Attempting jumps and other stunts WHAT CAN HAPPEN Loss of control accident and or vehicle overturn HOW TO AVOID THE HAZARD Never attempt jumps and other stunts Avoid exhibition driving WARNING POTENTIAL HAZARD Operating on frozen bodies of water WHAT CAN HAPPEN Severe injury or death can result if the vehicle and or the operator fall through the ice HOW TO AVOID THE HAZARD Never operate the RANGER on a frozen body of water SAFETY Operator Safety 4 WARNING POTENTIAL HAZARD Failure to inspect the vehicle before operating Failure to properly maintain the vehicle WHAT CAN HAPPEN Accident equipment damage HOW TO AVOID THE HAZARD Always inspect your RANGER before each use to make sure it s in safe operating condition Always follow the inspection and maintenance procedures and schedules described in the Owner s Manual 4 WARNING POTENTIAL HAZARD Failure to use extra caution when operating this vehicle on unfamiliar ter
93. y affect handling and control of the vehicle and may cause the vehicle to go out of control Avoid operating the vehicle on pavement If you must operate on a paved surface travel slowly and do not make sudden turns or stops WARNING POTENTIAL HAZARD Operating this vehicle without proper instruction WHAT CAN HAPPEN Loss of control accident HOW TO AVOID THE HAZARD The risk of an accident is greatly increased if the operator does not know 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 SAFETY Operator Safety 4 WARNING POTENTIAL HAZARD Operating this vehicle on public streets roads or highways WHAT CAN HAPPEN Collision with another vehicle HOW TO AVOID THE HAZARD Never operate this vehicle on any public street road or highway including dirt or gravel In many states it s illegal to operate vehicles of this type on public streets roads and highways 4 WARNING POTENTIAL HAZARD Operating this vehicle after consuming alcohol or drugs WHAT CAN HAPPEN Could seriously affect your judgment Could cause you to react more slowly Could affect your balance and perception Could result in an accident HOW TO AVOID THE HAZARD Driving a RANGER requires your full attention DO NOT drink alcohol or use drugs or medications before or while driving The

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