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Polaris 6x6 Offroad Vehicle User Manual

1. 0 69 Rear Gearcase o ec be ea Eas 70 Transmission 4X4 Crew 66 Transmission 6X6 00 67 111 INDEX O Oil Recommendation Engine 63 Operation on Public Lands 58 Operator Safety csse e ismi 13 20 Outlets Auxiliary i e soe 22 P P rk Brake este eR REPRE URS 25 Park Brake Adjustment 80 Park Brake Inspection 0 79 Parking on an Incline 00 43 Parking the Vehicle 00 43 Part Numbers eie o Ree sere 100 Periodic Maintenance Chart 59 61 Plug Gap ceneroj shee Sy cs ewe eaten Sele pes 71 Plig TOLqUe e e ode a ones x 71 Pl g ACCESSO eges eee prt plonge ns 22 Plugs Fouled ss er REPETITA 71 Plugs Spatk nds cis nets tet sod Sa Eee pre 71 Polaris Products lesse 100 Polishing the Vehicle 00 90 Power Steering iis gyda sada eres 24 Power Steering Unit Cleaning 82 Pre Ride Inspection 004 35 Product Part Numbers 4 100 Public Lands i eg ERE erre 58 PVT Break In 5i ine eee e tee 34 PVT Drying eL hotels ete REIS 75 PVT System ume rS sh Hae nae Sng S 74 75 PVT Waitin eiai ederet gain 74 15 PVT Cleaning Debris 0 dio R Radiator EE EPOR 72 Radiator Coolant Level 0 000 73 Rear Gearcase 6X6 00 0 70 Rear Suspension Adjustment 80
2. Hood Headlight 2 single beam 50W quartz halogen Taillights 10 L E D 28W Brake Light 10 L E D 3 1W Clutching See your POLARIS dealer for clutching specifications 99 POLARIS PRODUCTS Part Number Description Engine Lubricant 2870791 Fogging Oil 12 0z 355 ml Aerosol 2876244 PS 4 Full Synthetic 5W 50 4 Cycle Oil qt 95 I 2876245 PS 4 Full Synthetic 5W 50 4 Cycle Oil gal 3 8 1 Gearcase Transmission Lubricants 2878068 AGL Full Synthetic Gearcase Lubricant amp Transmission Fluid qt 95 1 2878069 AGL Full Synthetic Gearcase Lubricant amp Transmission Fluid gal 3 8 1 2877922 Demand Drive Fluid qt 95 I 2877923 Demand Drive Fluid gal 3 8 I 2870465 Pump for Gallon 3 8 I Jug Coolant 2871534 Polaris Antifreeze 60 40 Premix qt 95 1 2871323 Polaris Antifreeze 60 40 Premix gal 3 8 1 Grease Specialized Lubricants 2871312 Grease Gun Kit Premium All Season 2871322 All Season Grease 3 0z 89 ml cartridge 2871423 All Season Grease 14 0z 414 ml cartridge 2876160 ATV Angle Drive Fluid qt 95 I 2872276 ATV Angle Drive Fluid 2 5 gal 9 5 I 2871460 Premium Starter Grease 2871515 U Joint Grease 3 0z 89 ml cartridge 2871551 U Joint Grease 14 0z 414 ml cartridge 2871329 Dielectric Grease Nyogel Additives Miscellaneous 2871326 Carbon Clean 2872189 DOT 4 Brake Fluid 2871956 Loctite 565 Thread Seala
3. 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 engage the park brake before getting out of the vehicle See page 25 Always apply the brakes before engaging or releasing the park brake Always stop the engine before refueling Remove flammable material containers from the box before filling them with fuel Make sure the refueling area is well ventilated and free of any source of flame or sparks Gasoline is extremely flammable See page 18 for fuel safety warnings Always remove the ignition key when the vehicle is not in use to prevent unauthorized use by someone under the age of 16 or without a driver s license and proper training or accidental starting FOR MORE INFORMATION ABOUT SAFETY call POLARIS at 1 800 342 3764 Equipment Modifications Do not install any non POLARIS approved accessory or modify the vehicle for the purpose of increasing speed or power Any modifications or installation of non POLARIS approved accessories could create a substantial safety hazard and increase the risk of bodily injury The warranty on your POLARIS vehicle will be terminated if any non POLARIS approved equipment and or modifications have been added to the vehicle that increase speed or power The addition of certain accessories inclu
4. This indicator appears if an EFl related fault occurs Do not operate the vehicle if this warning appears Serious engine damage could result See your dealer 29 FEATURES AND CONTROLS Instrument Cluster Rider Information Center The rider information center is located in the instrument cluster All segments will light up for one second at start up If the instrument cluster fails to illuminate a battery over voltage may have occurred and the instrument cluster may have shut off to protect the electronic speedometer If this occurs take the vehicle to your POLARIS dealer for ge mp 7 BE EE Trip 1 NA NA ANA RET NA IAN TN VANUS VNTEN UN proper diagnosis The information center is set to display standard units of measurement and a 12 hour clock at the factory To change to metric and or a 24 hour clock see page 31 1 Gear Indicator This indicator displays gear shifter position H High Gear L Low Gear N Neutral R Reverse Gear Gear Signal Error or shifter between gears 2 Fuel Gauge The segments of the fuel gauge show the level of fuel in the fuel tank When the last segment clears a low fuel warning is activated All segments including the fuel icon will flash Refuel immediately Tip If the fuel icon fails to display an open or short circuit has occurred in the fuel sensor circuit See your dealer 3 Information Display Area This area displays odometer trip meter engine hour m
5. Center Suspension Independent w 9 in 23 cm of travel Rear Suspension Independent w 9 in 23 cm of travel Lubrication System Pressurized Wet Sump 96 SPECIFICATIONS RANGER 6X6 Driving System Type PVT Shift Type Single Lever Console H L N R Gear Reduction Low 8 71 1 Gear Reduction Reverse 7 91 1 Gear Reduction High 3 85 1 Drive Ratio Front 3 818 1 Drive Ratio Final 3 70 1 Tire Size Front 25x10 12 Tire Size Center Rear 25x11 12 Tire Pressure Front 10 psi 69 kPa Tire Pressure Center Rear 12 psi 83 kPa Brakes Front Rear Foot Activated 4 wheel hydraulic disc Brake Park Hand activated mechanical Hood Headlight 2 single beam 50W quartz halogen Taillights 10 L E D 28W Brake Light 10 L E D 3 1W Clutching See your POLARIS dealer for clutching specifications 97 SPECIFICATIONS Maximum Weight Capacity RANGER CREW 800 1750 lbs 795 kg includes weight of operator passengers cargo acces sories Dry Weight 1495 Ibs 678 kg Test GVW Rollover Protection System ROPS 3360 Ibs 1524 kg per OSHA 29 CFR 1928 53 Fuel Capacity 8 8 gal 33 3 1 Engine Oil Capacity 2 qts 1 9 1 Coolant Capacity 1 6 gal 6 1 Towing Capacity 2000 Ibs 907 kg Hitch Tongue Capacity 150 Ibs 68 kg Max Cargo Box Load 1000 Ibs 454 kg Over
6. Clutch malfunction See your POLARIS dealer Poor engine performance Check for fouled plugs or foreign material in gas tank or fuel lines See your dealer Slippage from failure to warm up belt Always warm up the belt by operating below 30 MPH for one mile 5 miles or more when temperature is below freezing Wrong or missing belt Install the recommended belt Improper break in Always break in a new belt and or clutch See pages 34 and 74 101 TROUBLESHOOTING Park Brake Engine Limiting Feature Fails to Disengage Possible Cause Solution Park brake is not completely disengaged Ensure lever is in forward most position Park brake connector malfunction or switch move ment or failure Disconnect the connector if temporary continued operation is necessary see your dealer promptly for service Engine Doesn t Turn Over Possible Cause Solution Low battery voltage Recharge the battery to 12 8 VDC Loose battery connections Check all connections and tighten Loose solenoid connections Check all connections and tighten Loose electronic control box connections Inspect clean reinstall connectors Engine Turns Over Fails to Start Possible Cause Solution Out of fuel Refuel Water is present in fuel Drain the fuel system and refuel Old or non recommended fuel Replace with fresh recommended fuel Fouled or defec
7. On paved surfaces pavement may seriously affect handling and control With non Polaris approved accessories they may seriously affect stability ALWAYS Wear your seat belt Vehicle rollover can cause severe injury or death Secure cab nets or doors and keep hands and feet inside vehicle at all times Wear a helmet eye protection gloves long sleeve shirt long pants and over the ankle boots Reduce speed and use extra caution when carrying passengers Avoid sharp turns or turns while applying heavy throttle Operate slowly in reverse avoid sharp turns or sudden braking Make sure passengers read and understand all safety labels ALL RIDERS MUST WEAR AN APPROVED HELMET AND PROTECTIVE GEAR ALL RIDERS MUST WEAR SEAT BELTS NEVER USE ON PUBLIC ROADS NEVER USE WITH DRUGS OR ALCOHOL READ OWNER S MANUAL FOLLOW ALL INSTRUCTIONS AND WARNINGS For your nearest Polaris dealer call 1 800 POLARIS or visit www polaris com Polaris Sales Inc PELARIS zou Medina MN 55340 Phone 1 888 704 5290 Part No 9924689 Rev 01 Printed in USA
8. PMS 419 RANGER 800 EFI RANGER 800 EPS RANGER CREW 800 EFI RANGER 6X6 Owner s Manual for Maintenance and Safety L A WARNING Read understand and follow all of the instructions and safety precautions in this manual and on all product labels Failure to follow the safety precautions could result in serious injury or death A WARNING The engine exhaust from this product contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm WELCOME Thank you for purchasing a POLARIS vehicle and welcome to our world wide family of POLARIS enthusiasts Be sure to visit us online at www polaris com for the latest news new product introductions upcoming events career opportunities and more Here at POLARIS we proudly produce an exciting line of utility and recreational products Snowmobiles e All terrain vehicles ATVs Low emission vehicles LEVs RANGERQ utility vehicles RZR sport vehicles VICTORY motorcycles e GEMQ electric vehicles We believe POLARIS sets a standard of excellence for all utility and recreational vehicles manufactured in the world today Many years of experience have gone into the engineering design and development of your POLARIS vehicle making it the finest machine we ve ever produced For safe and enjoyable operation of your vehicle be sure to follow the instructions and recommendations in this
9. sseeeseeeese 29 Inspection Pre Ride 00000 35 Instrument Cluster 2 000 29 33 Intake Restrictor Plate 0 005 63 Interference Electromagnetic 58 K Key Periodic Maintenance Chart 59 L Lamp Replacement Headlight 83 Light Swatch 2 2 ecieskete e mete 23 Lights x65 vae ES AER ORUSOREA ST T USE 83 84 Load Capacity eei censi er RE Rt rene 44 Lubrication Recommendations 62 M Main Gearcase 6X6 0 000 c eee ee eee 67 Maintenance Log 00005 109 Maintenance Periodic 59 61 Metric Display ve Rennen 31 Middle Gearcase sc occ set eee UR EDS 69 Mode B tton es serran ep aieea des 23 Modifications to Vehicle 005 15 N Noise Emission Control System 58 Oo Obstacles eee 40 Engine 3 eee nere oen 63 64 Transmission 4X4 Crew 66 Oil and Filter Care During Storage 91 Oil Change BNSine 2I teste vv ERRARE ag 64 Front Gearcase serso vesc nes 68 Main Gearcase 4X4 Crew 66 Main Gearcase 6X6 LL 67 Middle Gearcase 69 Rear Gearcase 000005 70 Transmission 4X4 Crew 66 Transmission 6X6 005 67 Oil Level Engine 55s gar OR 63 Front Gearcase 00005 68 Main Gearcase 4X4 Crew 66 Main Gearcase 6X6 L 67 Middle Gearcase
10. 2 Avoid excessively steep hills fe 3 Keep both feet on the floor 4 Always check the terrain carefully before ascending any hill 5 Never climb hills with excessively slippery or loose surfaces 6 Proceed at a steady rate of speed and throttle opening Never open the throttle suddenly 7 Never go over the crest of a hill at high speed An obstacle a sharp drop or another vehicle or person could be on the other side of the hill Driving on a Sidehill Sidehilling Driving on a sidehill is not recommended Improper procedure could cause loss of control or rollover Avoid crossing the side of any hill unless absolutely necessary I Sa La If crossing a sidehill is unavoidable follow these precautions 1 Slow down 2 Exercise extreme caution 3 Avoid crossing the side of a steep hill Driving Downhill When driving downhill follow these precautions 1 Avoid excessively steep hills 2 Drive straight downhill Avoid descending a hill at an angle which would cause the vehicle to lean sharply to one side Travel straight downhill when possible 3 Slow down 4 Apply the brakes slightly to aid in slowing 41 OPERATION Driving Through Water Your POLARIS RANGER can operate through water up to a maximum recommended depth equal to the floorboards NOTICE Immersion can result in major damage if the vehicle isn t serviced correctly and promptly After immersion always take the ve
11. 46 E Electromagnetic Interference 58 Electronic Power Steering 24 Emission Control Crankcase 58 Emission Control Exhaust 58 Emission Control Noise 0000 58 Emissions Limited Warranty 107 108 Engaging A WD exirent i suse ed 47 Engine Break In see eer mm 34 Engine Fog ing eer y Ere 92 Engine Idle Speed eek eot 78 Engine Intake Restrictor Plate 63 Engine Qil oss ice ee reo Hea eed 63 64 Engine Starting eee SERE RR Ue 36 Engine Stopping 00 0000s eee 36 BPS Lr exceeds itte ie DUE 24 Equipment Modifications 15 Error Codes Engine 0 00000 33 Exhaust Emission Control System 58 Exhaust System Warning 77 Bye Protection uz oye Panacea dak 9 F Fan Cooling cll e ER ERR eda cond 72 Filter Cleaning Air 00 004 76 Filter Systems es cese eren ocd oasis 76 Filtet AIT ses sce scale BAG SPAGNA 76 Fluid Battery iS eo uar haa hb Reps 86 PUIG Btdke 5535 be Recent ett sud 79 Fluid Change Engine Olli scsi E RR tn 64 Front Gearcase 0 00005 68 Main Gearcase 4X4 Crew 66 Main Gearcase 6X6 Lus 67 Middle Gearcase 00 69 Rear Gearcase 00000 70 Transmission 4X4 Crew 66 Transmission 6X6 04 67 Fluid Level Engine O
12. Drive Responsibly Avoid loss of control and rollovers Avoid abrupt maneuvers sideways sliding skidding or fishtailing and never do donuts Slow down before entering a turn Avoid hard acceleration when turning even from a stop Plan for hills rough terrain ruts and other changes in traction and terrain Avoid paved surfaces Avoid sidehilling riding across slopes Be Sure Riders Pay Attention and Plan Ahead If you think or feel the vehicle may tip or roll reduce your risk of injury Keep a firm grip on the steering wheel or hand holds and brace yourself Rollovers have caused f severe injuries and death e Do not put any part of your body outside of the vehicle for any even on flat open areas reason LOCATE AND READ OWNER S MANUAL FOLLOW ALL INSTRUCTIONS AND WARNINGS ALWAYS REVIEW SAFETY VIDEO AND TAKE ROHVA TRAINING rohva org 7179984 Payload Warning Payload Warning WARNING RANGER Never Exceed If Total Payload Exceeds 4x4 Gas 25 mph 40 kph 630 Ibs 285 kg CA 4x4 Gas 40 mph 65 kph 630 Ibs 285 kg Crew Gas 35 mph 56 kph 1230 Ibs 558 kg 4x4 Diesel 25 mph 40 kph 1080 Ibs 490 kg 7180172 SAFETY Safety Labels and Locations Load Passenger Tire Pressure Warning Storage Box Load 250 Ibs 113 kg WARNING Never carry passengers in cargo box Passengers can be thrown off This can cause serious injury or death IMPROPER T
13. Transmission System suus 74 75 Transmission Warning 74 75 Transmission Drying 0 75 Transporting the Vehicle 93 Tread Depth irse tete ees edie 81 V Vehicle Identification Numbers 6 Vehicle Immersion 000005 76 Vehicle Transport selle esses 93 WwW Warning Symbols 0 0 000000 eee 4 Warning Transmission Modification 74 75 Washing the Vehicle 0 90 Water Immersion of Vehicle 76 Wheel Installation 00 0 eee eee 82 Wheel Nut Inspection 0 81 Wheel Nut Torque 0 00000 81 Wheel Removal sso cei Ree Res 82 Winch Cable Care nie secen poe Lee tee 55 Winch Maintenance and Service Safety 57 Winch Operation 004 51 54 Winch Safety Precautions 49 50 Winch Shock Loading 0 56 113 PMS 419 AWARNING Improper vehicle use can result in SEVERE INJURY or DEATH NEVER Operate If you are under age 16 and without a valid driver s license Without first viewing safety video and taking a ROHVA training course at www rohva org On excessively steep hills On public roads unless designated for off road use With a passenger who is not seated in a passenger seat or with passengers under age 12 or who cannot comfortably reach the floor and hand holds
14. if applicable 50 H 6M Inspect coolant strength seasonally pressure test system yearly gt Oil lines fasteners 50H 6M Inspect for leaks and loose fittings Park brake cable tension 100 H 6M Check tension adjust gt Engine oil change 100 H 6M Perform a break in oil change at one month gt Oil filter change 100 H 6M Replace with oil change gt Front Gearcase oil if equipped 100 H 12M Change fluid gt Middle Gearcase oil if equipped 100 H 12M Change fluid gt Rear gearcase oil if equipped 100 H 12M Change fluid gt Transmission oil 100 H 12M Change fluid D Fuel system 100 H 12M Check for leaks at tank cap lines fuel E valve filter pump throttle body replace lines every two years gt Radiator if applicable 100 H 12M 5 Inspect clean external surfaces gt Cooling Hoses if applicable 100 H 12M Inspect for leaks gt Engine mounts 100 H 12M z Inspect Exhaust muffler pipe 100 H 12M Inspect E Spark plug 100 H 12M Inspect replace as needed D Ignition timing 100 H 12M 7 Inspect Wiring 100 H 12M Inspect for wear routing security apply dielectric grease to connectors sub jected to water mud etc Clutches drive and driven 100 H 12M Inspect clean replace worn parts D Front wheel bearings 100 H 12M Inspect replace as needed D Brake fluid 200 H 24M 2 Change every two years Spark arrester 300 H 36 M Clean out Idle speed Adjust as needed D Toe adjustment Inspec
15. inspect and adjust park brake cable tension Tip If performing this service is difficult due to conditions or location open the hood and temporarily disconnect the park brake connector This will inactivate the limiting function Reconnect the connector as soon as possible and adjust the park brake cable to proper tension 1 Position the vehicle on a level surface 2 Shift the transmission to neutral 3 Loosen or tighten the nuts on the lever end of the park brake cable as needed 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 59 1 Position the vehicle on level ground 2 Lightly turn the steering wheel left and right There should be 0 8 1 0 20 25 mm of freeplay 3 If there is excessive freeplay or strange noises or the steering feels rough or catchy have the steering system inspected by an authorized POLARIS dealer Suspension Adjustments The front and rear suspensions can be adjusted to provide a stiffer suspension if necessary 1 Remove the top shock mounting bolts from the inside mounting holes 2 Reposition the shocks to the outside mounting holes 3 Reinstall the shock mounting bolts Torque to 30 ft Ibs 40 Nm Spring Adjustment Adjust the front and rear shock Outside Mounting Holes absorber springs by rotating the adjustment cam either clockwise or counterclockwise to incr
16. pre filter Inspect clean 76 Air box sediment tube Drain deposits whenever visible 76 Headlamp Check operation apply POLARIS dielectric grease 83 when lamp is replace Brake light tail lamp Check operation apply POLARIS dielectric grease 83 when lamp is replace Seat Belts Check length of belt for damage check latches for 27 proper operation Cab nets or doors Check for wear or damage ensure proper installation 26 35 OPERATION Starting the Engine 1 Always start the engine outdoors or in a well ventilated area Sit in the driver s seat and fasten the seat belt Secure the cab nets or doors Apply the brakes Engage the park brake Shift the transmission to neutral AP wn Do not press the throttle pedal while starting the engine Turn the ignition key past the ON RUN position to START Engage the starter for a maximum of five seconds Release the key when the engine starts 6 If the engine does not start within five seconds release the ignition switch and wait five seconds Repeat steps 5 and 6 until the engine starts 7 Vary the engine RPM slightly with the throttle to aid in warm up until the engine idles smoothly NOTICE Operating the vehicle immediately after starting could cause engine damage Allow the engine to warm up for several minutes before operating the vehicle Stopping the Engine 1 Release the throttle pedal completely and brake to a complete stop 2 Turn the engine off 3 Engage the park bra
17. slippery or loose terrain 2 Slow down before entering slippery areas 3 Maintain a high level of alertness reading the trail and avoiding quick sharp turns which can cause skids 4 Engage all wheel drive before wheels begin to lose traction NOTICE Severe damage to the drive train may occur if the AWD is engaged while the wheels are spinning Always allow the wheels to stop spinning before engaging AWD 5 Correct a skid by turning the steering wheel in the direction of the skid Never apply the brakes during a skid Sideways Turn in skid direction of COSC D C 2e SA Sy 4 CILS lt gt T4 C C Co C BY BS CC e 39 OPERATION Driving Over Obstacles Follow these precautions when operating over obstacles 1 Always check for obstacles before operating in a new area 2 Look ahead and learn to read the terrain Be constantly alert for hazards such as logs rocks and low hanging branches 3 Travel slowly and use extra caution when operating on unfamiliar terrain Not all obstacles are immediately visible 4 Avoid operating over large obstacles such as large rocks and fallen trees If unavoidable use extreme caution and operate slowly 5 Always have all passengers dismount and move away from the vehicle before operating over an obstacle that could cause a rollover 40 OPERATION Driving Uphill Whenever traveling uphill follow these precautions 1 Always travel straight uphill
18. the trip meter display contains a decimal point but the odometer displays without a decimal point Hour Meter Mode This mode logs the total hours the engine has been in operation Tachometer Mode The engine RPM is displayed digitally Tip Small fluctuations in the RPM from day to day may be normal because of changes in humidity temperature and elevation Programmable Service Interval When the hours of engine operation equal the programmed service interval setting the wrench icon will flash for 5 seconds each time the engine is started When this feature is enabled it provides a convenient reminder to perform routine maintenance The service interval is programmed at 50 hours at the factory Use the following procedure to change the service interval 1 Press the MODE button until remaining service hours display 2 Press and hold the MODE button 3 When the service hours flash press and release the MODE button to advance the hours to the desired setting including OFF Press and hold the MODE button to set the new service hour interval Diagnostic Display Mode The EFI diagnostic display mode is for informational purposes only Please see your POLARIS dealer for all major repairs The diagnostic mode is accessible only when the check engine warning indicator activates after the key has been turned on Leave the key on if you want to view the active code failure code The diagnostic mode becomes inaccessible if the ke
19. wear fraying or stiffness If any damage is found or if the seat belt does not operate properly have the seat belt system checked and or replaced by an authorized POLARIS dealer 4 To clean dirt or debris from the seat belts sponge the straps with mild soap and water Do not use bleach dye or household detergents 27 FEATURES AND CONTROLS Rollover Protective Structure ROPS The Rollover Protective Structure ROPS on this vehicle meets OSHA 1928 53 rollover performance requirements Always have your authorized POLARIS dealer thoroughly inspect the ROPS if it ever becomes damaged in any way No device can assure occupant protection in the event of a rollover Always follow all safe operating practices outlined in this manual to avoid vehicle rollover WARNING Vehicle rollover could cause severe injury or death Always avoid operating in a manner that could result in vehicle rollover Storage Compartments A storage compartment is located under the driver s seat and on CREW models under the left rear seat On 6X6 models a lockable storage box is located behind the ROPS Always make sure the cover is securely latched before operating The box is accessible from both sides of the vehicle ROPS all models Small Storage Compartment left side only Large Storage Compartment CREW only ic a 28 Instrument Cluster High water pressure may damage components
20. ALL IMPLIED WARRANTIES INCLUDING BUT NOT LIMITED TO ANY IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE ARE LIMITED IN DURATION TO THE WARRANTY PERIOD DESCRIBED HEREIN POLARIS DISCLAIMS ALL EXPRESS WARRANTIES NOT STATED IN THIS WARRANTY Some states do not allow limitations on how long an implied warranty lasts so the above limitation may not apply if it is inconsistent with the controlling state law This limited warranty excludes failures not caused by a defect in material or workmanship This limited warranty does not cover damage due to accidents abuse or improper handling maintenance or use This limited warranty also does not cover any engine that has been structurally altered or when the vehicle has been used in racing competition This limited warranty also does not cover physical damage corrosion or defects caused by fire explosions or other similar causes beyond the control of POLARIS Owners are responsible for performing the scheduled maintenance identified in the owner s manual POLARIS may deny warranty claims for failures that have been caused by the owner s or operator s improper maintenance or use by accidents for which POLARIS has no responsibility or by acts of God Any qualified repair shop or person may maintain replace or repair the emission control devices or systems on your vehicle POLARIS recommends that you contact an authorized POLARIS dealer to perform any service that may be necessa
21. Overall Width tires 58 in 147 3 cm Overall Height 76 in 193 cm Wheelbase 76 in 193 cm Cargo Box Dimensions Inside 36 5 x 54 x 11 5 in 93 x 137 x 29 cm Ground Clearance 11 5 in 29 2 cm Min Turning Radius 158 in 401 cm Engine 4 valve 4 stroke twin cylinder with counter balance Displacement 760 cc Bore x Stroke 80 x 76 5 Alternator Output 500 W 3000 RPM Compression Ratio 10 0 1 Starting System Electric Fuel System Electronic Fuel Injection Ignition System Bosch EFI ECU Controlled Spark Plug Gap RC7YC3 035 in 0 9 mm Front Suspension Dual A arm w 9 6 in 24 4 cm of travel Rear Suspension Independent w 9 in 23 cm of travel Lubrication System Pressurized Wet Sump 94 SPECIFICATIONS RANGER 800 EFI EPS Driving System Type PVT 4 wheel independent shaft lockable differential Shift Type Single Lever H L N R Gear Reduction Low 7 70 1 Gear Reduction Reverse 7 00 1 Gear Reduction High 3 6 1 Drive Ratio Front 3 818 1 Drive Ratio Rear 3 105 1 Tire Size Front 25 x 10 12 26 x 9 12 for select models Tire Size Rear 25 x 11 12 26x 11 12 for select models Tire Pressure Front 10 psi 69 KPa Tire Pressure Rear 12 psi 83 KPa Brakes Front Rear Foot Activated 4 wheel hydraulic disc Brake Park Hand activated mechani
22. Receiver Hitchs ime rate erste Codon eai tds 24 Removing the Vehicle from Storage 93 Reverse Operation serere vdana sims rastas 43 Rider Information Center 30 33 Riding Gear cist hos sank eem ex e rone eee 8 9 Rollover Protective Structure 28 ROPS Cab Frame esee e cde eee eee 28 112 S Safety Labels ui osl c Eno x 10 12 Safety Symbols peer rete en ets 4 Safety Winch Maintenance 57 Seat Belts saene arenes Sa heiaes dat ohare Ghee 27 Seat Removal sse Rp ds Gob RETE Re 27 Severe Use Definition 59 SIET a Peer Tr PIECE 22 Shifting Gears sss eni b e ERR eee Hees oes 22 Shock Loading the Winch 56 Shock Spring Adjustment 0 80 Signal Words ore nesai RERUM des 4 Spark Arrester Warning 00 TI Spark Plug Gap 0 0 eee 71 Spark Plug Inspection 0 71 Spark Plug Recommendations 71 Spark Plug Torque 0 0005 71 Spark Plugs reor te Ree nes 71 Spark Plugs Fouled i rseseriea n aa 71 Specifications 4X4 000 94 95 Specifications 6X6 00000 96 97 Specifications Crew 00 98 99 Specifications Gearcase 0000 65 Speed Towing mex Rer emus 45 Speedometer 1 caw ss de ere eee 29 Spring Shock Adjustment 80 Stabilizing the Fuel 0 02 e eee 91 S
23. Wash the vehicle by hand or with a garden hose using mild soap Do not use alcohol to clean the instrument cluster Do not allow insect sprays to contact the lens Speedometer The speedometer displays vehicle speed in either miles per hour MPH or kilometers per hour km h See page 31 Center Indicator Lamps FEATURES AND CONTROLS Speedometer Indicator Rider Information MODE Button Lamp Indicates Condition Vehicle Speed When standard mode is selected speed displays in miles per hour When metric mode is selected speed displays in kilometers per hour E Over Temperature This lamp illuminates to indicate an overheated engine If the indicator flashes the overheating condition remains and the system will automatically reduce engine power f EPS Warning This indicator illuminates briefly when the key is turned to the ON position If the light remains on the EPS system is inoperative See your authorized POLARIS dealer for service Neutral This lamp illuminates when the transmission is in neutral and the ignition key is in the ON position High Beam This lamp illuminates when the headlamp switch is set to high beam Helmet Seat Belt This lamp flashes for several seconds when the key is turned to the ON position The lamp is a reminder to the operator to ensure all riders are wearing helmets and seat belts before operating NI ED Check Engine
24. a receiver hitch bracket for a trailer hitch To avoid injury and property damage always heed the warnings and towing capacities outlined on pages 44 45 Brake Pedal Throttle l Brak Depress the brake pedal to slow or stop the vehicle Apply Pedal Podal aS the brakes while starting the engine Throttle Pedal Push the throttle pedal down to increase engine speed Spring pressure returns the pedal to the rest position when released Always check that the throttle pedal returns normally before starting the engine Make sure there s adequate throttle pedal freeplay See page 78 for throttle pedal adjustment procedures Adjustable Steering Wheel The steering wheel can be tilted upward or downward for rider preference Lift and hold the adjustment lever toward you while moving the steering wheel upward or downward Release the lever when the steering wheel is at the desired position Electronic Power Steering EPS Electronic power steering if equipped engages when the ignition key is turned to the ON position EPS remains engaged whether the vehicle is moving or idle To conserve battery power the EPS will shut down 5 minutes after the engine is stopped if the key remains in the ON position The EPS warning indicator will illuminate to indicate the EPS has shut down Turn the key off and on to reset the unit See page 29 for EPS Warning Indicator information Fuel Cap The fuel tank filler cap is located on the righ
25. any POLARIS Servicing Dealer to perform warranty service In the country where your product was purchased Warranty or Service Bulletin repairs must be done by an authorized POLARIS dealer If you move or are traveling within the country where your product was purchased Warranty and Service Bulletin repairs may be requested from any authorized POLARIS dealer that sells the same line as your product Outside the country where your product was purchased If you are traveling temporarily outside the country where your product was purchased you should take your product to an authorized POLARIS dealer You must show the dealer photo identification from the country of the selling dealer s authorized location as proof of residence Upon residence verification the servicing dealer will be authorized to perform the warranty repair If you move If you move to another country be sure to contact POLARIS Customer Assistance and the customs department of the destination country before you move Product importation rules vary considerably from country to country You may be required to present documentation of your move to POLARIS in order to continue your warranty coverage You may also be required to obtain documentation from POLARIS in order to register your product in your new country You should warranty register your product at a local POLARIS dealer in your new country immediately after you move to continue your warranty coverage and to ensure that
26. at an angle it may be necessary to re distribute the winch cable across the winch drum You will need an assistant to perform this task Release the clutch on the winch Feed out the winch cable that is unevenly bunched up in one area Re engage the winch clutch Have an assistant pull the winch cable tightly with about 100 Ibs 45 kg of tension using the hook strap Slowly winch the cable in while your assistant moves the end of the winch cable back and forth horizontally to evenly distribute the winch cable on the drum Doing this reduces the chances of the winch cable wedging itself between lower layers of winch cable m gom m 54 WINCH GUIDE Winch Cable Care For your safety always replace POLARIS winch parts including the cable with genuine POLARIS replacement parts available at your authorized POLARIS dealer WARNING Use of worn or damaged cable could lead to sudden failure and SEVERE INJURY 1 Always inspect your winch before each use Inspect for worn or loose parts including mounting hardware Never use the winch if any part needs repair or replacement 2 Always inspect your winch cable before each use Inspect for worn or kinked winch cable A Akinked winch cable made of wire rope is shown at right Even after being straightened out this cable has already been permanently and severely damaged Promptly discontinue use of a winch cable in this condition B Akinked winch cable made of wire
27. 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 Seat Belts This POLARIS vehicle is equipped with three point lap and diagonal seat belts on all seats Always make sure the seat belts are secured for all riders before operating WARNING Falling from a moving vehicle could result in serious Latch Plate injury or death Always fasten your seat belt securely before operating or riding in the RANGER To wear the seat belt properly follow this procedure 1 Pull the seat belt latch downward and across your chest toward the buckle at the inner edge of the seat The belt should fit snugly across your hips and diagonally across your chest Make sure the belt is not twisted 2 Push the latch plate into the buckle until it clicks 3 Release the strap it will self tighten Buckle 4 To release the seat belt press the square red button in the buckle s center Seat Belt Inspection Inspect all seat belts for proper operation before each use of the vehicle 1 Push the latch plate into the buckle until it clicks The latch plate must slide smoothly into the buckle A click indicates that it s securely latched 2 Push the red release latch in the middle of the buckle to make sure it releases freely 3 Pull each seat belt completely out and inspect the full length for any damage including cuts
28. hands on the steering wheel if driving or on a passenger hand hold Never permit a guest to operate this vehicle unless the guest has read this manual and all product labels Always use the cab nets or doors while riding in this vehicle Always keep hands feet and all other body parts inside the vehicle at all times Always wear a helmet eye protection gloves long sleeve shirt long pants and over the ankle boots Never use this vehicle with drugs or alcohol as these conditions impair judgment and reduce operator reaction time INTRODUCTION Vehicle Identification Numbers Record your vehicle s identification numbers and key number in the spaces provided Remove the spare key and store it in a safe place An ignition key can be duplicated only by ordering a POLARIS key blank using your key number and mating it with one of your existing keys The ignition switch must be replaced if all keys are lost Engine Serial Number VIN 4X4 6X6 Vehicle Model Number Frame VIN Engine Serial Number Key Number INTRODUCTION European Vibration and Noise The driver perceived noise and hand arm and whole body vibration levels of this machinery is measured per prEN 15997 The operating conditions of the machinery during testing The vehicles were in like new condition The environment was controlled as indicated by the test procedure s The uncertainty of vibration exposure measurement is depen
29. in order to meet vehicle class regulations This plate MUST NOT be removed for any reason Removal of the intake restrictor plate will void the warranty on the vehicle Engine Oil Always check and change the engine oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 59 Always change the oil filter whenever changing oil WARNING Vehicle operation with insufficient deteriorated or contaminated engine oil will cause accelerated wear and may result in engine seizure accident and injury Always perform the maintenance procedures as outlined in the Periodic Maintenance Chart Oil Recommendations POLARIS recommends the use of POLARIS PS 4 5W 50 4 Cycle Oil or a similar oil See page 100 for the part numbers of POLARIS products NOTICE Mixing brands or using a non recommended oil may cause serious engine damage Always use the recommended oil Never substitute or mix oil brands Always check and change the oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 59 Always use the recommended engine oil Oil Check The oil dipstick and fill tube is located on the engine 1 Position the vehicle on a level surface 2 Remove the seat and the underseat storage box Dipstick 3 Lift the lever lock to remove the dipstick Wipe it dry with a clean cloth 4 Reinstall the dipstick completely but do not lock it The dipstick must be screwed completely in to keep the angle and depth o
30. loss of control or accident Always use the size and type of tires specified for your vehicle Always maintain proper tire pressure as described in the owner s manual and on safety labels Operating on Slippery Terrain Failure to use extra caution when operating on excessively rough slippery or loose terrain could cause loss of traction loss of control accident or rollover Do not operate on excessively slippery surfaces Always slow down and use additional caution when operating on slippery surfaces Skidding or sliding due to loss of traction can cause loss of control or rollover if tires regain traction unexpectedly Always follow proper procedures for operating on slippery surfaces as described in this owner s manual See page 39 Operating on Frozen Bodies of Water Severe injury or death can result if the vehicle and or the operator fall through the ice Never operate the vehicle on a frozen body of water unless you have first verified that the ice is sufficiently thick to support the weight and moving force of the vehicle you and your passengers and your cargo together with any other vehicles in your party Always check with local authorities and residents to confirm ice conditions and thickness over your entire route Vehicle operators assume all risk associated with ice conditions on frozen bodies of water Unauthorized Use of the Vehicle Leaving the keys in the ignition can lead to unauthorized use of the vehicle by someone un
31. may damage components and could remove paint and labels Avoid directing the water stream at the following items Wheel bearings Brakes Switches and controls Radiator Cab and body panels Electrical components and wiring Transmission seals Labels and decals If an informational or graphic label becomes illegible or comes off contact your POLARIS dealer to purchase a replacement Replacement safety labels are provided by POLARIS at no charge Polishing the Vehicle POLARIS recommends the use of common household aerosol furniture polish for polishing the finish on your POLARIS vehicle Follow the instructions on the container Avoid the use of automotive products some of which can scratch the finish of your vehicle Always use clean cloths and pads for cleaning and polishing Old or reused cloths and pads may contain dirt particles that will scratch the finish 90 MAINTENANCE Cleaning and Storage Storage Tips NOTICE Starting the engine during the storage period will disturb the protective film created by fogging and damage could occur Never start the engine during the storage period Clean the Exterior Make any necessary repairs and clean the vehicle as recommended See page 90 Stabilize the Fuel 1 Fill the fuel tank 2 Add POLARIS Carbon Clean Fuel Treatment or POLARIS Fuel Stabilizer Follow the instructions on the container for the recommended amount Carbon Clean removes water from fuel systems st
32. miles of vehicle travel or 30 calendar months from the date of purchase whichever comes first The warranty period for ATVs less than 100cc emissions certified vehicles starts on the date of purchase by original retail purchaser and continues for a period of 250 hours of engine operation 2500 kilometers 3100 miles of vehicle travel or 30 calendar months from the date of purchase whichever comes first This EPA emissions warranty period is extended for at least as long as the standard factory warranty that Polaris provides on the vehicle as a whole The EPA emissions warranty period does not further extend if you purchase additional warranty coverage in the form of a service contract or other paid warranty extension but emission related parts may be covered subject to the terms of any such paid service contract or paid warranty extension This emissions limited warranty covers components whose failure increases the vehicle s regulated emissions and it covers components of systems whose only purpose is to control emissions Repairing or replacing other components not covered by this warranty is the responsibility of the vehicle owner This emissions limited warranty does not cover components whose failure does not increase the vehicle s regulated emissions For exhaust emissions emission related components include any engine parts related to the following systems Air induction system Ignition system Fuel system Exhaust gas recirculati
33. 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 POLARIS POLARIS RANGER and RANGER CREW are registered trademarks of POLARIS Industries Inc Copyright 2013 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 The original instructions for this vehicle are in English Other languages are provided as translations of the original instructions Printed in U S A 2014 RANGER 800 EFI RANGER 800 EPS RANGER 6X6 RANGER CREW 800 Owner s Manual P N 9924689 2 TABLE OF CONTENTS Introduction ssasecesthetk
34. rope that has been straightened out is shown at right Even though it may look usable the cable has been permanently and severely damaged It can no longer transmit the load that it could prior to kinking Promptly discontinue use of a winch cable in this condition C Awinch cable made of synthetic rope should be inspected for signs of fraying Replace the cable if fraying is observed shown at right Promptly discontinue use of a winch cable in this condition D Also replace the winch cable if there are fused or melted fibers Such an area of the synthetic rope will be stiff and appear smooth or glazed Promptly discontinue use of a winch cable in this condition 59 WINCH GUIDE Shock Loading WARNING Your winch cable is very strong but it is NOT designed for dynamic or shock loading Shock loading may tension a winch cable beyond its strength and cause the cable to break The end of a broken winch cable under such high loading can cause SEVERE INJURY or DEATH to you and other bystanders Winch cables are designed to NOT absorb energy This is true of both wire rope and synthetic rope winch cables 1 Never attempt to jerk a load with the winch For example never take up slack in the winch cable by moving the winching vehicle in an attempt to move an object This is a dangerous practice It generates high winch cable loads that may exceed the strength of the cable Even a slowly moving vehicle can create large shoc
35. serious injury or death if the throttle pedal sticks during operation Always check the pedal for free movement and return before starting the engine and occasionally 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 Throttle Freeplay Inspection If the throttle pedal 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 on page 59 Adjust the freeplay if necessary 1 Apply the brakes Engage the park brake Shift the transmission to neutral Throttle Pedal 2 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 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 Throttle Freeplay Adjustment 1 Remove the seat 2 Locate the throttle cable adjuster 3 Squeeze the end of the rubber boot and slide it far enough to expose
36. than the upper level line add brake fluid to the upper MAX line 5 Apply the brake forcefully for a few seconds and check for fluid leakage around the fittings Brake Inspection 1 Check the brake system for fluid leaks 2 Check the brake pedal for excessive travel or a spongy feel 3 Check the friction pads for wear damage and looseness Check brake discs for signs of cracks excessive corrosion warping or other damage Clean any grease using an approved brake cleaner or alcohol WARNING Do not apply WD 40 or any petroleum product to brake discs These types of products are flammable and may also reduce the friction between the brake pad and caliper 5 Inspect the brake disc spline and pad wear surface for excessive wear Change pads when worn to 3 64 1 mm Park Brake Inspection Park Brake Release 1 Apply the brakes 2 Pullthe park brake lever downward as far as possible 3 Check the vehicle for movement The vehicle should not roll while parked If the vehicle moves adjust the park brake 79 MAINTENANCE Brakes Park Brake Adjustment Inspect and adjust park brake cable tension after the first 25 hours of operation and every 100 hours thereafter to ensure proper cable tension Loss of tension in the park brake cable may cause BRAKE to display in the rider information center along with activation of the limiting feature If this occurs move the park brake lever to the forward most position then
37. the end of the inline cable adjuster 4 Loosen the adjuster lock nut 5 Rotate the boot to turn the adjuster until 1 16 to 1 8 1 5 3 mm of freeplay is achieved at the throttle pedal See page Boot 78 Tip While adjusting lightly flip the throttle pedal up and down 6 Tighten the lock nut 7 Squeeze the end of the rubber boot and slide it over the cable LocKN adjuster to its original position ock Nut Adjuster 78 MAINTENANCE Brakes The front and rear brakes are hydraulic disc type brakes activated by the brake pedal See page 24 Brake Fluid Inspect the brake system routinely Inspect the level of the brake fluid before each operation WARNING After opening a bottle of brake fluid always discard any unused portion Never store or use a partial bottle Brake fluid is hygroscopic meaning it rapidly absorbs moisture from the air The moisture causes the boiling temperature of the brake fluid to drop which can lead to early brake fade and the possibility of accident or severe injury Change the brake fluid every two years and any time the fluid becomes contaminated the fluid level is below the minimum or if the type and brand of the fluid in the reservoir are unknown 1 Position the vehicle on a level surface Maximum Minimum 2 View the brake fluid level at the reservoir in the driver s side wheel well 3 The level should be between the upper MAX and lower MIN level lines 4 If the fluid level is lower
38. the engine to cool before removing the pressure cap 2 Slowly remove the radiator cap 3 View the coolant level through the opening 4 Use a funnel and slowly add coolant as needed Tip This procedure is required only if the cooling system has been drained for maintenance and or repair But if the overflow bottle has run dry the level in the radiator should also be inspected 5 Reinstall the pressure cap Use of a non standard pressure cap will not allow the recovery system to function properly See your dealer for the correct replacement part 73 MAINTENANCE POLARIS Variable Transmission PVT System AWARNING Failure to comply with the instructions in this warning can result in severe injury or death Do not modify any component of the PVT system Doing so may reduce its strength so that a failure may occur at a high speed The PVT system has been precision balanced Any modification will cause the system to be out of balance creating vibration and additional loads on components The PVT system rotates at high speeds creating large amounts of force on clutch components As the owner you have the following responsibilities for your own safety and the safety of others Always follow all recommended maintenance procedures Always look for and remove debris inside and around the clutch and vent system when replacing the belt See your dealer as outlined in the owner s manual This PVT system is intended for use on POLAR
39. the first 25 hours of operation and every 100 hours thereafter to ensure proper cable tension See page 80 PVT Break in Clutches Belt A proper break in of the clutches and drive belt will ensure a longer life and better performance Break in the clutches and belt by operating at slower speeds during the break in period as recommended Pull only light loads Avoid aggressive acceleration and high speed operation during the break in period If a belt fails always clean any debris from the duct and from the engine compartment 34 Pre Ride Inspection OPERATION Failure to inspect and verify that the vehicle is in safe operating condition before operating increases the risk of an accident Always inspect the vehicle before each use to make sure it s in safe operating condition Item Remarks Page Brake system pedal travel Ensure proper operation Brake fluid Ensure proper level 79 Front suspension Inspect lubricate if necessary 62 Rear suspension Inspect lubricate if necessary 62 Steering Ensure free operation 80 Tires Inspect condition and pressure 81 Wheels fasteners Inspect ensure fastener tightness 81 Frame nuts bolts fasteners Inspect ensure tightness Fuel and oil Ensure proper levels 30 63 Coolant level Ensure proper level 73 Coolant hoses Inspect for leaks Throttle Ensure proper operation 78 Indicator lights switches Ensure operation 23 Air filter
40. under load Never use the winch for lifting or transporting people Never use the winch to hoist or suspend a vertical load Never immerse or submerse your winch in water Take your winch to your dealer for service if this occurs Always inspect your winch and winch cable before each use Never winch the hook fully into the winch This can cause damage to winch components Unplug the remote control from the vehicle when the winch is not in use to prevent inadvertent activation and use by unauthorized persons Never grease or oil the winch cable This will cause the winch cable to collect debris that will shorten the life of the cable WINCH GUIDE Winch Operation Read the Winch Safety Precautions in the preceding pages before using your winch Tip aad practicing the operation and use of your winch before you actually need to use it in the field AWARNING Improper winch use can result in SEVERE INJURY or DEATH Always follow all winch instructions and warnings in this manual Each winching situation is unique Take your time to think through the winching you are about to do Proceed slowly and deliberately Never hurry or rush during winching Always pay attention to your surroundings You may need to change your winching strategy if it is not working Always remember that your winch is very powerful There are simply some situations that you and your winch will not be able to deal with Do not be afrai
41. 7 Add the recommended oil 8 Reinstall the fill plug Torque to specification 9 Check for leaks Dispose of used oil properly 68 Gearcases Middle Gearcase 6X6 Always check and change the middle gearcase oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 59 Maintain the oil level even with the bottom thread of the fill plug hole Refer to the Gearcase Specifications Chart on page 65 for recommended lubricants capacities and torque specifications See page 100 for the part numbers of POLARIS products MAINTENANCE The middle gearcase fill plug 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 needed 4 Reinstall the fill plug Torque to specification Oil Change 1 Remove the fill plug 2 Place a drain pan under the drain plug 3 Remove the drain plug Allow the oil to drain completely 4 Clean and reinstall the drain plug Torque to specification 5 Add the recommended fluid 6 Reinstall the fill plug Torque to specification 7 Check for leaks Discard used oil properly O of E 07199 9 cA X Que e F d tM poe Ti O i uw 9 1 G 9 Ri Fill Plug Drain Plug 69 MAINTENANCE Gearcases Rear Gearcase 6X6 Always check and change the rear gearcase oil at the intervals outlined in the Periodic Maintenance Chart beginning on pa
42. 8 V 8 Z87 1 or CE Make sure protective eye wear is kept clean Gloves Wear gloves for comfort and for protection from sun cold weather and other elements Boots Wear sturdy over the ankle boots for support and protection Never ride a POLARIS vehicle with bare feet or sandals Clothing Wear long sleeves and long pants to protect arms and legs Rider Comfort Under certain operating conditions heat generated by the engine and exhaust system can elevate temperatures in the driver and passenger cab area The condition occurs most frequently when a vehicle is being operated in high ambient temperatures at low speeds and or high load conditions for an extended period of time The use of certain windshield roof and or cab systems may contribute to this condition by restricting airflow Any discomfort due to heat buildup in this area can be minimized by wearing proper riding apparel and by varying speeds to increase airflow SAFETY Safety Labels and Locations Warning labels have been placed on the vehicle for your protection Read and follow the instructions of the labels on the vehicle carefully If any of the labels depicted in this manual differ from the labels on your vehicle always read and follow the instructions of the labels on the vehicle If any label becomes illegible or comes off contact your POLARIS dealer to purchase a replacement Replacement safety labels are provided by POLARIS at no charge The part number is prin
43. CARGO Always load the cargo box with the load as far forward and as low as possible When operating over rough or hilly terrain reduce speed and cargo to maintain stable driving conditions Always operate the vehicle with extreme care when hauling or towing loads Slow down and drive in the lowest gear available SECURE ALL LOADS BEFORE OPERATING Unsecured loads can create unstable operating conditions which could result in loss of control of the vehicle OPERATE ONLY WITH STABLE AND SAFELY ARRANGED LOADS When handling off centered loads that cannot be centered securely fasten the load and operate with extra caution Always attach the tow load to the hitch point designated for your vehicle HEAVY LOADS CAN CAUSE BRAKING AND CONTROL PROBLEMS Use extreme caution when applying brakes with a loaded vehicle Avoid terrain or situations that may require backing downhill USE EXTREME CAUTION when operating with loads that extend over the rack sides Stability and maneuverability may be adversely affected causing vehicle rollover DO NOT TRAVEL FASTER THAN THE RECOMMENDED SPEEDS Vehicle should never exceed 10 MPH 16 km h while towing a load on a level grass surface Vehicle speed should never exceed 5 MPH 8 km h when towing loads in rough terrain while cornering or while ascending or descending a hill Load Capacity The RANGER has been designed to carry or tow specific capacities Always read and understand the load distribution warn
44. EREERTIERRS E ES RERERGVETERRERE 4 Safely uisus EFE E NEN ee NEM A aces aus RW 8 Features and Controls 000 cece eee ee eee eee 21 Operation cciccceactkcseapesioosteeceuteseseeesuas 34 WINCH Gude 254 ods cccee red EEn aeee ENSE ERRES ERE 49 Emission Control Systems 000 0c eee ee ee eee 58 Maintenance sce nc seme ses es See eee aes ciee ee EM ud 59 Specifications eokebve tee enshetdeseetscses sede eons 94 POLARIS Products lt 24 6655 2s tcne8theeisitaanwes 100 Troubleshooting usur RRERERRE ER ER bade e ee nee 101 Warranty rcl E oe ERE EOE a AE E e UE E 104 Maintenance LOG isse REFERS ERES A EREERE 109 INGOX sos bce ctashe brem RPEEREEEEEENSEEReSRPIuEXEFEEES 110 INTRODUCTION The RANGER is an off road vehicle Familiarize yourself with all laws and regulations concerning the operation of this vehicle in your area The following signal words and symbols appear throughout this manual and on your vehicle Your safety is involved when these words and symbols are used Become familiar with their meanings before reading the manual A The safety alert symbol indicates a potential personal injury hazard DANGER A DANGER indicates a hazardous situation that if not avoided will result in death or serious injury WARNING A WARNING indicates a hazardous situation that if not avoided could result in death or serious injury CAUTION A CAUTION indicates a hazardous situation that if not avoided could result i
45. IRE PRESSURE OR OVERLOADING CAN CAUSE LOSS OF CONTROL RESULTING IN SERIOUS INJURY OR DEATH Reduce speed and allow greater distance for braking when carrying cargo Overloading or carrying tall off center or unsecured loads will increase your risk of losing control Loads should be centered and carried as low as possible in box For stability on rough or hilly terrain reduce speed and cargo RANGER 4x4 6x6 Crew CA4x4 MAXIMUM CARGO BOX 1000 Ibs 1250 Ibs 1000 Ibs 600 Ibs LOAD 454 kg 567 kg 454 kg 272 kg TIRE PRESSURE IN PSI FRONT 10 69 FRONT 10 69 FRONT 12 83 FRONT 10 69 KPa REAR 12 83 CENTER 12 83 REAR 14 97 REAR 12 83 REAR 12 83 MAXIMUM WEIGHT CAPACITY INCLUDES 1500 Ibs 2000 Ibs 1750 Ibs 1100 Ibs WEIGHT OF OPERATOR 682 kg 907 kg 795 kg 499 kg PASSENGER CARGO AND ACCESSORIES Read Operation and Maintenance Manual for more detailed loading information 7180170 Clutch Cover Warning WARNING NO STEP 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 7172563 Shift Caution CAUTION To avoid transmission damage shift only when vehicle is stationary and at idle 7172674 12 SAFETY Operator Safety AWA
46. IS products only Do not install it in any other product Always make sure the PVT housing is securely in place during operation 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 74 MAINTENANCE POLARIS Variable Transmission PVT System Belt Replacement Debris Removal If a belt fails always clean any debris from the duct and from the clutch and engine compartments when replacing the belt WARNING Failure to remove ALL debris when replacing the belt could result in vehicle damage loss of control and severe injury or death 1 2 Tip Remove the seat and the underseat storage box Remove the clutch cover screws and open the clutch cover Remove all debris wrapped in and around the PVT system Remove all debris from the entire clutch air duct Remove ALL Debris passage Check for signs of damage to seals on the transmission and engine See your dealer promptly for service if any seals appear to be damaged 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 PVT Drying There may be some instances when water is acciden
47. 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 109 Tip Service and adjustments are important for proper vehicle operation If you re not familiar with safe service and adjustment procedures have a qualified dealer perform these operations Vehicles subjected to heavy or severe use patterns must be inspected and serviced more frequently Severe Use Definition Frequent immersion in mud water or sand Frequent or prolonged operation in dusty environments Racing or race style high RPM use Prolonged low speed heavy load operation Extended idle 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 Maintenance Chart Key Perform these operations more often for vehicles subjected to severe use E Enmis
48. POLARIS gives a SIX MONTH LIMITED WARRANTY on all components of your POLARIS vehicle against defects in material or workmanship POLARIS further warrants that the spark arrestor in this product will meet the efficiency requirements of USFS standard 5100 1C for at least 1000 hours when subjected to normal use and when maintenance and installation are in accordance with POLARIS recommendations This warranty covers parts and labor charges for repair or replacement of defective parts and begins on the date of purchase by the original retail purchaser This warranty is transferable to another owner during the warranty period through a POLARIS dealer but any such transfer will not extend the original term of the warranty The duration of this warranty may vary by international region based upon local laws and regulations REGISTRATION At the time of sale the Warranty Registration Form must be completed by your dealer and submitted to POLARIS within ten days of purchase Upon receipt of this registration POLARIS will record the registration for warranty No verification of registration will be sent to the purchaser as the copy of the Warranty Registration Form will be your proof of warranty coverage If you have not signed the original registration and received the customer copy please contact your dealer immediately NO WARRANTY COVERAGE WILL BE ALLOWED UNLESS YOUR VEHICLE IS REGISTERED WITH POLARIS Initial dealer preparation and set up of your vehicle
49. RNING Serious injury or death can result if you do not follow these instructions and procedures which are outlined in further detail within your owner s manual Read this entire manual and all labels carefully Follow the operating procedures described Never allow anyone under the age of 16 to operate this vehicle and never allow anyone without a valid driver s license to operate this vehicle Do not carry a passenger until you have at least two hours of driving experience with this vehicle No person under the age of 12 may ride as a passenger in this vehicle All riders must be able to sit with backs against the seat both feet flat on the floor and both hands on the steering wheel if driving or on a passenger hand hold The driver and all passengers must wear helmet eye protection gloves long sleeve shirt long pants over the ankle boots and seat belt at all times Always use the cab nets or doors while riding in this vehicle Always keep hands and feet inside the vehicle at all times Always keep both hands on the steering wheel and both feet on the floorboards of the vehicle during operation Never permit a guest to operate this vehicle unless the guest has read this manual and all product labels To reduce rollover risk be especially careful when encountering obstacles and slopes and when braking on hills or during turns This vehicle is for off road use only Never operate on public roads unl
50. TH IN THIS WARRANTY ARE THE ONLY REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF THIS WARRANTY POLARIS SHALL HAVE NO LIABILITY TO ANY PERSON FOR INCIDENTAL CONSEQUENTIAL OR SPECIAL DAMAGES OF ANY DESCRIPTION WHETHER ARISING OUT OF EXPRESS OR IMPLIED WARRANTY OR ANY OTHER CONTRACT NEGLIGENCE OR OTHER TORT OR OTHERWISE THIS EXCLUSION OF CONSEQUENTAL INCIDENTAL AND SPECIAL DAMAGES IS INDEPENDENT FROM AND SHALL SURVIVE ANY FINDING THAT THE EXCLUSIVE REMEDY FAILED OF ITS ESSENTIAL PURPOSE THE IMPLIED WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE IS EXCLUDED FROM THIS LIMITED WARRANTY ALL OTHER IMPLIED WARRANTIES INCLUDING BUT NOT LIMITED TO THE IMPLIED WARRANTY OF MERCHANTABILITY ARE LIMITED IN DURATION TO THE ABOVE SIX MONTH WARRANTY PERIOD POLARIS DISCLAIMS ALL EXPRESS WARRANTIES NOT STATED IN THIS WARRANTY SOME STATES DO NOT PERMIT THE EXCLUSION OR LIMITATION OF INCIDENTAL OR CONSEQUENTIAL DAMAGES OR ALLOW LIMITATIONS ON THE DURATION OF IMPLIED WARRANTIES SO THE ABOVE LIMITATIONS MAY NOT APPLY TO YOU IF INCONSISTENT WITH CONTROLLING STATE LAW 105 WARRANTY HOW TO OBTAIN WARRANTY SERVICE If your vehicle requires warranty service you must take it to a POLARIS Servicing Dealer When requesting warranty service you must present your copy of the Warranty Registration From 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
51. The rear tires will also catch the rear of a raised box damaging the vehicle and creating hazardous driving conditions Never operate this vehicle with the cargo box in the raised position 46 OPERATION All Wheel Drive AWD Engaging AWD Press the top of the switch to engage All Wheel Drive AWD The 4X4 indicator illuminates in the rider information center to indicate that the vehicle is in AWD See page 30 When the AWD switch is on the front wheels will Differential Lock automatically engage any time the rear wheels lose traction When the rear wheels regain traction the Differential Unlock front wheels will automatically disengage There is no limit to the length of time the vehicle may remain in AWD Tip The AWD switch may be turned on or off while the vehicle is moving Engage the AWD before getting into conditions where front wheel drive may be needed If the rear wheels are spinning release the throttle before switching to AWD NOTICE Switching to AWD while the rear wheels are spinning may cause severe drive shaft and clutch damage Always switch to AWD while the rear wheels have traction or are at rest AWD Disengaging AWD Move the AWD switch to the center or bottom position to disengage AWD If the switch is turned off while the front hubs are driving they will not release until the rear wheels regain traction In some situations the front gearcase
52. a defect in materials or workmanship and provides no coverage for consumable components general wear items or any parts exposed to friction surfaces stresses environmental conditions and or contamination for which they were not designed or not intended including but not limited to the following items Wheels and tires Finished and unfinished surfaces Suspension components Carburetor Throttle body components Brake components Engine components Seat components Drive belts e Clutches and components Hydraulic components and fluids Steering components Circuit breakers Fuses Batteries Electronic components Light bulbs Sealed beam lamps Spark plugs Filter Sealants Lubricants Coolants Bushings Bearings Lubricants and Fluids 1 Mixing oil brands or using non recommended oil may cause engine damage We recommend the use of POLARIS engine oil 2 Damage or failure resulting from the use of non recommended lubricants or fluids is not covered by this warranty This warranty provides no coverage for personal loss or expense including mileage transportation costs hotels meals shipping or handling fees product pick up or delivery replacement rentals loss of product use loss of profits or loss of vacation or personal time THE EXCLUSIVE REMEDY FOR BREACH OF THIS WARRANTY SHALL BE AT POLARIS OPTION REPAIR OR REPLACEMENT OF ANY DEFECTIVE MATERIALS COMPONENTS OR PRODUCTS THE REMEDIES SET FOR
53. abilizes fuel and removes carbon deposits from pistons rings valves and exhaust systems 3 Allow the engine to run for 15 20 minutes to allow the stabilizer to disperse through the entire fuel delivery system Oil and Filter Change the oil and filter See page 64 Air Filter Air Box 1 Inspect and clean or replace the pre cleaner and air filter See page 76 2 Clean the air box 3 Drain the sediment tube 91 MAINTENANCE Cleaning and Storage Storage Tips Inspect and Lubricate Inspect all cables and lubricate all areas of the vehicle as recommended in the Periodic Maintenance Chart beginning on page 59 Battery Maintenance See page 88 for storage and charging procedures Fluid Levels Inspect the fluid levels Add or change fluids as recommended in the Periodic Maintenance Chart beginning on page 59 Front gearcase fluid Rear and Middle gearcase fluids 6X6 Transmission fluid Brake fluid change every two years and any time the fluid looks dark or contaminated Coolant test strength fill Fog the Engine 1 Treat the fuel system with POLARIS Carbon Clean Follow the instructions on the container Start the engine Allow it to idle for several minutes so the Carbon Clean reaches the injectors Stop the engine 2 Remove the spark plugs and add 2 3 tablespoons of engine oil To access the plug holes use a section of clear 1 4 hose and a small plastic squeeze bottle filled with the pre measured amou
54. ailure always place a damper on the winch cable A damper can be a heavy jacket tarp or other soft dense object A damper can absorb much of the energy released if a winch cable breaks when winching Even a tree limb can help as a damper if no other items are available to you B Lay the damper on top of the mid point of the winch cable length that is spooled out C On a long pull it may be necessary to stop winching so that the damper can be repositioned to the new mid point of the winch cable Always release the tension on the winch cable before repositioning the damper D Avoid being directly in line with the winch cable whenever possible Also never permit others to stand near or in line with the winch cable during winch operation Never hook the winch cable back onto itself This will damage the winch cable and may result in winch cable failure Never use straps chains or other rigging items that are damaged or worn The ONLY time a winch equipped vehicle should be moving when using the winch is when that vehicle itself is stuck The winch equipped vehicle should NEVER be in motion to shock load the winch cable in an attempt to move a second stuck vehicle See the Shock Loading section on page 56 For your safety always follow these guidelines when winching a vehicle free A Release the winch clutch and spool out the necessary length of winch cable B Align the winch cable as close as possible to the winching vehicl
55. all Length 145 in 368 cm Overall Width box 60 in 152 4 cm Overall Width tires 58 in 147 3 cm Overall Height 76 in 193 cm Wheelbase 108 in 274 cm Cargo Box Dimensions Inside 36 5 x 5A x 11 5 in 93 x 137 x 29 cm Ground Clearance 11 5 in 29 cm Min Turning Radius 255 in 648 cm Engine 4 valve 4 stroke twin cylinder with counter balance Displacement 760 cc Bore x Stroke 80 x 76 5 Alternator Output 500 W 3000 RPM Compression Ratio 10 0 1 Starting System Electric Fuel System Electronic Fuel Injection Ignition System Bosch EFI ECU Controlled Spark Plug Gap RC7YC3 035 in 0 9 mm Front Suspension Dual a arm w 9 6 in 24 4 cm of travel Rear Suspension Independent w 9 in 23 cm of travel Lubrication System Pressurized Wet Sump 98 SPECIFICATIONS RANGER CREW 800 Driving System Type PVT 4 wheel independent shaft lockable differential Shift Type Single Lever H L N R Gear Reduction Low 7 70 1 Gear Reduction Reverse 7 0 1 Gear Reduction High 4 63 1 Drive Ratio Front 3 818 1 Drive Ratio Final 3 105 1 Tire Size Front 26x9 12 Tire Size Rear 26 x 11 12 Tire Pressure Front 12 psi 83 KPa Tire Pressure Rear 14 psi 97 KPa Brakes Front Rear Foot Activated 4 wheel hydraulic disc Brake Park Hand activated mechanical
56. an test E Engine breather filter if equipped 25H Monthly g Inspect replace if necessary gt Engine oil change break in 25H 1M Perform a break in oil change at one month gt Front Gearcase oil if equipped 25H 1M Perform a break in oil level check gt Middle Gearcase oil if equipped 25 H 1M Perform a break in oil level check gt Rear gearcase oil if equipped 25H 1M Perform a break in oil level check gt Transmission oil 25H 1M Perform a break in oil level check Park brake cable tension 25H 1M Check tension adjust gt General lubrication 50H 3M Lubricate all fittings pivots cables etc Shift Linkage 50H 6M Inspect lubricate adjust D Steering 50 H 6M Lubricate gt Front Suspension 50 H 6M z Lubricate gt Rear Suspension 50 H 6M Lubricate gt Perform these procedures more often for vehicles subjected to severe use E Emission Related Service D Have an authorized POLARIS dealer perform these services 60 Periodic Maintenance Chart MAINTENANCE Item Maintenance Interval Remarks whichever comes first Hours Calendar Miles Km D Throttle cable throttle pedal 50 H 6M Inspect adjust lubricate E replace if necessary E Throttle body air intake ducts 50 H 6M Inspect duct for proper sealing air leaks ange Drive belt 50 H 6M Inspect adjust replace as needed Cooling system
57. an under the drain plug Remove the drain plug Allow the oil to drain completely 3 Wipe the magnetic end of the drain plug clean to remove accumulated metallic filings Install a new sealing washer Reinstall the drain plug Torque to specification Add the recommended oil Do not overfill Reinstall the fill plug Torque to specification Check for leaks Dispose of used oil properly Drain Plug MINAS 67 MAINTENANCE Gearcases Front Gearcase Always check and change the front gearcase oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 59 Maintain the oil level even with the bottom thread of the fill plug hole Refer to the Gearcase Specifications Chart on page 65 for recommended lubricants capacities and torque specifications See page 100 for the part numbers of POLARIS products Oil Check The front gearcase fill plug is located on the right side of the front gearcase 1 Position the vehicle on a level surface 2 Remove the fill plug Check the oil level 3 Add the recommended oil as needed 4 Reinstall the fill plug Torque to specification Oil Change 1 Support the vehicle securely with a jackstand 2 Remove the front tire on the driver s side 3 Remove the fill plug 4 Place a drain pan under the drain plug on the bottom right hand side 5 Remove the drain plug Allow the oil to drain completely 6 Clean and reinstall the drain plug Torque to specification
58. ar fill plug and add the recommended oil as needed 4 Reinstall both fill plugs Torque to specification Oil Change The drain plug is located near the bottom of the gearcase Remove the rear fill plug and the level check fill plug Place a drain pan under the gearcase Remove the drain plug Allow the oil to drain completely Clean and reinstall the drain plug Torque to specification Add the recommended oil Reinstall both fill plugs Torque to specification NNW PWN e Check for leaks Dispose of used oil properly Level Check and Alternate Fill Plug Drain Plug 66 MAINTENANCE Gearcases Transmission Main Gearcase 6X6 Always check and change the transmission oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 59 Maintain the oil level even with the bottom of the fill plug hole Refer to the Gearcase Specifications Chart on page 65 for recommended lubricants capacities and torque specifications See page 100 for the part numbers of POLARIS products Oil Check The fill plug is located at the rear of the vehicle 1 Position the vehicle on a level surface 2 Remove the fill plug 3 Check the oil level 4 Add the recommended oil as needed 5 Reinstall the fill plug Torque to specification Oil Change The drain plug is located on the bottom of the transmission Access the drain plug through the drain hole in the skid plate 1 Remove the fill plug 2 Place a drain p
59. avoid backing downhill 3 Back slowly 4 Apply the brakes lightly for stopping 5 Avoid turning at sharp angles 6 Never open the throttle suddenly Parking the Vehicle 1 Apply the brakes Stop the vehicle on a level surface 2 When parking inside a garage or other structure be sure that the structure is well ventilated and that the vehicle is not close to any source of flame or sparks including any appliance with pilot lights 3 Turn the engine off 4 Engage the park brake 5 Remove the ignition switch key to prevent unauthorized use Parking on an Incline Avoid parking on an incline if possible If it s unavoidable follow these precautions MA pr Apply the brakes Place the transmission in gear Engage the park brake Turn the engine off Block the rear wheels on the downhill side 43 OPERATION Hauling Cargo AWARNING Hauling cargo improperly can alter vehicle handling and may cause loss of control or brake instability which can result in serious injury or death Always follow these precautions when hauling cargo Never exceed the maximum weight capacity of the vehicle When determining the weight you are adding to the vehicle include the weight of the operator passenger accessories loads in the rack or box and the load on the trailer tongue The combined weight of these items must not exceed the maximum weight capacity REDUCE SPEED AND ALLOW GREATER DISTANCES FOR BRAKING WHEN HAULING
60. cal Hood Headlight 2 single beam 50W quartz halogen Taillights 10 L E D 28W Brake Light 10 L E D 3 1W Clutching See your POLARIS dealer for clutching specifications 95 SPECIFICATIONS Maximum Weight Capacity RANGER 6X6 2000 Ibs 907 kg includes weight of operator passenger cargo accesso ries Dry Weight 1551 Ibs 703 5 kg Test GVW Rollover Protection System ROPS 3660 Ibs 1660 kg per OSHA 29 CFR 1928 53 Fuel Capacity 8 8 gal 33 3 I Engine Oil Capacity 2 qts 1 9 1 Coolant Capacity 3 25 qts G D Towing Capacity 2000 Ibs 907 kg Max Cargo Box Load 1250 lbs 567 kg Overall Length 137 in 348 cm Overall Width box 60 in 152 4 cm Overall Width tires 58 in 147 3 cm Overall Height 76 in 193 cm Wheelbase 105 in 267 cm Cargo Box Dimensions Inside 42 5 x 54 x 11 5 in 108 x 137 x 29 cm Ground Clearance 12 in 30 5 cm Min Turning Radius 243 in 617 cm Engine 4 valve 4 stroke twin cylinder with counter balance Displacement 760 cc Bore x Stroke 80 x 76 5 Alternator Output 500 W 3000 RPM Compression Ratio 10 0 1 Starting System Electric Fuel System Electronic Fuel Injection Ignition System Bosch EFI ECU Controlled Spark Plug Gap RC7YC3 035 in 0 9 mm Front Suspension Dual a arm w 9 6 in 24 4 cm of travel
61. charge with desulfating charger At least 20 hours 89 MAINTENANCE Cleaning and Storage Washing the Vehicle Keeping your POLARIS vehicle clean will not only improve its appearance but it can also extend the life of various components NOTICE High water pressure may damage components POLARIS recommends washing the vehicle by hand or with a garden hose using mild soap NOTICE Certain products including insect repellents and chemicals will damage plastic surfaces Do not allow these types of products to contact the vehicle The best and safest way to clean your POLARIS vehicle is with a garden hose and a pail of mild soap and water 1 Use a professional type washing cloth cleaning the upper body first and the lower parts last 2 Rinse with clean water frequently 3 Dry surfaces with a chamois to prevent water spots Washing Tips Avoid the use of harsh cleaners which can scratch the finish Do not use a power washer to clean the vehicle Do not use medium to heavy duty compounds on the finish Always use clean cloths and pads for cleaning and polishing Old or reused cloths and pads may contain dirt particles that will scratch the finish Grease all zerk fittings immediately after washing Allow the engine to run for a while to evaporate any water that may have entered the engine or exhaust system If a high pressure water system is used for cleaning not recommended exercise extreme caution The water
62. cohol or Drugs Operating the vehicle after consuming alcohol or drugs could adversely affect operator judgment reaction time balance and perception Never drink alcohol or use drugs or medications before or while operating this vehicle Seat Belts Riding in this vehicle without wearing the seat belt increases the risk of serious injury in the event of rollover loss of control other accident or sudden stop Seat belts may reduce the severity of injury in these circumstances All riders must wear seat belts at all times Protective Apparel Riding in this vehicle without wearing an approved helmet and protective eyewear increases the risk of a serious injuries in the event of an accident Operator and all passengers must always wear an approved helmet that fits properly and eye protection goggles or face shield 16 SAFETY Operator Safety Cab Nets Riding in this vehicle without using the cab nets or doors if equipped increases the risk of serious injury or death in the event of an accident or rollover Always use the cab nets or doors while riding in this vehicle Always keep hands and feet inside the vehicle at all times Failure to Inspect Before Operating Failure to inspect and verify that the vehicle is in safe operating condition before operating increases the risk of an accident Always perform the pre ride inspection before each use of your RANGER to make sure it s in safe operating condition See pag
63. d reinstall or replace with new plugs Attempt to start the engine If necessary repeat the drying procedure Take the vehicle to your dealer for service as soon as possible whether you succeed in starting it or not If water has been ingested into the PVT follow the procedure on page 75 for drying Filter Systems Air Filter Always change the air filter at the intervals outlined in the Periodic Maintenance Chart beginning on page 59 Service the air filter more frequently if the vehicle is operated in wet conditions or at high throttle openings for extended periods 1 2 Tip Tip 5 76 Lift the cargo box to access the air box Air Filter Remove the air box cover and inspect the gasket It should adhere tightly to the cover and seal all the way around Grasp the filter end to prevent damage to the filter paper Remove the air filter Do not attempt to clean the main element Install a new air filter Apply a small amount of general purpose grease to the sealing edges of the filter before installing Inspect the air box for oil or water deposits If present drain into a suitable container MAINTENANCE Spark Arrester AWARNING Failure to heed the following warnings while servicing the spark arrester could result in serious injury or death Do not perform service on the spark arrester while the system is hot Exhaust system temperatures can reach 1000 F Allow components to cool suffic
64. d to ask others to help when this happens 1 Always inspect the vehicle winch winch cable and winch controls for any signs of damage or parts in need of repair or replacement before each use Pay particular attention to the first 3 feet 1 meter of winch cable if the winch is being used or has been used for lifting an accessory plow assembly Promptly replace any worn or damaged cable 2 Never operate a winch or a vehicle in need of repair or service 3 Always apply your vehicle s park brake and or park mechanism to hold the vehicle in place C during winching Use wheel chocks if needed Hook Strap X S E LF Ca 51 WINCH GUIDE Winch Operation 4 Always use the hook strap when handling the hook WARNING Never put your fingers into the hook This could lead to SEVERE INJURY A Attach the hook itself onto the load or use a tow strap or NET chain to secure the load to the winch cable Tip A tow strap is NOT intended to stretch A recovery strap NO YES is designed to stretch WARNING Never use a recovery strap when winching due to the excessive energy that can be released if the winch cable breaks This can result in SEVERE INJURY or DEATH See the Shock Loading section on page 56 B Never hook the winch cable back onto itself This will damage the winch cable and may result in winch cable failure WARNING Replace the winch cable at the first sign of damage to prevent SEVERE INJURY or DEATH in the eve
65. dent on many factors including Instrument and calibration uncertainty Variations in the machine such as wear of components Variation of machine operators such as experience or physique Ability of the worker to reproduce typical work during measurements Environmental factors such as ambient noise or temperature SAFETY Safe Riding Gear The driver and all passengers must wear helmet eye protection gloves long sleeve shirt long pants over the ankle boots and seat belt at all times Protective gear reduces the chance of injury Sleeves Helmet Wearing a helmet can prevent a severe head injury Whenever riding this POLARIS vehicle always wear a helmet that meets or exceeds established safety standards Approved helmets in the USA and Canada bear a U S Department of Transportation DOT label Approved helmets in Europe Asia and Oceania bear the ECE 22 05 label The ECE mark consists of a circle surrounding the letter E followed by the distinguishing number of the country which has granted approval The approval number and serial number will also be displayed 051039 on the label 0006 31 SAFETY Safe Riding Gear Eye Protection Do not depend on eyeglasses or sunglasses for eye protection Whenever riding this POLARIS vehicle always wear shatterproof goggles or use a shatterproof helmet face shield POLARIS recommends wearing approved Personal Protective Equipment PPE bearing markings such as VESC
66. der the age of 16 without a drivers license or without proper training This could result in an accident or rollover Always remove the ignition key when the vehicle is not in use Hot Exhaust Systems Exhaust system components are very hot during and after use of the vehicle Hot components can cause burns and fire Do not touch hot exhaust system components Always keep combustible materials away from the exhaust system Use caution when traveling through tall grass especially dry grass to avoid debris build up around the exhaust system 20 Component Locations FEATURES AND CONTROLS Your vehicle is equipped with cab nets on both sides of the vehicle Cab nets or doors if equipped must be used by both operator and passengers at all times Any illustrations without cab nets are only to allow component identification Always use the cab nets or doors Not all models come with all features Refer to the specifications section on page 94 ROPS Cab Frame Radiator Front Bumper Brush Guard Receiver Hitch Muffler Spark Arrester CV Boot Rear Caliper SS Z Fuel Tank Cap Tailgate Tailgate Latch Release 21 FEATURES AND CONTROLS Console Instrument Park Brake Gear Selector Cluster Lever Shifter 12V Auxiliary Storage Storage Cup Holder Outlets Tray Gompanment Auxiliary Outlets The 12 volt receptacles have spad
67. ding but not limited to mowers blades tires sprayers or large racks may change the handling characteristics of the vehicle Use only POLARIS approved accessories and familiarize yourself with their function and effect on the vehicle SAFETY Operator Safety AWARNING Failure to operate the RANGER properly can result in a collision loss of control accident or rollover which may result in serious injury or death Heed all safety warnings outlined in this section of the owner s manual See the OPERATION section of the owner s manual for proper operating procedures Age Restrictions This vehicle is an ADULT VEHICLE ONLY NEVER operate this vehicle if you are under age 16 and NEVER operate without a valid driver s license Never operate with a passenger under the age of 12 All riders must be able to sit with backs against the seat both feet flat on the floor and both hands on the steering wheel if driving or on a passenger hand hold Operating Without Instruction Operating this vehicle without proper instruction increases the risk of an accident The operator must understand how to operate the vehicle properly in different situations and on different types of terrain All operators must read and understand the Owner s Manual and all warning and instruction labels before operating the vehicle All operators should review the safety DVD provided with this vehicle and take a ROHVA training course www rohva org Using Al
68. e s centerline C Attach the winch cable hook to the anchor point or the stuck vehicle s frame following instructions in this manual D Re engage the clutch on the winch E Slowly winch in the slack in the winch cable F Select the proper vehicle gear to propel the stuck vehicle in the direction of winching G Shift to the lowest gear available on the stuck vehicle H Slowly and carefully apply vehicle throttle and winch together to free the vehicle l Stop inching as soon as the stuck vehicle is able to propel itself without the help of the winch J Detach the winch cable hook K Rewind the winch cable evenly back onto the winch drum following the instructions in this manual Never attempt to winch another stuck vehicle by attaching the winch cable to a suspension component brush guard bumper or cargo rack Vehicle damage may result Instead attach the winch to a strong portion of the vehicle frame or hitch 53 WINCH GUIDE Winch Operation 13 Extensive winching will run down the battery on the winching vehicle Let the winching vehicle s engine run while operating the winch to prevent the battery from running low if winching for long periods 14 The winch motor may become hot during winch use If you winch for more than 45 seconds or if the winch stalls during operation stop winching and permit the winch to cool down for 10 minutes before using it again 15 After winching is complete especially if winching
69. e 35 Always follow all inspection and maintenance procedures and schedules described in this owner s manual See page 59 Operating With a Load on the Vehicle The weight of both cargo and passengers impacts vehicle operation For your safety and the safety of others carefully consider how your vehicle is loaded and how to safely operate the vehicle Follow the instructions in this manual for loading tire pressure gear selection and speed Do not exceed vehicle weight capacities The vehicle s maximum weight capacity is listed in the specifications section of this manual and on a label on the vehicle When more passenger weight is added cargo weight may need to be reduced accordingly The recommended tire pressures are listed in the specifications section of this manual and on a label on the vehicle Always follow these guidelines Under ANY of these conditions Do ALL of these steps Passenger and or cargo exceeds half the maximum weight capacity 1 Slow down Operating in rough terrain 2 Verify tire pressure 3 Use extra caution when Operating over obstacles operating Climbing an incline Towing 17 SAFETY Operator Safety Handling Gasoline Gasoline is highly flammable and explosive under certain conditions Always exercise extreme caution whenever handling gasoline Always turn off the engine when refueling Always refuel outdoors or in a well ventilated area free of any sou
70. e connections on the back that may be used to power an auxiliary light or other optional accessories or lights The connections are behind the console under the dash On CREW models an additional receptacle is located on the rear of the driver s seat Gear Selector 12V Aor assor H High Gear ute L Low Gear N Neutral R Reverse Low gear is the primary driving range for the RANGER High gear is intended for use on hard packed surfaces with light loads To shift gears brake to a complete stop When the engine is idling move the lever to the desired gear NOTICE Shifting gears with the engine speed above idle or while the vehicle is moving could cause transmission damage Always shift when the vehicle is stationary and the engine is at idle Tip Maintaining shift linkage adjustment is important to assure proper transmission function See your dealer if you experience any shifting problems Using Low Range Always shift into low gear for any of the following conditions e Operating in rough terrain or over obstacles e Loading the vehicle onto a trailer e Towing heavy loads 22 FEATURES AND CONTROLS Switches AWD Differential Switch Ignition Switch Light Switch Ignition Switch The ignition switch is a three position key operated Mode Button switch The key can be removed from the switch when it is in the OFF position OFF The engine is off Electrical circuits are off except Acc 12V ON Electrical c
71. e plugs Loose ignition connections Check all connections and tighten Water present in fuel Replace with new fuel Low battery voltage Recharge battery to 12 8 VDC Incorrect fuel Replace with recommended fuel Clogged air filter Inspect and clean or replace Other mechanical failure Possible Lean Fuel Cause Low or contaminated fuel See your dealer Solution Add or change fuel clean the fuel system Low octane fuel Possible Rich Fuel Cause Fuel is very high octane Replace with recommended fuel Solution Replace with lower octane fuel Engine Stops or Loses Power Possible Cause Solution Out of fuel Refuel Water is present in fuel Replace with new fuel Fouled or defective spark plugs Inspect clean and or replace spark plug Worn or defective spark plug wires See your dealer Incorrect spark plug gap or heat range Set gap to specs or replace plug Loose ignition connections Check all connections and tighten Low battery voltage Recharge the battery to 12 8 VDC Incorrect fuel Replace with fresh recommended fuel Clogged air filter Inspect and clean or replace Other mechanical failure See your dealer Overheated engine Clean radiator screen and core clean engine exterior see your dealer 103 WARRANTY LIMITED WARRANTY POLARIS Sales Inc 2100 Highway 55 Medina MN 55340
72. ease or decrease spring tension Rear Suspension Shown Adjustment is similar for Front Suspension 80 MAINTENANCE Tires AWARNING Operating your vehicle with worn tires improperly inflated tires non standard tires or improperly installed tires will affect vehicle handling and could cause an accident resulting in serious injury or death Always follow all tire maintenance procedures as outlined in this manual and on the labels on the vehicle Always use POLARIS approved size and type of tires for this vehicle when replacing tires Tire Tread Depth i Always replace tires when tread depth is 1 8 3 mm Z worn to 1 8 3 mm or less Axle and Wheel Nut Torque DP ASS Specifications Inspect the following items occasionally for tightness and if they ve been loosened for maintenance service Do not lubricate the stud or the lug nut Nut Type Location Nut Torque Lug Nut Front and Rear 30 ft los 41 Nm PLUS 1 4 TURN Aluminum Wheels Nut and Washer Front and Rear 35 ft lbs 47 Nm Steel Wheels O Spindle Nut Front 70 ft Ibs 95 Nm Hub Retaining Nuts Center and Rear 110 ft Ibs 150 Nm 81 MAINTENANCE Tires Wheel Removal Apply the brakes Engage the park brake Stop the engine Place the transmission in gear Loosen the wheel nuts slightly Elevate the side of the vehicle by placing a suitable stand under the frame Pee Qe Remove the wheel nuts and washers Re
73. en operating on unfamiliar terrain Always be alert to changing terrain conditions Jumps and Stunts Attempting wheelies jumps and other stunts increases the risk of an accident or rollover Never attempt wheelies jumps or other stunts Avoid exhibition driving Improper Hill Climbing Climbing hills improperly can cause loss of control or vehicle rollover Always follow proper procedures for climbing hills as described in this owner s manual See page 41 Descending Hills Improperly Improperly descending a hill could cause loss of control or rollover Always follow proper procedures for traveling down hills as described in this owner s manual See page 41 Stalling While Climbing a Hill Stalling or rolling backwards while climbing a hill could cause a rollover Always maintain a steady speed when climbing a hill If all forward speed is lost Apply the brakes Place the transmission in reverse and slowly allow the vehicle to roll straight downhill while applying light brake pressure to control speed If you begin rolling downhill Never apply engine power Apply the brakes gradually until the vehicle is fully stopped Place the transmission in reverse and slowly allow the vehicle to roll straight downhill while applying light brake pressure to control speed 19 SAFETY Operator Safety Improper Tire Maintenance Operating this vehicle with improper tires or with improper or uneven tire pressure could cause
74. ess marked for off road use Always avoid paved surfaces Never consume alcohol or drugs before or while operating this vehicle Never operate at excessive speeds Always travel at a speed proper for the terrain visibility and operating conditions and your experience Never attempt jumps or other stunts Always inspect the vehicle before each use to make sure it s in safe operating condition Always follow the inspection procedures described in this manual SAFETY O 14 perator Safety Always travel slowly and use extra caution when operating on unfamiliar terrain Be alert to changing terrain Never operate on excessively rough slippery or loose terrain Always follow proper procedures for turning Practice turning at slow speeds before attempting to turn at faster speeds Never turn at excessive speeds Always have this vehicle checked by an authorized POLARIS dealer if it has been involved in an accident Never operate this vehicle on hills too steep for the vehicle or for your abilities Practice on smaller hills before attempting larger hills Always follow proper procedures for climbing hills as described in this manual See page 41 Check the terrain carefully before attempting to climb a hill Never climb hills with excessively slippery or loose surfaces Never apply throttle suddenly Never make sudden gear changes Never go over the top of a hill at high speed Always follow the proper procedures outl
75. eter and programmable service hour interval 4 Under Over Voltage This warning usually indicates that the vehicle is operating at an RPM too low to keep the battery charged It may also occur when the engine is at idle and high electrical load lights cooling fan accessories is applied Drive at a higher RPM or recharge the battery to clear the warning 5 Clock The clock displays time in a 12 hour or 24 hour format See page 31 for resetting instructions 6 Service Indicator A flashing wrench symbol alerts the operator that the preset service interval has been reached The vehicle should be brought to your dealer for scheduled maintenance See page 31 for resetting instructions 7 4X4 Indicator This indicator illuminates when the 4X4 system is engaged switch is on 4X4 8 Turf Mode Indicator This indicator illuminates when the operator unlocks the 30 differential See page 48 FEATURES AND CONTROLS Instrument Cluster Rider Information Center Use the MODE button to toggle through the information area options Display Units Standard Metric The display can be changed to display either standard or metric units of measurement Tip To exit the set up mode at any time wait 10 seconds The display automatically exits and returns to the odometer display Standard Display Metric Display Distance Miles Kilometers Fuel U S Gallons Liters Imperial Gallons Temperature Fahrenheit Celsius Time 12 Hour C
76. evel Ground 15 grade Weight Spee RANGER 4x4 2000 Ibs 907 kg 850 Ibs 386 kg 150 Ibs 68 1 kg 10 MPH 16 km h RANGER 6x6 2000 Ibs 907 kg 850 Ibs 386 kg 150 Ibs 68 1 kg 10 MPH 16 km h RANGER CREW 2000 Ibs 907 kg 850 Ibs 386 kg 150 Ibs 68 1 kg 10 MPH 16 km h Belt Life To extend belt life use the lowest gear possible when hauling or towing heavy cargo 45 OPERATION Dumping the Cargo Box 1 Select a level site to dump the cargo box Do not attempt to dump or unload the vehicle while parked on an incline 2 Apply the brakes Place the transmission in gear Engage the park brake 3 Dismount the vehicle 4 Ensure that the cargo is positioned evenly or toward the front of the cargo box 5 Release the tailgate by pulling up on the tailgate latch WARNING If the weight distribution on the box is located toward the rear of the box when the release lever is pulled forward the box may dump unexpectedly and cause serious injury to the operator or bystanders Never operate the dump lever without ensuring that the load is positioned evenly or at the front of the box 6 Stand clear and pull up on the cargo box release lever Lift the front of the cargo box to dump the cargo 7 Lower the cargo box and push down securely to latch WARNING Operating the vehicle while the cargo box is raised could result in severe injury The box could close unexpectedly and cause injury to the driver or passenger
77. f the stick consistent 5 Remove the dipstick and check the oil level Maintain the oil level in the safe range Do not overfill Tip Due to the dipstick entry 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 of the dipstick 6 After reinstalling the dipstick be sure to seat the lever lock 7 Reinstall the underseat storage box and the seat Check Level on Top Side 63 MAINTENANCE Engine Oil Oil and Filter Change Always change the oil and filter at the intervals outlined in the Periodic Maintenance Chart beginning on page 59 Always change the oil filter whenever changing oil 1 2 3 4 Position the vehicle on a level surface Run the engine for two to three minutes until warm Stop the engine Clean the area around the drain plug Place a drain pan beneath engine crankcase CAUTION Hot oil can cause burns to skin Do not allow hot oil to contact skin 5 6 7 10 11 12 13 14 15 16 17 18 19 20 21 64 Remove the drain plug Allow the oil to drain completely Reinstall the sealing washer on the drain plug The sealing surfaces on drain plug and crankcase should be clean and free of burrs nicks or scratches Reinstall the drain plug Torque to 20 ft lbs 27 Nm Remove the seat and the underseat storage box Place shop towels beneath the oil filter Using an oil filter wrench turn t
78. fficials or military personnel on assignment outside of the country where the product was purchased will continue to be covered by the Limited Warranty Please work with your dealer to resolve any warranty issues Should your dealer require any additional assistance they will contact the appropriate person at POLARIS This warranty gives you specific legal rights and you may also have other rights which vary from state to state or in different countries If any of the above terms are void because of federal state local law all other warranty terms will remain in effect For questions call POLARIS Customer Assistance United States amp Canada 1 800 POLARIS 1 800 765 2747 French 1 800 268 6334 106 WARRANTY U S A EPA Emissions Limited Warranty This emissions limited warranty is in addition to the POLARIS standard limited warranty for your vehicle POLARIS Industries Inc warrants that at the time it is first purchased this emissions certified vehicle is designed built and equipped so it conforms with applicable U S Environmental Protection Agency emission regulations POLARIS warrants that the vehicle is free from defects in materials and workmanship that would cause it to fail to meet these regulations The warranty period for off road vehicles 100cc or greater emissions certified vehicles starts on the date of purchase by original retail purchaser and continues for a period of 500 hours of engine operation 5000 kilometers 3100
79. ge 59 Refer to the Gearcase Specifications Chart on page 65 for recommended lubricants capacities and torque specifications See page 100 for the part numbers of POLARIS products The rear gearcase fill plug is on the driver s side of the rear gearcase Oil Check Maintain the oil level even with the bottom thread of the fill plug hole 1 Position the vehicle on a level surface 2 Remove the fill plug Check the oil level 3 Add the recommended oil as needed 4 Reinstall the fill plug Torque to specification Oil Change Fill Drain Plug 1 Remove the fill plug Plug 2 Place a drain pan under the drain plug 3 Remove the drain plug Allow the oil to drain completely 4 Clean and reinstall the drain plug Torque to specification 5 Add the recommended oil 6 Reinstall the fill plug Torque to specification 7 Check for leaks Dispose of used oil properly 70 MAINTENANCE Spark Plugs Spark Plug Recommendations Refer to the specifications section beginning on page 94 for the recommended spark plug type for your vehicle Always torque spark plugs to specification NOTICE Using non recommended spark plugs can result in serious engine damage Always use POLARIS recommended spark plugs Spark Plug Gap Torque Model Electrode Gap New Plug Torque Used Plug Torque All 035 9 mm 18 ft Ibs 18 ft Ibs 24 Nm 24 Nm Spark Plug Inspection Spark plug condition is indicative of eng
80. he filter counter clockwise to remove it Using a clean dry cloth clean the filter sealing surface on the crankcase Lubricate the o ring on the new filter with a film of fresh engine oil Check to make sure the o ring is in good condition Install the new filter and turn by hand until the filter gasket contacts the sealing surface then turn and additional 1 2 turn Remove the dipstick and fill the sump with two quarts 1 9 1 of recommended oil Shift the transmission to neutral Apply the brakes Engage the park brake Start the engine Allow it to idle for one to two minutes Stop the engine Inspect for leaks Check the oil level on the dipstick and add oil as necessary to bring the level to the upper mark on the dipstick Reinstall the underseat storage box and the seat Dispose of used filter and oil properly Gearcases Gearcase Specification Chart MAINTENANCE RANGER 4X4 Gearcase Specifications Gearcase Lubricant Capacity Fill Plug s Drain Plug Torque Torque Main Gearcase AGL Gearcase 34 oz 12 ft Ibs 12 ft Ibs Transmission Lubricant amp 1000 ml 16 3 Nm 16 3 Nm Transmission Fluid Front Gearcase Demand Drive Fluid 9 3 oz 8 10 ft Ibs 11 ft Ibs 275 ml 11 13 6 Nm 15 Nm RANGER 6x6 Gearcase Specifications Gearcase Lubricant Capacity Fill Plug Torque Drain Plug Torque Main Gearcase AGL Gearcase 43 6 oz 12 ft Ibs 12 ft Ibs Transmission Lub
81. hicle 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 76 and take the vehicle to your dealer at the first opportunity Follow these procedures when operating through water 1 Determine water depths and current before entering water 2 Choose a crossing where both banks have gradual inclines 3 Proceed slowly avoiding rocks and obstacles 4 Avoid operating through deep or fast flowing water WARNING The large tires on your RANGER may cause the vehicle to float 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 5 After leaving water always dry the brakes by applying light pressure to the pedal repeatedly until braking action is normal Q ite Floorboard vw f dug EE Es NOTICE After running your vehicle in water it s critical that you perform the services outlined in the Periodic Maintenance Chart beginning on page 59 Give special attention to engine oil transmission oil all gearcase fluids and all grease fittings 42 OPERATION Driving in Reverse Follow these precautions when operating in reverse 1 Always check for obstacles or people behind the vehicle Always inspect left and right fields of vision before backing 2 Always
82. iently 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 operate without the spark arrestor Never go under the vehicle while it s inclined Use the following procedure to periodically purge accumulated carbon from the exhaust pipe 1 Remove the arrester clean out plugs located on the bottom of the muffler 2 Place the transmission in neutral 3 Engage the park brake 4 Start the engine 5 Purge accumulated carbon from the system by momentarily revving the engine several times 6 If carbon is expelled cover or plug the exhaust outlet Outlet Cl an Out and rap on the pipe around the clean out plugs while Plugs revving the engine several more times 7 If particles are still suspected to be in the muffler elevate the rear of the vehicle one foot higher than the front Block the wheels 8 Repeat steps 5 and 6 until no more particles are expelled when the engine is revved 9 Stop the engine Allow the arrester to cool 10 Reinstall the arrester plugs and remove the outlet cover or plug 77 MAINTENANCE Throttle System AWARNING Failure to check or maintain proper operation of the throttle system can result in an accident and lead to
83. ight of a rider on the seat while performing this step If a headlight needs adjustment locate the adjustment screw at the back of the headlight Loosen the screw adjust the headlight and tighten the screw Repeat steps 5 7 until the lamp is properly adjusted Fuses MAINTENANCE If the engine stops or will not start or if you experience other electrical failures a fuse may need replacement Locate and correct any short circuits that may have caused the blown fuse then replace the fuse Spare fuses are provided in the fuse box The power steering fuse if equipped is located on the power steering wiring harness near the fuse box If you suspect that a fuse or relay may not be working properly please see your POLARIS dealer Fuse Feature Supported 20A Accessories 12V Power Receptacle 10A Electronic Fuel Injection 20A Engine Control Module 20A Lights 20A Main Fuse Ignition Instrument Cluster 30A Power Steering if equipped 7177659 S P ECM FAN FUEL PUMP A R RELAY RELAY RELAY E 10 LIGHTS DRIVE ACCESSORY B CH 20A 20A 20A A RELAY FUEL PUMP E 10A 20 85 MAINTENANCE Battery AWARNING Battery electrolyte is poisonous It contains sulfuric acid Serious burns can result from contact with skin eyes or clothing Antidote External Flush with water Internal Drink large quantities of water or milk Follow with milk of magnesia beate
84. il 54 eb se reni 63 Front Ge rease ing loose ole neg 68 Main Gearcase 4X4 Crew 66 Main Gearcase 6X6 Lus 67 Middle Gearcase 00 69 Rear Gearcase 0 00 000s 70 Transmission 4X4 Crew 66 Transmission 6X6 04 67 Fluid Levels During Storage 92 Fluid Part Numbers 0 0 00005 100 Fogging the Engine 004 92 Fouled Plugs eb RR CRT ERSTES E 71 Front Gearcase 6 24 cdenee ode aed wes a bees 68 E el Cap code Exe bcd P bones ehe 24 Fuel Safety eoe exe e e add aaa 18 Fel Stabilizer ser m Gn ebbe tes 91 Fuel Tank Filler Cap cereri eee naties 24 FUSES sched iced ans een reae uod aa causis 85 G Gap Spark Pl g ecce RR RR Rn 71 Gasoline Handling 0 18 Gear Selector cies cee dea we e e 22 Gearcase Specification Chart 65 Grearcase Front sea wns dU A 68 Gearcase Middle 4 ce redet eei 69 Gearcase Rear 6X6 merene ce eee eee 70 GealCdS68 oiv haue DERE E RARO 65 70 Gears Shif ng ze prece err vh 22 Gloves ue EXER ren cede deae 9 H Hauling Cargo ies irte mre e Rd 44 Headlight Beam Adjustment 84 Headlight Lamp Replacement 83 HEMET RR pRUETURM E 8 Hitcli 2 ovi wr pies Gis e LUE IAS 24 Hitch Weight 2 oset e o e here IR 45 l Idle Speed uo oit RE RE naw be 78 Ignition Switch sers e e 23 Indicator Lamps
85. ine operation The spark plug firing end condition should be read after the engine is warmed up and the vehicle is driven at higher speeds Immediately check the spark plug for correct color CAUTION A hot exhaust system and engine can cause burns Wear protective gloves when removing a spark plug for inspection 1 Remove the seat Remove the spark plug cap 2 Using the spark plug wrench provided in the tool kit remove the plug by rotating it counterclockwise 3 Reverse the procedure for spark plug installation Torque to specification Normal Plug The normal insulator tip is gray tan or light brown There will be few combustion deposits The electrodes are not burned or eroded This indicates the proper type and heat range for the engine and the service The tip should not be white A white insulator tip indicates overheating caused by use of an improper spark plug or incorrect throttle body adjustments Wet Fouled Plug The wet fouled insulator tip is black A damp oil film covers the firing end There may be a carbon layer over the entire nose Generally the electrodes are not worn General causes of fouling are excessive oil use of non recommended oil or incorrect throttle body adjustments 71 MAINTENANCE Cooling System The engine coolant level is controlled or maintained by the recovery system The recovery system components are the overflow bottle radiator filler neck radiator pressure cap and connecting hose A
86. ined in this manual for traveling downhill and for braking on hills See page 41 Check the terrain carefully before descending a hill Never travel downhill at high speed Avoid going downhill at an angle which would cause the vehicle to lean sharply to one side Travel straight down the hill where possible Always check for obstacles before operating in a new area Never attempt to operate over large obstacles such as large rocks or fallen trees Always follow the proper procedures outlined in this manual when operating over obstacles See page 40 Always be careful of skidding or sliding On slippery surfaces such as ice travel slowly and exercise caution to reduce the chance of skidding or sliding out of control Never operate your vehicle in fast flowing water or in water deeper than that specified in this manual See page 42 Wet brakes may have reduced stopping ability Test your brakes after leaving water If necessary apply them lightly several times to let friction dry out the pads Always be sure there are no obstacles or people behind your vehicle when operating in reverse When it s safe to proceed in reverse move slowly Avoid turning at sharp angles in reverse SAFETY Operator Safety Always use the proper size and type of tires specified in this manual Always maintain proper tire pressure as specified on safety labels Never modify this vehicle through improper installation or use of non POLARIS approved accessories
87. ings listed on the warning labels The total load operator passenger accessories cargo and weight on hitch must not exceed the maximum weight capacity of the vehicle See page 12 WARNING Driving with passengers in the cargo box can result in severe injury or death Never allow passengers to ride in the cargo box Passengers must always ride in the cab with seat belts fastened securely Towing Loads Towing improperly can alter vehicle handling and may cause loss of control or brake instability Always follow these precautions when towing 1 Never load more than 150 Ibs 68 1 kg tongue weight on the towing bracket 2 Always shift to low gear for towing 3 When towing a disabled RANGER vehicle place the disabled vehicle s transmission in neutral Do not operate the vehicle faster than 10 MPH 16 km h when towing 4 Do not operate the vehicle faster than 10 MPH 16 km h when towing See page 44 Towing a trailer increases braking distance OPERATION 5 Do not tow more than the recommended weight for the vehicle See the towing capacity chart below and the specifications charts beginning on page 94 6 Attach a trailer to the trailer hitch bracket only Do not attach a trailer to any other location or you may lose control of the vehicle 7 Never tow a trailer on a grade steeper than 15 Model Total Towed Total Towed Total Hitch Maximum Load Weight Load Weight Vertical Towin L
88. inning on page 59 Do not obstruct or deflect air flow through the radiator by installing unauthorized accessories in front of the radiator or behind the cooling fan Interference with the radiator air flow can lead to overheating and consequent engine damage NOTICE Washing the vehicle with a high pressure hose could damage the radiator fins and impair the radiator s effectiveness Using a high pressure system is not recommended 72 MAINTENANCE Cooling System Overflow Bottle Coolant Level Always check and change the coolant at the intervals outlined in the Periodic Maintenance Chart beginning on page 59 Maintain the coolant level between the minimum and maximum marks on the bottle when the fluid is cool The overflow bottle is located in front of the right front wheel 1 Position the vehicle on a level surface 2 View the coolant level in the overflow bottle Radiator Overflow 3 Ifthe coolant level is below the safe operating Cap Bottle range lift the hood and locate the overflow bottle lid Remove the cap and use a funnel to add coolant through the filler opening Reinstall the cap Tip If coolant must be added often or if the overflow bottle runs completely dry there may be a leak in the system Have the cooling system inspected by your POLARIS dealer Radiator Coolant Level 1 Lift the hood CAUTION Escaping steam can cause burns Never remove the pressure cap while the engine is warm or hot Always allow
89. intenance Chart beginning on page 59 Transporting the RANGER Follow these procedures when transporting the vehicle 1 2 3 4 Apply the brakes Engage the park brake Stop the engine Place the transmission in gear Secure the fuel cap oil cap hood and seat Ensure that the seats are attached correctly and are not loose WARNING Cargo and other loose vehicle parts may fly off while transporting this vehicle Secure or remove all cargo and inspect the unit for loose parts prior to transport 5s 6 Always tie the frame of the RANGER to the transporting unit securely with suitable straps or rope Do not attach tie straps to the front A arm bolt pockets Remove the key to prevent loss during transporting 93 SPECIFICATIONS Maximum Weight Capacity RANGER 800 EFI EPS 1500 Ibs 681 kg including operator passenger cargo accessories 1100 Ibs 499 kg Models sold in California Dry Weight 1237 Ibs 561 kg Test GVW Rollover Protection System ROPS 2940 Ibs 1333 5 kg per OSHA 29 CFR 1928 53 Fuel Capacity 8 8 gal 33 3 1 Engine Oil Capacity 1 9 qts 1 81 Coolant Capacity 3 25 qts G D Towing Capacity 2000 Ibs 907 kg Hitch Tongue Capacity 150 lbs 68 kg Max Cargo Box Load 1000 lbs 454 kg 600 Ibs 272 kg Models sold in California Overall Length 114 in 289 6 cm Overall Width box 60 in 152 4 cm
90. ircuits are on Electrical equip ment can be used START Turn the key to the START position to engage the electric starter The key returns to the ON position when released Mode Button The MODE button is located on the instrument cluster Use the MODE button to toggle through mode options available in the instrument cluster See pages 29 33 Light Switch The ignition switch key must be in the ON RUN HIGH position to operate the headlights Press the top of the rocker switch toward the dash to place the headlights on high beam Move the rocker switch to the center LOW position to place the headlights on low beam Press the bottom of the rocker switch to turn off the OFF headlights AWD Differential Lock Switch The AWD Differential Switch has three positions All Wheel Drive AWD AWD Differential Lock 2WD Differential Unlock Differential Lock Press the top of the rocker switch to engage All Wheel Drive AWD See page 47 for operating Differential Unlock instructions Move the rocker switch to the center position to lock the differential and operate in rear wheel drive Press the bottom of the switch to unlock the differential and allow the two rear drive wheels to operate independently See page 48 for differential lock operating instructions 23 FEATURES AND CONTROLS Trailer Hitch Bracket This vehicle is equipped with
91. is very important in ensuring trouble free operation Purchasing a machine in the crate or without proper dealer set up will void your warranty coverage WARRANTY COVERAGE AND EXCLUSIONS LIMITATIONS OF WARRANTIES AND REMEDIES This POLARIS limited warranty excludes any failures that are not caused by a defect in material or workmanship THIS WARRANTY DOES NOT COVER CLAIMS OF DEFECTIVE DESIGN This warranty also does not cover acts of God accidental damage normal wear and tear abuse or improper handling This warranty also does not cover any vehicle component or part that has been altered structurally modified neglected improperly maintained or used for purposes other than for which it was designed This warranty excludes damages or failures resulting from improper lubrication improper engine timing improper fuel surface imperfections caused by external stress heat cold or contamination operator error or abuse improper component alignment tension adjustment or altitude compensation snow water dirt or other foreign substance ingestion contamination improper maintenance modified components use of aftermarket or unapproved components accessories or attachments unauthorized repairs or repairs made after the warranty period expires or by an unauthorized repair center 104 WARRANTY LIMITATIONS OF WARRANTIES AND REMEDIES This warranty excludes damages or failures caused by abuse accident fire or any other cause other than
92. ive eere 47 48 Disengaging AWD 47 Engaging AWD 47 Locking the Differential 48 All Wheel Drive Switch 23 Arrester Spark Warning TI Auxiliary Outlets lesse 22 Axle Nut Inspection 0 81 Axle Nut Torque cas csgoag Re 81 B Battery sovlecc pex Eh e tesa eT 86 89 Charging Conventional 89 Charging Sealed 89 Fluid err er RR RE ere 86 InstallatiOn 2e teemRehR nb 88 Removal icc cn hs ee m EE 87 NLOLARE l2 cs cer ehe th CER Lane 88 Battery Warnings sees 0 00 ees 86 Beam Adjustment Headlight 84 Belt Burning be ner Reed 101 Belt Life said bate ornate eS eere Re egre 45 Belt Replacement 2 esce 75 Belt Wear uie dye E eSREOEN EA aes d 101 Boots oerna ERR RRRPPRR IER ERN EY 9 Brake Fluid nere tees 79 Brake Insp ction 2252s eR REX Y 79 Brake Light Inspection 83 Brake Ped l 2er ems 24 Brake Park one o aise scien s 25 Brake Park Adjustment 80 Brake Park Inspection 79 Brake RARE VU 79 80 Braking 222 e e RE HERES CEDAT 36 Break In Period 4 rr LR mer 34 C Cab Frame ROPS i scs sso e an 28 Cab Net ea deco tete eee eoe pa ce 26 Cal BOs mins xe es tre Bele earn dune dee 44 Cargo Box Dumping 46 Chart Gearcase Specifications 65 Periodic Mai
93. k loads in a winch cable WARNING SEVERE INJURY or DEATH can result from a broken winch cable 2 Never quickly turn the winch ON and OFF repeatedly jogging This puts extra load on the winch winch cable and generates excessive heat from the motor This is a form of shock loading 3 Never tow a vehicle or other object with your winch Towing an object with a winch produces shock loading of the cable even when towing at slow speeds Towing from a winch also positions the towing force high on the vehicle This can cause instability of the vehicle and possibly lead to an accident 4 Never use recovery straps with your winch Recovery straps are designed to stretch and can store energy This stored energy in the recovery strap is released if a winch cable fails making the event even more hazardous Similarly never use elastic bungie cords for winching 5 Never use the winch to tie down a vehicle to a trailer or other transportation vehicle This type of use also causes shock loading that can cause damage to the winch winch cable or vehicles used Your winch cable is designed and tested to withstand the loads produced by the winch motor when operated from a stationary vehicle Always remember that the winch and winch cable are NOT designed for shock loading 56 WINCH GUIDE Winch Maintenance and Service Safety WARNING Improper or lack of winch maintenance and service could lead to SEVERE INJURY or DEATH Always follow al
94. ke WARNING A rolling vehicle can cause serious injury Always engage the park brake after stopping the engine Braking 1 Release the throttle pedal completely 2 Press on the brake pedal evenly and firmly 3 Practice starting and stopping using the brakes until you re familiar with the controls Tip When the throttle pedal is released completely and the engine speed drops near an idle the vehicle has no engine braking 36 Driving Procedure 1 10 11 Wear a helmet eye protection gloves long sleeve shirt long pants and over the ankle boots Perform the pre ride inspection See page 35 Sit in the driver s seat and fasten the seat belt Always use the cab nets or doors while riding in this vehicle Start the engine and allow 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 OPERATION Keeping both hands on the steering wheel slowly release the brakes and depress the throttle with your right foot to begin driving Drive slowly Practice maneuvering and using the throttle and brakes on level surfaces Do not carry a passenger until you have at least two hours of driving experience with this vehicle 37 OPERATION Driving with a Passenger 1 2 9 Perform the pre ride inspection See page 35 Make sure all passengers are at least 12 years of age and tall eno
95. l winch instructions and warnings in this manual 1 Always inspect your winch before each use Inspect for worn or kinked winch cable Also inspect for worn or loose parts including mounting hardware Permit your winch motor to cool down prior to servicing your winch 3 Never work on your winch without first disconnecting the battery connections to prevent accidental activation of the winch 4 For your safety always replace POLARIS winch parts including the cable with genuine POLARIS replacement parts available at your authorized POLARIS dealer 5 Some winch models use wire rope as the winch cable Other winches use a specially designed synthetic rope as the winch cable 6 Never replace a synthetic rope winch cable with a consumer grade polymer rope such as can be purchased in a hardware store Although they may look similar they are NOT alike A polymer rope not designed for winch use will stretch and store excessive energy when winching WARNING Failure of a stretched rope under winching conditions will release all of the stored energy This will increase the chances of SEVERE INJURY or DEATH 57 EMISSION CONTROL SYSTEMS Noise Emission Control System Do not modify the engine intake or exhaust components as doing so may affect compliance with U S A EPA noise control requirements 40 CFR 205 and local noise level requirements Operation on Public Lands in the U S A Your POLARIS vehicle has a spark arrester that was
96. le in place during winching Use wheel chocks if needed Always align the vehicle and winch with the load directly in front of the vehicle as much as possible Avoid winching with the winch cable at an angle to the winching vehicle s centerline whenever possible If winching at an angle is unavoidable follow these precautions A Look at the winch drum occasionally Never let the winch cable stack or accumulate at one end of the winch drum Too much winch cable at one end of the winch drum can damage the winch and the winch cable B If stacking occurs stop winching Follow step 15 on page 54 to feed and rewind the cable evenly before continuing the winch operation 49 WINCH GUIDE Winch Safety Precautions 13 14 15 16 17 18 19 20 21 22 23 24 25 50 Never winch up or down at sharp angles This can destabilize the winching vehicle and possibly cause it to move without warning Never attempt to winch loads that weigh more than the winch s rated capacity The winch motor may become hot during winch use If you winch for more than 45 seconds or if the winch stalls during operation stop winching and permit the winch to cool down for 10 minutes before using it again Never touch push pull or straddle the winch cable while winching a load Never let the winch cable run through your hands even if wearing heavy gloves Never release the clutch on the winch when the winch cable is
97. lock 24 Hour Clock 1 Turn the key to the OFF position 2 Press and hold the MODE button while turning the key to the ON position 3 When the display flashes the distance setting tap the MODE button to advance to the desired setting 4 Press and hold the MODE button to save the setting and advance to the next display option 5 Repeat the procedure to change remaining display settings Clock Mode Tip The clock must be reset any time the battery has been disconnected or discharged 1 Turn the key to the ON position Use the MODE button to toggle to the odometer display Press and hold the MODE button until the hour segment flashes Release the button With the segment flashing tap the MODE button to advance to the desired setting Press and hold the MODE button until the next segment flashes Release the button Repeat steps 3 4 twice to set the 10 minute and 1 minute segments After completing the 1 minute segment step 4 will save the new settings and exit the clock mode Turn the key to the OFF position WP WN D 31 FEATURES AND CONTROLS Instrument Cluster Rider Information Center Odometer Mode The odometer records and displays the distance traveled by the vehicle Trip Meter Mode The trip meter records the distance traveled by the vehicle if reset before each trip To reset select the trip meter mode Press and hold the MODE button until the meter resets to zero In the Rider Information Center
98. may remain locked after turning the AWD switch off If this occurs you may notice increased steering effort and some vehicle speed restriction Perform the following procedure to unlock the front gearcase 1 Stop the vehicle Operate in reverse for at least 10 feet 3 m Stop completely Shift into low gear and drive forward Ge es If the front gearcase remains locked after following these instructions see your dealer for service 47 OPERATION All Wheel Drive AWD Locking the Differential NOTICE Damage to the differential can occur if it is engaged while the vehicle is traveling at high speeds or while the rear wheels are spinning Slow the vehicle to nearly stopped before engaging the differential Locking the differential in slippery or low traction conditions helps improve traction Move the rocker switch to the center position 2WD to lock the differential and operate in rear wheel drive On 6X6 models all four rear wheels will be drive wheels Press the bottom of the switch to unlock the differential and allow the rear drive wheels to operate independently This mode of operation is well suited to turf driving or whenever aggressive traction is not required On 6X6 models the center wheels will remain drive wheels 4X4 Models 6X6 Models fy 4 it T T yt tT got s i tT HET i e 48 WINCH GUIDE These safety warnings and instructions apply if y
99. move the wheel Wheel Installation Apply the brakes Place the transmission in gear Engage the park brake PeNP Place the wheel in the correct position on the wheel hub Be sure the valve stem is toward the outside and rotation arrows on the tire point toward forward rotation WARNING Improperly installed wheels can adversely affect tire wear and vehicle handling which can result in serious injury or death Always ensure that all nuts are torqued to specification Do not service axle nuts that have a cotter pin installed See d your POLARIS dealer 5 Attach the wheel nuts and washers and finger tighten 8 6 Carefully lower the vehicle to the ground 7 Torque the wheel nuts to specification See page 81 Power Steering Unit If your model is equipped with power steering frequently clean the areas around and on the power Clean Often steering unit to allow proper cooling Clean these areas thoroughly a 82 MAINTENANCE Lights Poor lighting can result in reduced visibility when driving Headlight and taillight lenses become dirty during normal operation Clean lights frequently and replace burned out lamps promptly Do not operate this vehicle at night or in low light conditions until the headlight is replaced Always make sure lights are adjusted properly for best visibility When servicing a halogen lamp don t touch the lamp with bare fingers Oil from your skin leaves a residue causi
100. n egg or vegetable oil Call physician immediately Eyes Flush with water for 15 minutes and get prompt medical attention Batteries produce explosive gases Keep sparks flame cigarettes etc away Ventilate when charging or using in an enclosed space Always shield eyes when working near batteries KEEP OUT OF REACH OF CHILDREN Your vehicle may have either a sealed battery which requires little maintenance or a conventional battery A sealed battery can be identified by its flat covers on the top of the battery A conventional battery has six filler caps on the top of the battery Always keep battery terminals and connections free of corrosion If cleaning is necessary remove the corrosion with a stiff wire brush Wash with a solution of one tablespoon baking soda and one cup water Rinse well with tap water and dry off with clean shop towels Coat the terminals with dielectric grease or petroleum jelly Be careful not to allow cleaning solution or tap water into the battery Battery Fluid Conventional Battery Lower Upper Mark A poorly maintained battery will deteriorate rapidly Check the Mark battery fluid level often Maintain the fluid level between the upper and lower level marks Add only distilled water Tap water contains minerals that are harmful to a battery 86 MAINTENANCE Battery Battery Removal A WARNING Improperly connecting or disconnecting battery cables can result in an explosion and cause seri
101. n minor or moderate injury NOTICE A NOTICE indicates a situation that could result in property damage The Prohibition Safety Sign indicates an action NOT to take in order to avoid a hazard O The Mandatory Action Sign indicates an action that NEEDS to be taken to avoid a hazard INTRODUCTION Failure to follow the warnings contained in this manual can result in severe injury or death Your POLARIS RANGER is not a toy and can be hazardous to operate This vehicle handles differently than other vehicles such as cars trucks or other off road vehicles A collision or rollover can occur quickly even during routine maneuvers like turning or driving on hills or over obstacles if you fail to take proper precautions Read this owner s manual and review the safety DVD that came with your vehicle A free extra copy of the DVD can be obtained by contacting your local POLARIS dealer Understand all safety warnings precautions and operating procedures before operating the vehicle Keep this manual with the vehicle Review the safety DVD and take the free online Recreational Off Highway Vehicle Association ROHVA training course at www rohva org This vehicle is an ADULT VEHICLE ONLY You MUST be at least age 16 and have a valid driver s license to operate this vehicle No person under the age of 12 may ride as a passenger in this vehicle All riders must be able to sit with backs against the seat both feet flat on the floor and both
102. ng a hot spot that will shorten the life of the lamp Headlight Lamp Replacement 1 Open the hood CAUTION Hot components can cause burns to skin Allow lamps to cool before servicing 2 Unplug the headlamp from the wiring harness Be sure to pull on the connector not on the wiring Wiring Harness 3 Turn the lamp counterclockwise to remove it 4 Install the new lamp Tip Make sure the tab on the lamp locates properly in the housing 5 Reinstall the harness assembly into the headlight assembly Brake Lights When the brake pedal is depressed the brake light comes on Check the brake light before each ride 1 Turn the ignition switch to the ON position 2 Depress the brake pedal The brake light should come on after about 10 mm 0 4 in of pedal travel If the light doesn t come on check the bulb 83 MAINTENANCE Lights Headlight Beam Adjustment 84 xj 8 20 x V8 20 cm 25 ft 7 6 m Place the vehicle on a level surface with the headlight approximately 25 ft 7 6 m from a wall Place the transmission in gear Engage the park brake Measure the distance from the floor to the center of the headlight and make a mark on the wall at the same height Apply the brakes Start the engine Turn on the headlights Observe the headlight aim The most intense part of the headlight beam should be aimed 8 20 cm below the mark placed on the wall Include the we
103. nt 100 TROUBLESHOOTING Drive Belt Wear Burn Possible Cause Solution Driving onto a pickup or tall trailer in high range Use low range during loading Starting out going up a steep incline Use low range See warnings on page 41 Driving at low RPM or ground speed 3 7 MPH Drive at a higher speed or use low range more frequently Insufficient warm up at low ambient temperatures Warm the engine at least 5 minutes With the transmission in neutral advance the throttle to about 1 8 throttle in short bursts 5 to 7 times The belt will become more flexible and prevent belt burning Slow easy clutch engagement Use the throttle quickly and effectively Towing pushing at low RPM low ground speed Use low range only Utility use plowing Use low range only Stuck in mud or snow Shift the transmission to low range and carefully use fast aggressive throt tle application to engage clutch WARNING Excessive throttle may cause loss of control and vehicle roll over Climbing over large objects from a stopped position Shift the transmission to low range and carefully use fast brief aggressive throttle application to engage clutch WARNING Excessive throttle may cause loss of control and vehicle roll over Belt slippage from water or snow ingestion into the PVT system Dry out the PVT See page 75 Inspect clutch seals for damage if repeated leaking occurs
104. nt of failure For your safety always replace POLARIS winch parts including the cable with genuine POLARIS replacement parts available at your authorized POLARIS dealer C If possible keep the winch cable aligned with the centerline of the winching vehicle This will help the spooling of the winch cable and reduce the load on the fairlead D If freeing a stuck vehicle by attaching to a tree use an item such as a tow strap to avoid damaging the tree during winch operation Sharp cables and chains can damage and even kill trees Please remember to TreadLightly treadlightly org E Before operating the winch be sure that the safety latch on the winch cable hook is fully seated when the load is attached F Never operate your winch with a damaged hook or latch Always replace damaged parts before using the winch 5 Never remove the hook strap from the hook NO 6 Release the winch clutch and pull out the winch cable ES 7 Pulling out as much cable as possible maximizes the winch s pulling capacity Always be sure that at least five 5 full turns of winch cable are wrapped around the winch drum at all times The friction provided by this wrapped cable allows the drum to pull on the winch cable and move the load 52 WINCH GUIDE Winch Operation 8 10 11 12 Read and adhere to the following information for winch damping to ensure safe winch use A In order to absorb energy that could be released by a winch cable f
105. nt of oil Do this carefully If you miss the plug holes oil will drain from the spark plug cavities into the hole at the front of the cylinder head and appear to be an oil leak 3 Reinstall the spark plugs Torque to specification See page 71 4 Apply dielectric grease to the inside of each spark plug cap and reinstall the caps onto the plugs 5 Turn the engine over several times Oil will be forced in and around the piston rings and ring 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 Storage Area Covers Be sure the storage area is well ventilated Cover the vehicle with a genuine POLARIS cover Do not use plastic or coated materials They do not allow enough ventilation to prevent condensation and may promote corrosion and oxidation 92 MAINTENANCE Removal from Storage 1 Pow Check the battery electrolyte level and charge the battery if necessary Install it in the vehicle Make sure the battery vent hose is routed properly and that it s not pinched or restricted in any way Make sure the spark plug is tight Fill the fuel tank with fuel Check all the points listed in the Daily Pre Ride Inspection section on page 35 Tightness of the bolts nuts and other fasteners should be checked by an authorized POLARIS dealer Lubricate at the intervals outlined in the Periodic Ma
106. ntenance 59 61 Check Engine Indicator 33 Cleaning and Storage 90 92 Clothing sat ripen ERO dr ie tcs 9 Clutching 4X4 iaden aa saa ai eee 95 Cl tchitg 6X0 24 eot rb pae due 97 Clutching Crew iiis a REIR a 99 110 C Component Locations 00 21 Console ele re du wea Ree on eddie 22 Coolant Level Overflow Bottle Coolant 73 Coolant Level Radiator 005 73 Coolant Adding or Changing 72 Cooling Fan 0 0 cece ee eee eee ees 72 Coolng System ced eerte rd 72 73 Crankcase Emission Control System 58 D Differential Lock Switch 0 23 Differential Locking 00 48 Disengaging AWD osos en 47 Display Units Standard Metric 31 Drive Belt Wear 00 0 cee e eee 101 Drivetrain Break In 00000 34 Driving Downhill 20 0 0 inoden 41 Driving in Reverse lesse 43 Driving on a Sidehill ssleuuuu 41 Driving on Slippery Surfaces 39 Driving Over Obstacles 0 40 Driving Procedure 0 000005 37 Driving Through Water 0005 42 Driving Uplull 1 b 9 a ween Ies 41 Driving with a Passenger 38 Driving After Driving in Water 75 Drying the Transmission 75 Dumping the Cargo Box 0
107. od of three months or more remove the battery from the vehicle ensure that it s fully charged and store it out of the sun in a cool dry place Check battery voltage each month during storage and recharge as needed to maintain a full charge See page 89 POLARIS recommends maintaining battery charge by using a POLARIS Battery Tender charger or by charging about once a month to make up for normal self discharge Battery Tender can be left connected during the storage period and will automatically charge the battery if the voltage drops below a pre determined point 88 MAINTENANCE Battery Battery Charging Conventional Battery 1 Remove the battery from the vehicle to prevent damage from leaking or spilled electrolyte during charging See page 87 2 Charge the battery with a charging output no larger than 1 10 of the battery s amp hr rating Charge as needed to raise the specific gravity to 1 270 or greater 3 Reinstall the battery See page 88 Make sure the positive terminal is toward the front of the vehicle Battery Charging Sealed Battery The following battery charging instructions apply only to the installation of a sealed battery Read all instructions before proceeding with the installation of this battery The sealed battery is already filled with electrolyte and has been sealed and fully charged at the factory Never pry the sealing strip off or add any other fluid to this battery The single most important thing abo
108. on systems The following parts are also considered emission related components for exhaust emissions Aftertreatment devices Sensors Crankcase ventilation valves Electronic control units The following parts are considered emission related components for evaporative emissions Fuel Tank Vacuum Control Diaphragms Fuel Cap Control Cables FuelLine Control Linkages FuelLine Fittings Purge Valves Clamps Vapor Hoses Pressure Relief Valves Liquid Vapor Separator Control Valves Carbon Canister Control Solenoids Canister Mounting Brackets Electronic Controls Carburetor Purge Port Connector As related to the evaporative emission control system 107 WARRANTY U S A EPA Emissions Limited Warranty The exclusive remedy for breach of this limited warranty shall be at the exclusive option of POLARIS repair or replacement of any defective materials components or products THE REMEDIES SET FORTH IN THIS LIMITED WARRANTY ARE THE ONLY REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF THIS WARRANTY POLARIS SHALL HAVE NO LIABILITY TO ANY PERSON FOR INCIDENTAL CONSEQUENTIAL OR SPECIAL DAMAGES OF ANY DESCRIPTION WHETHER ARISING OUT OF EXPRESS OR IMPLIED WARRANTY OR ANY OTHER CONTRACT NEGLIGENCE OR OTHER TORT OR OTHERWISE THIS EXCLUSION OF CONSEQUENTIAL INCIDENTAL AND SPECIAL DAMAGES IS INDEPENDENT FROM AND SHALL SURVIVE ANY FINDING THAT THE EXCLUSIVE REMEDY FAILED OF ITS ESSENTIAL PURPOSE
109. our vehicle came equipped with a winch or if you choose to add an accessory winch to your vehicle AWARNING Improper winch use can result in SEVERE INJURY or DEATH Always follow all winch instructions and warnings in this manual Your winch may have a cable made of either wire rope or specially designed synthetic rope The term winch cable will be used for either unless noted otherwise Winch Safety Precautions APP WNP o 10 11 12 Read all sections of this manual Never use alcohol or drugs before or while operating the winch Never allow children under 16 years of age to operate the winch Always wear eye protection and heavy gloves when operating the winch Always keep body hair clothing and jewelry clear of the winch cable fairlead and hook when operating winch Never attempt to jerk a load attached to the winch with a moving vehicle See the Shock Loading section on page 56 Always keep the area around the vehicle winch winch cable and load clear of people especially children and distractions while operating the winch Always turn the vehicle ignition power OFF when it and the winch are not being used Always be sure that at least five 5 full turns of winch cable are wrapped around the winch drum at all times The friction provided by this wrapped cable allows the drum to pull on the winch cable and move the load Always apply your vehicle s park brake and or park mechanism to hold the vehic
110. ous injury or death When removing the battery always disconnect the negative black cable first When reinstalling the battery always connect the negative black cable last 1 Remove the seat Remove the storage bin 2 Remove the screws from the battery hold down strap and remove the strap 3 Disconnect the black battery cable first Disconnect the red battery cable last 5 Lift the battery out of the vehicle Be careful not to tip a conventional battery sideways which could spill electrolyte NOTICE If electrolyte spills immediately wash it off with a solution of one tablespoon baking soda and one cup water to prevent damage to the vehicle Hold Down Strap 87 MAINTENANCE Battery Battery Installation Using a new battery that has not been fully charged can damage the battery and result in a shorter life It can also hinder vehicle performance Follow the battery charging instructions on page 89 before installing the battery Ensure that the battery is fully charged 2 Place the fully charged battery in the battery holder under the driver s seat with the terminals toward the rear of the vehicle 3 Connect and tighten the red cable first Connect and tighten the black cable last 4 Verify that cables are properly routed and install the hold down strap Tighten the screws securely A Position Terminals Battery Storage Toward Rear Whenever the vehicle is not used for a peri
111. perating on Pavement This vehicle s tires are designed for off road use only not for use on pavement Operating this vehicle on paved surfaces including sidewalks paths parking lots and driveways may adversely affect the handling of the vehicle and may increase the risk of loss of control and accident or rollover Avoid operating the vehicle on pavement If it s unavoidable travel slowly travel short distances and avoid sudden turns or stops Operating on Public Roads Operating this vehicle on public streets roads or highways could result in a collision with another vehicle Never operate this vehicle on any public street road or highway including dirt and gravel roads unless designated for off highway use In some areas it s unlawful to operate this vehicle on public streets roads and highways 18 SAFETY Operator Safety Turning Improperly Turning improperly could cause loss of traction loss of control accident or rollover Always follow proper procedures for turning as described in this owner s manual Never turn abruptly or at sharp angles Never turn at high speeds Practice turning at slow speeds before attempting to turn at faster speeds Operating in Unfamiliar Terrain Failure to use extra caution when operating on unfamiliar terrain could result in an accident or rollover Unfamiliar terrain may contain hidden rocks bumps or holes that could cause loss of control or rollover Travel slowly and use extra caution wh
112. rce of flame or sparks Always use an approved gasoline container to store fuel and remove the container from the vehicle before filling to avoid fuel ignition due to electrical static discharge Do not smoke or allow open flames or sparks in or near the area where refueling is performed or where gasoline is stored Do not overfill the tank Do not fill the tank neck f gasoline spills on your skin or clothing immediately wash it off with soap and water and change clothing Exposure to Exhaust Engine exhaust fumes are poisonous and can cause loss of consciousness or death in a short time Never start the engine or let it run in an enclosed area The engine exhaust from this product contains chemicals known to cause cancer birth defects or other reproductive harm Operate this vehicle only outdoors or in well ventilated areas Operating a Damaged Vehicle Operating a damaged vehicle can result in an accident After any rollover or other accident have a qualified service dealer inspect the entire machine for possible damage including but not limited to seat belts rollover protection devices brakes throttle and steering systems Operating at Excessive Speeds Operating this vehicle at excessive speeds increases the operator s risk of losing control Always operate at a speed that s appropriate for the terrain the visibility and operating conditions your skills and experience and your passengers skills and experience O
113. ricant amp 1290 ml 16 3 Nm 16 3 Nm Transmission Fluid Front Gearcase Demand Drive Fluid 9 3 oz 8 10 ft Ibs 11 ft Ibs 275 ml 11 13 6 Nm 15 Nm Middle Gearcase ATV Angle Drive Fluid 6 75 oz 14 ft Ibs 14 ft Ibs 200 ml 19 4 Nm 19 4 Nm Rear Gearcase ATV Angle Drive Fluid 18 oz 14 ft Ibs 14 ft Ibs 532 ml 19 4 Nm 19 4 Nm RANGER CREW Gearcase Specifications Gearcase Lubricant Capacity Fill Plug s Drain Plug Torque Torque Main Gearcase AGL Gearcase 34 oz 12 ft Ibs 12 ft Ibs Transmission Lubricant amp 1000 ml 16 3 Nm 16 3 Nm Transmission Fluid Front Gearcase Demand Drive Fluid 9 3 oz 8 10 ft Ibs 11 ft Ibs 275 ml 11 13 6 Nm 15 Nm 65 MAINTENANCE Gearcases Transmission Main Gearcase 4X4 CREW Always check and change the transmission oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 59 Refer to the Gearcase Specifications Chart on page 65 for recommended lubricants capacities and torque specifications See page 100 for the part numbers of POLARIS products Oil Check The fill plug is located on the rear of the gearcase A level check alternate fill plug is located on the side of the gearcase Maintain the oil level even with the bottom of the level check fill plug hole threads 1 Position the vehicle on a level surface 2 Remove the level check fill plug Check the oil level 3 Remove the re
114. ry for your vehicle POLARIS also recommends that you use only Pure POLARIS parts It is a potential violation of the Clean Air Act if a part supplied by an aftermarket parts manufacturer reduces the effectiveness of the vehicle s emission controls Tampering with emission controls is prohibited by federal law California Residents Certain POLARIS off road vehicles are available in 49 state and 50 state versions Only the 50 state models are certified for sale in California The 50 state models available for sale in California are identified by the letter C in the model name e g R13UH88A C The POLARIS 50 state models are designed and built with features such as a reduced cargo box capacity Any modifications to these features may be a violation of the applicable California regulations and may void this limited emissions warranty offered by the manufacturer If you have any questions regarding your warranty rights and responsibilities please contact POLARIS Customer Assistance United States amp Canada 1 800 POLARIS 1 800 765 2747 French 1 800 268 6334 108 MAINTENANCE LOG Use the following chart to record periodic maintenance DATE MILES KM OR HOURS TECHNICIAN SERVICE PERFORMED COMMENTS 109 INDEX A Accessory Outlets 4 6 06 sees ren 22 Alt Filter een re exo de Ese dete ares 76 Air Filter Cleaning 000 76 All Wheel Dr
115. s coolant operating temperature increases the expanding heated excess coolant is forced out of the radiator past the pressure cap and into the overflow bottle As engine coolant temperature decreases the contracting cooled coolant is drawn back up from the tank past the pressure cap and into the radiator Some coolant level drop on new vehicles is normal as the system is purging itself of trapped air Observe coolant levels and maintain as recommended by adding coolant to the overflow bottle Adding or Changing Coolant 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 Antifreeze 60 40 premix or a 50 50 mixture of high quality aluminum compatible anti freeze coolant and distilled water POLARIS Antifreeze is already premixed and ready to use Do not dilute with water See page 100 for the part numbers of POLARIS products Always follow the manufacturer s mixing recommendations for the freeze protection required in your area Any time the cooling system has been drained for maintenance or repair replace the coolant If the recovery bottle has run dry the level in the radiator should be inspected Add coolant as needed Radiator and Cooling Fan Always check and clean the screen and radiator fins at the intervals outlined in the Periodic Maintenance Chart beg
116. section of this owner s manual Break In Period The break in period for your new RANGER is the first twenty hours of operation or the time it takes to use the first two tanks full of fuel No single action on your part is as important as a proper break in period Careful treatment of a new engine will result in more efficient performance and longer life for the engine Perform the following procedures carefully NOTICE Excessive heat build up during the first three hours of operation will damage close fitted engine parts Do not operate at full throttle or high speeds for extended periods during the first three hours of use Engine and Drivetrain Break in 1 Fill the fuel tank with fuel Review the fuel warnings on page 18 2 Check the oil level Add the recommended oil as needed to maintain the oil level in the normal safe operating range 3 Drive slowly at first Select an open area that allows room to familiarize yourself with vehicle operation and handling 4 Vary throttle positions Do not operate at sustained idle 5 Perform regular checks on fluid levels controls and areas outlined on the daily pre ride inspection checklist See page 35 During the break in period change both the oil and the filter at 25 hours 6 Pull only light loads 7 Check fluid levels of transmission and all gearcases after the first 25 hours of operation and every 100 hours thereafter 8 Inspect and adjust park brake cable tension after
117. sion related service Failure to conduct this maintenance will not void the emissions warranty but may affect emissions D Have an authorized POLARIS dealer perform these services WARNING Improperly performing the procedures marked with a D could result in component failure and lead to serious injury or death Have an authorized POLARIS dealer perform these services 59 MAINTENANCE Periodic Maintenance Chart Perform all services at whichever maintenance interval is reached first Item Maintenance Interval Remarks whichever comes first Hours Calendar Miles Km Steering Front suspension Rear suspension Tires Brake fluid level Pre Ride Make adjustments as need ed See Brake pedal travel Pre Ride Checklist on page 35 Brake system Wheels fasteners Frame fasteners Engine oil level 4 Air filter pre filter gt Daily s Inspect clean often replace as needed E Air box sediment tube Daily Drain deposits when visible Coolant if applicable Daily Check level daily change coolant every 2 years gt Power steering unit if equipped Daily Inspect daily clean often Headlamp tail lamp Daily Check operation apply dielectric grease if replacing Air filter main element Weekly Inspect replace as needed T Brake pad wear 10H Monthly Inspect periodically Battery 20H Monthly 5 Check terminals cle
118. t hand side of the vehicle near the passenger seat When refueling always use either leaded or unleaded gasoline with a minimum pump octane number of 87 R M 2 octane Do not use fuel with ethanol content greater than 10 percent such as E 85 fuel 24 FEATURES AND CONTROLS Park Brake Lever To help prevent the vehicle from rolling engage the park brake when parking the vehicle When the park Pi c PEDE brake is fully engaged BRAKE appears in the rider WA A ir 7 E7 CAL information display Engine speed is limited to 1300 IAN in AN EN FN Pu RPM in all gears except neutral If throttle is applied this limiting feature prevents operation which protects HH rys gag the park brake pads from excessive wear Tip This feature will not operate properly if the park brake connector or switch under the hood malfunctions or becomes disconnected or if the switch has moved Check for disconnection then see your dealer promptly if this feature fails to operate properly Inspect and adjust park brake cable tension after the first 25 hours of operation and every 100 hours thereafter to ensure proper cable tension See page 80 Always apply the service brakes before engaging or releasing the park brake 1 Apply the brakes 2 Pull the park brake lever downward as far as possible 3 To release the park brake apply the brakes Press the park brake release inward and move the lever upward as far as possible WARNING Operating
119. t periodically adjust when parts are replaced x Auxiliary brake if equipped Inspect daily adjust as needed Headlight aim Adjust as needed gt Perform these procedures more often for vehicles subjected to severe use E Emission Related Service D Have an authorized POLARIS dealer perform these services 61 MAINTENANCE Lubrication Recommendations Check and lubricate all components at the intervals outlined in the Periodic Maintenance Chart beginning on page 59 or more often under severe use such as wet or dusty conditions Items not listed in the chart should be lubricated at the general lubrication interval Item Lube Method Engine Oil PS 4 5W 50 4 Cycle Oil Add to proper level on dipstick See page 63 Brake Fluid DOT 4 Brake Fluid Maintain level between fill lines See page 79 Main Gearcase Oil Transmission AGL Gearcase Lubricant amp Transmission Fluid See page 67 6X6 See page 66 4X4 CREW Front Gearcase Oil Demand Drive Fluid See page 68 Middle Gearcase Oil 6X6 ATV Angle Drive Fluid See page 69 Rear Gearcase Oil 6X6 ATV Angle Drive Fluid See page 70 Prop Shaft U joints 6X6 U Joint Grease Locate fittings and grease Front Prop Shaft Yoke U Joint Grease Locate fittings and grease 3 pumps maximum 62 MAINTENANCE Engine Intake Restrictor Plate Some RANGER 800 models are equipped with an intake restrictor plate
120. tarting the Engine pusei eeii iiias 36 Steering Wheel Inspection 80 Steering Wheel Adjustment 24 Stopping the Engine 36 SOTAL csset dass Selene oases RES e ed 90 92 Storage ATER iced oh pe d p ere 92 Storage Compartments 00 28 Storage Battery esee eee 88 Storage COVERS sses sese t m e tsa ssa 92 Storage Fluid Levels 0 000 92 Storage Oil and Filter 0 0005 91 Storage Removal cis cer Re 93 Suspension Adjustment Rear 80 Switches AWD Switch 0205 23 Differential Lock Switch 23 ISON 42r turo re eS tase 23 Light ceceetemRERRSEST RS 23 Mode Button 0000 23 T Tachometet sis meme me 32 Throttle Body 2 2 sacee acted n emere Rm 78 Throttle Freeplay Adjustment 78 Throttle Freeplay Inspection 78 Throttle Pedal eee dae cabs wes 24 Throttle SyStem eee nore a rois 78 Tilt Steering sarissa seorsim para re 24 dare Tread Depth cese hm hen 81 Tates eicere oreet hc eae e Pee M teins 81 82 Torque Axle NUuts nene em ee 81 Torque Spark Plug esee 71 Torque Wheel Nut disci noche RR RR 81 Towing Loads 45 TOWIDE Speed uie tede puteo ep ttes 45 Trailer Hitch oer Re terre 24 Transmission 4XA4 Crew 0 0000 eee 66 Transmission 6X6 1 0 0 0000 cece eee eee 67 Transmission Operation 74 75
121. ted on the label Proper Use Warning Seat Belt Drive Responsibly Warning Proper Use Warning 4X4 6X6 Require Proper Use of Your Vehicle Do your part to prevent injuries Do not allow careless or reckless driving Make sure operators are 16 or older with a valid driver s license Do not let people drive or ride after using alcohol or drugs Do not allow operation on public roads unless designated for off highway vehicle access collisions with cars and trucks can occur Do not exceed seating capacity 3 occupants 7179979 Proper Use Warning CREW Require Proper Use of Your Vehicle Do your part to prevent injuries Do not allow careless or reckless driving Make sure operators are 16 or older with a valid driver s license Do not let people drive or ride after using alcohol or drugs Do not allow operation on public roads unless designated for off highway vehicle access collisions with cars and trucks can occur Do not exceed seating capacity 6 occupants 7179981 10 SAFETY Safety Labels and Locations Seat Belt Drive Responsibly Warning WARNING Improper vehicle use can result in SEVERE INJURY or DEATH Be Prepared Fasten seat belts Wear an approved helmet and protective gear ALWAYS use vehicle cab nets and or doors Each rider must be able to sit with back against seat feet flat on the floor and hands on steering wheel or hand holds Stay completely inside the vehicle
122. tested and qualified to be in accordance with the USFS standard 5100 1c Federal law requires that this spark arrester be installed and functional when the vehicle is operated on public lands Operation of off road vehicles on public lands in the U S A is regulated by 43 CFR 420 Violations are subject to monetary penalties Federal regulations can be viewed online at www gpoaccess gov ecft Crankcase Emission Control System This engine is equipped with a closed crankcase system Blow by gases are forced back to the combustion chamber by the intake system All exhaust gases exit through the exhaust system Exhaust Emission Control System Exhaust emissions are controlled by engine design An electronic fuel injection EFI system controls fuel delivery The engine and EFI components are set at the factory for optimal performance and are not adjustable The emissions label is located on the frame under the seat Electromagnetic Interference This spark ignition system complies with Canadian ICES 002 This vehicle complies with the EMC requirements of European directives 97 24 EC and 2004 108 EC Non ionizing Radiation This vehicle emits some electromagnetic energy People with active or non active implantable medical devices such as heart monitoring or controlling devices should review the limitations of their device and the applicable electromagnetic standards and directives that apply to this vehicle 58 MAINTENANCE Periodic
123. 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 25 FEATURES AND CONTROLS Cab Nets Riding in this vehicle without using the cab nets or doors if equipped increases the risk of serious injury or death in the event of an accident or rollover Cab nets or doors must be used by both operator and passengers at all times Make sure all latches are secure before operating the vehicle Always inspect cab nets and latches for tightness wear and damage before each use of the vehicle Use the strap adjusters to tighten any loose straps Promptly replace worn or damaged cab nets and latches with new cab nets and latches Please see your authorized POLARIS dealer Securing a Net 1 After entering the vehicle insert the lower net rod into the net mount on the floor Make sure the ball at the end of the rod is properly secured in the mount 2 Connect the latch at the top edge of the net to the receiver latch mounted on the front frame Opening a Net 1 To exit the vehicle release the latch at the top front edge of the cab net 2 Rotate the net rearward and pull upward on the lower net rod to remove it from the mount 3 Allow the net to hang freely outside the vehicle while dismounting Net Mount 26 FEATURES AND CONTROLS Seat Removal Pull up on the front of the seat and slide it toward the
124. tive spark plugs Inspect plugs and replace if necessary No spark to spark plug Inspect plugs and replace if necessary Water or fuel in crankcase Immediately see your POLARIS dealer Low battery voltage Recharge the battery to 12 8 VDC Mechanical failure See your dealer Engine Backfires Possible Cause Solution Weak spark from spark plug Inspect clean and or replace spark plugs Incorrect spark plug gap or heat range Set gap to specs or replace plugs Old or non recommended fuel Replace with fresh recommended fuel Incorrectly installed spark plug wires See your dealer Incorrect ignition timing See your dealer Mechanical failure See your dealer Loose ignition connections Check all connections and tighten Water present in fuel Replace with fresh recommended fuel Engine Pings or Knocks Possible Cause Solution Poor quality or low octane fuel Replace with recommended fuel Incorrect ignition timing See your dealer Incorrect spark plug gap or heat range Set gap to specs or replace plugs 102 TROUBLESHOOTING Engine Runs Irregularly Stalls or Misfires Possible Cause Solution Fouled or defective spark plugs Inspect clean and or replace spark plugs Worn or defective spark plug wires See your dealer Incorrect spark plug gap or heat range Set gap to specs or replac
125. tly ingested into the PVT system Use the following instructions to dry it out before operating Qy Uu sx po ee Position the vehicle on a level surface Remove the drain plug Allow the water to drain completely Reinstall the drain plug 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 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 Test for belt slippage If the belt slips repeat the process Take the vehicle to your dealer for service as soon as possible 75 MAINTENANCE Vehicle Immersion NOTICE If your vehicle becomes immersed major engine damage can result if the machine is not thoroughly inspected Take the vehicle to your dealer before starting the engine If it s impossible to take your RANGER to a dealer before starting it follow the steps outlined below I AON Me n 8 Move the vehicle to dry land or at the very least to water below the footrests Dry any water present in the air box Filter replacement is required if water is present 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 an
126. ugh to comfortably and safely sit in a passenger seat with the seat belt secured put both feet on the floor and grasp the hand hold Make sure all passengers are wearing helmet eye protection gloves long sleeve shirt long pants and over the ankle boots Make sure all passengers secure their seat belt Make sure all cab nets or doors are properly secured Do not carry more than the recommended number of passengers for your vehicle See page 10 Allow a passenger to ride only in a passenger seat Slow down Always travel at a speed appropriate for your skills your passengers skills and operating conditions Avoid unexpected or aggressive maneuvers that could cause discomfort or injury to a passenger Vehicle handling may change with a passenger and or cargo on board Allow more time and distance for braking 10 Always follow all operating guidelines as outlined on safety labels and in this manual 38 OPERATION Driving on Slippery Surfaces AWARNING Skidding or sliding can cause loss of control or rollover if tires regain traction unexpectedly When operating on slippery surfaces such as ice or loose gravel reduce speed and use extra caution to reduce the chance of skidding or sliding out of control Do not operate on excessively slippery surfaces Whenever riding on slippery surfaces such as wet trails or loose gravel or during freezing weather follow these precautions 1 Do not operate on excessively rough
127. ut maintaining a sealed battery is to keep it fully charged Since the battery is sealed and the sealing strip cannot be removed you must use a voltmeter or multimeter to measure DC voltage WARNING An overheated battery may explode causing severe injury or death Always watch charging times carefully Stop charging if the battery becomes very warm to the touch Allow it to cool before resuming charging For a refresh charge follow all instructions carefully 1 Check the battery voltage with a voltmeter or multimeter A fully charged battery will register 12 8 V or higher 2 If the voltage is less than 12 8 volts recharge the battery at 1 2 amps or less until battery voltage is 12 8 or greater 3 When using an automatic charger refer to the charger manufacturer s instructions for recharging When using a constant current charger use the guidelines below for recharging Always verify battery condition before and 1 2 hours after the end of charging State of Charge THE Voltage Action Using constant current Charge charger standard amps specified on top of battery 100 12 8 13 0 volts None check at 3 mos from date of None required manufacture 75 100 12 5 12 8 volts May need slight charge if no charge 3 6 hours given check in 3 months 50 75 12 0 12 5 volts Needs charge 5 11 hours 25 50 11 5 12 0 volts Needs charge At least 13 hours verify state of charge 0 25 11 5 volts or less Needs
128. y is turned off and on and the warning indicator is no longer active This allows the determination of persistent as well as intermittent faults Inactive codes are stored in the history of the unit 32 FEATURES AND CONTROLS Instrument Cluster Rider Information Center Engine Error Codes The error screen displays only when the Error Code CHECK ENGINE light is on or when it goes Number 0 9 on and off during one ignition cycle Error codes are not stored When the key is turned OFF the code and message is lost but will reappear if the fault reoccurs after restarting the engine If the CHECK ENGINE light illuminates retrieve the error codes from the display Suspect Parameter Number SPN 1 Ifthe error codes are not displayed use the MODE button to toggle until Ck ENG displays on the main line of the display Failure Mode Indicator FMI 2 Press and hold the MODE button to enter the diagnostics code menu 3 Record the three numbers displayed in the gear position clock and odometer displays 4 Press the MODE button to advance to the next error code 5 Press and hold the MODE button to exit the diagnostics code menu 6 See an authorized POLARIS dealer for code details and diagnosis 33 OPERATION Failure to operate the vehicle properly can result in a collision loss of control accident or rollover which may result in serious injury or death Read and understand all safety warnings outlined in the safety
129. you receive information and notices regarding your vehicle If you purchase from a private party If you purchase a POLARIS product from a private party to be kept and used outside of the country in which the product was originally purchased all warranty coverage will be denied You must nonetheless register your product under your name and address with a local POLARIS dealer in your country to ensure that you receive safety information and notices regarding your product EXPORTED PRODUCTS EXCEPT WHERE SPECIFICALLY REQUIRED BY LAW THERE IS NO WARRANTY OR SERVICE BULLETIN COVERAGE ON THIS PRODUCT IF IT IS SOLD OUTSIDE THE COUNTRY OF THE SELLING DEALER S AUTHORIZED LOCATION This policy does not apply to products that have received authorization for export from POLARIS Dealers may not give authorization for export You should consult an authorized dealer to determine this product s warranty or service coverage if you have any questions This policy does not apply to products registered to government officials or military personnel on assignment outside the country of the selling dealer s authorized location This policy does not apply to Safety Bulletins NOTICE If your product is registered outside of the country where it was purchased and you have not followed the procedure set above your product will no longer be eligible for warranty or service bulletin coverage of any kind other than safety bulletins Products registered to Government o

Polaris 6x6 Offroad Vehicle User Manual

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