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Polaris 500 Offroad Vehicle User Manual

1. 43 OPERATION Driving Safely Hauling Cargo A WARNING Hauling cargo improperly can alter vehicle handling and may cause loss of control or brake instability which can result in serious injury or death Always follow these precautions when hauling cargo REDUCE SPEED AND ALLOW GREATER DISTANCES FOR BRAKING WHEN HAULING CARGO Always load the cargo box with the load as far forward and as low as possible When operating over rough or hilly terrain reduce speed and cargo to maintain stable driving conditions Always operate the vehicle with extreme care when hauling or towing loads Slow down and 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 the vehicle to overturn DO NOT TRAVEL FASTER THAN THE RECOMMENDED SPEEDS Vehi
2. IS M y Panl N Ignition Storage A 12V Box Switoh Storage Accessory Storage Tray Outlet eis nt Choke Knob 28 FEATURES AND CONTROLS Gear Selector H High Gear H L Low Gear N Neutral L Gear R Reverse Selector y NOTE Low gear is the primary driving range for the R RANGER High gear is intended for use on hard packed surfaces with light loads To change gears stop the vehicle SS lt I and with the engine idling move the lever to the desired gear Do not attempt to shift gears with engine speed above idle or while the vehicle is moving NOTE Maintaining shift linkage adjustment is important to assure proper transmission function See your dealer if you experience any shifting problems CAUTION Do not attempt to shift the transmission while the vehicle is moving or damage to the transmission could result Always shift when the vehicle is stationary and the engine is at idle 29 FEATURES AND CONTROLS Brake Pedal Depress the brake pedal to slow or stop the vehicle Apply the brakes while starting the engine Throttle Pedal Push the pedal down to increase engine speed Spring pressure returns the pedal to the rest position when released Always check that the throttle pedal returns normally before start ing the engine Make sure there s adequate throttle pedal freeplay See page 80 for throttle peda
3. 121 MAINTENANCE LOG DATE MILES KM OR HOURS TECHNICIAN SERVICE PERFORMED COMMENTS 122 A Adding Coolant 69 Adjustment Headlight Beam 88 Park Brake 82 Rear Spring 83 Rear Suspension 83 Throttle Freeplay 80 Age Restrictions 8 Air Filter 00 0 e cee eee 75 Air Filter Cleaning 75 All Wheel Drive 50 All Wheel Drive Lock Switch 31 Arrestor Spark Warning 78 Auxiliary Outlet 25 AWD foie led isis ee bad eevee 50 AWD Differential Lock Switch 31 Axle Nut Torque 85 B Battery c ccc arenes 90 95 Charging Conventional 94 Charging Sealed Battery 94 95 Conventional 90 Fluid Replenishment 93 Installation 92 Removal 91 Storage tt alee acces hare ca 93 Beam Adjustment Headlight 88 Before Riding 33 Belt Burning 107 Belt Lite js ee eue cas peak died 47 Belt Wears bred abe center pah 107 Belts Seat 00 27 84 Brake Pliid s su say seey s aca das 81 Inspection 82 MSDS odo ye wa ee atte acives 89 Pedal co cas acs cite ns Sees 30 Parkete ta onr eda ate 30 Park Brake Adjustment 82 Braking
4. 75 Fela eee eek satu nae 75 Systems 75 76 Fluid Levels During Storage 99 Fluid Battery 93 Fluid Brake 0 81 Fogging the Engine 100 Fouled Plugs 0 68 Freeplay Adjustment Throttle 80 Freeplay Steering Wheel 83 Front Gearcase Lubrication 65 Oil Change 65 Oil Check 65 Fuel Cape tit aE Fas Ho sean 26 Filter cfs as ce eee site Peek 75 Gages oe i eh eee Bice 2a es 26 Saletyna s nea ea ae anuni 21 Stabilizer ios pti parerii 99 G Gap Spark Plug 67 Gear Selector 29 Gearcase Lubrication 63 Specification Chart 63 124 G Geareases i 6 eden eden ee 63 66 Gears shifting 29 H Hauling a Load 44 45 Hauling Cargo 44 45 Headlight Beam Adjustment 88 Headlight Lamp Replacement 87 Hitch Weight 47 l Idle RPM Adjustment 77 Ignition Switch 31 Indicator Light Replacement 89 Indicator Lights 25 Inspection Axle Nuts 85 Brakes sens clones ac heen cos ins 82 Park Brake 82 Pr Rid s is eosa 4 ca wa eanvaeas 33 Seat Belts n n nannaa 84 Steering Wheel 83 Throttle Freeplay 79 Wheel Nuts 85 Installation Battery
5. 5 7 Safety Symbols 9 Seat Belt Inspection 84 Seat Belts 00 27 84 Seat Removal 26 Selector Gear 005 29 Severe Use Definition 52 Shifter eras 85 ash alaa els 29 Shifting Gears 0 29 Signal Words 0005 9 Spark Arrestor Warning 78 Spark Arrestor Cleaning 78 Spark Plug Condition 68 AD tas oN eters INE EI IAE 67 Removal s bose sls Doses nator eet 68 TOrqQues esc cucides bea aeS av ah 67 Recommendations 67 68 Fouled 0 68 Specifications 102 105 Specifications Gearcase 63 Speed Towing 47 Spring Rear Adjustment 83 Stabilizing the Fuel 99 Starting the Engine 34 35 Steering Wheel Inspection 83 Stopping the Engine 35 125 INDEX S Storage oe ania eaa ee eee 96 100 Storage and Inspection 99 Storage and Lubrication 99 Storage ATCA ie si iach pong tee are 100 Battery 5 34 02 ai 93 COVETS 3 5 saat se eee 100 Fluid Levels 99 Oil and Filter 99 Removal From 101 Suspension Adjustment Rear 83 Switch AWD Differential Lock 31 Switch Ignition 31 Switch Light 31 Switches ons cues ol vee 31 Synthetic Oil 2 2 eee 58 T Throttle Fr
6. If it s impossible to take your RANGER to a dealer before starting it fol low the steps outlined below 1 Move the vehicle to dry land or at the very least to water below the footrests Disconnect the fuel pump wires 3 Remove the spark plug Place a clean container under the engine and loosen the carbu retor drain screw two turns 5 Turn the engine over several times using the electric start 6 Inspect the drained fuel for water or sediment Drain Screw 7 Dry the spark plug and reinstall it or install a new plug 8 Tighten the carburetor drain screw 9 Reconnect the fuel pump wires 10 Attempt to start the engine If necessary repeat the drying proce dure 11 Take the vehicle to your dealer for service as soon as possible whether you succeed in starting it or not NOTE If water has been ingested into the PVT follow the procedure on page 73 for drying 74 MAINTENANCE Filter Systems Air Filter Always change the air filter at the intervals outlined in the Periodic Maintenance Chart beginning on page 52 1 Lift the cargo box to access the air box 2 Remove the air box cover and inspect the gasket It should adhere tightly to the cover and seal all the way around 3 Remove the air filter 4 Do not attempt to clean the main element Install a new air filter NOTE Apply a small amount of general purpose grease to the sealing edges of the filter Se before insta
7. 92 Installation Wheels 86 Interference Electromagnetic 51 K Key Periodic Maintenance Chart 53 L Lamp Replacement Headlight 87 Lamp Replacement Indicator Lights 89 Level Coolant 70 71 Life of B lti 2 0 2085 Semi eevaas 47 Light Switch 31 Lights 0000 87 89 Lights Brake 0 0002 89 Lights Indicator 25 Load Capacity 45 Loads Towing 0 47 Lubricant Part Numbers 106 Lubrication For Storage 99 Recommendations 57 Front Gearcase 65 Gearcases inch is Seale ese ek 63 Main Gearcase 63 Rear Gearcase 66 Transmission 63 M Main Gearcase Lubrication 63 Oil Change 64 Oil Check 63 Maintenance Log 121 122 Maintenance Periodic 52 56 Modifications 20 13 N Noise Emission Control System 51 0 Obstacles n nanunua 41 Oil and Filter Care During Storage 99 Oil and Filter Change 61 62 Oil Change Engine 5 5 60 Front Gearcase 65 Main Gearcase 64 Rear Gearcase 66 Transmission 64 Oil Check Engines won cata es ees 59 Front Gearcase 65 Main Gearcase 63 Rear Gearcase 66 Tran
8. 110 WARRANTY LIMITED WARRANTY Polaris Sales Inc 2100 Highway 55 Medina MN 55340 gives a SIX MONTH LIM ITED WARRANTY on all components of the Polaris RANGER against defects in mate rial or workmanship Polaris also gives a one year limited warranty on the final drive chain for failure due to defects This warranty covers the parts and labor charges for repair or replacement of defective parts which are covered by this warranty This war ranty begins on the date of purchase This warranty is transferable to another consumer during the warranty period through a Polaris dealer REGISTRATION At the time of sale the Warranty Registration Form must be completed by your dealer and submitted to Polaris within ten days Upon receipt of this registration Polaris will record the registration for warranty No verification of registration will be sent to the purchaser as the copy of the Warranty Registration Form will be the warranty entitle ment If you have not signed the original registration and received the customer copy please contact your dealer immediately NO WARRANTY COVERAGE WILL BE ALLOWED UNLESS YOUR VEHICLE IS REGISTERED WITH POLARIS Initial dealer preparation and set up of your vehicle is very important in ensuring trou ble free operation Purchasing a machine in the crate or without proper dealer set up will void your warranty coverage WARRANTY COVERAGE AND EXCLUSIONS LIMITATIONS OF WARRANTIES AND REMEDIES The
9. Fuel Cap Fuel Gauge The fuel tank filler cap is located on the right hand side of the vehicle near the passenger seat It has a built in fuel gauge that indicates the amount of fuel remaining in the tank When the indicator needle nears the empty mark refuel at the earliest opportunity When refueling always use either leaded or unleaded gasoline with a minimum pump octane number of 87 R M 2 octane Do not use E 85 fuel 26 FEATURES AND CONTROLS Seat Belts A WARNING Falling from a moving vehicle could result in serious injury or death Always fasten your seat belt securely before operating or riding in the RANGER Passengers under five years of age require special restraints which are not available with this vehicle No person under the age of five may ride in the RANGER The RANGER is equipped with lap style seat belts for the operator and passenger To wear the seat belt properly follow this procedure 1 Place the belt across your lap as low on your hips as possible Make sure that the belt is not twisted 2 Push the latch plate into the buckle until it clicks 3 Release the strap it will self tighten NOTE The center belt must be tightened manually by pulling on the strap 4 Torelease the seat belt press the square red button in the buckle s center 27 FEATURES AND CONTROLS Console Indicator G M Lights eT Light AWD Differential Holder Shifter Switch didai
10. Clogged air filter Other mechanical failure Possible Lean Fuel Cause Low or contaminated fuel Inspect and clean or replace See your dealer Solution Add or change fuel clean the fuel system Low octane fuel Replace with recommended fuel Clogged fuel filter Replace filter Incorrect jetting See your dealer Possible Rich Fuel Cause Overuse of choke Solution Inspect clean and or replace spark plug Fuel is very high octane Replace with lower octane fuel Incorrect jetting See your dealer 109 TROUBLESHOOTING Engine Stops or Loses Power Possible Cause Solution Out of fuel Refuel Kinked or plugged fuel vent line Inspect and replace Overuse of choke Inspect clean and or replace spark plug 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
11. Pantone 4625C hy 500 2X4 Owner s Manual laintenance and Safety AWARNING Improper vehicle use can result in SEVERE INJURY or DEATH NEVER e Operate on public roads A collision can occur with another vehicle e Carry more than two passengers or passengers under age five e Use ALCOHOL or DRUGS before or while operating this vehicle e Operate at speeds too fast for your skills or the conditions Operate this vehicle on HILLS steeper than 15 degrees 15 To prevent flipover in hilly terrain use throttle and brakes gradually ALWAYS e Avoid paved surfaces which may adversely affect handling and control e Use proper RIDING TECHNIQUES to avoid vehicle overturns on hills and rough terrain and in turns e Wear eye protection REVERSE operation can be dangerous even at low speeds Steering becomes difficult To prevent flipover avoid sharp turns The park brake will supply increased braking but should be used as a parking brake only READ OWNER S MANUAL FOLLOW ALL INSTRUCTIONS AND WARNINGS THIS GENERAL PURPOSE OFF ROAD UTILITY VEHICLE DOES NOT MEET FEDERAL MOTOR VEHICLE SAFETY STANDARDS FOR ON ROAD VEHICLES For your nearest Polaris dealer POLARIS sa 1 800 POLARIS Ine Oy or visit www polarisindustries com Polaris Sales Inc 2100 Hwy 55 Medina MN 55340 Phone 763 417 8650 Fax 763 542 0599 Part No 9920634 Rev 02 Printed in USA F A WARNING Read understand
12. 2 4 1 Towing Capacity 1500 Ibs 681 kg Max Cargo Box Load 1000 Ibs 454 kg Engine 4 valve 4 stroke single cylinder with counter balance Displacement 499 cc Bore x Stroke 92 x 75 Pilot Jet 42 5 Main Jet 135 Needle Jet P 6 829 Jet Needle 4MB32 3 Air Screw 2 5 Alternator Output 250 W Compression Ratio 10 2 1 Starting System Electric Carburetor 34 mm CV Mikuni Ignition System CDI Ignition Timing 30 5000 RPM Spark Plug NGK BKR5E Front Suspension MacPherson strut w 8 25 in 21 cm of travel Rear Suspension Independent w 9 in 23 cm of travel 104 SPECIFICATIONS RANGER 4X4 Lubrication System Dry Sump Engine Oil 0W 40 Driving System Type PVT Shift Type Single Lever console Gear Reduction Low 8 71 1 Gear Reduction Reverse 5 9 1 Gear Reduction High 3 83 1 Drive Ratio Front 3 83 1 Drive Ratio Final 3 70 1 Tire Size Front 25x 10 12 Tire Size Rear 25x 11 12 Tire Pressure Front 8 12 psi Tire Pressure Rear 8 12 psi Brakes Front Rear Foot Activated 4 wheel hydraulic disc Brake Park Foot activated mechanical Hood Headlight 2 dual beam 35W quartz halogen Taillights 2 single beam 5W Brake Light 2 single beam 5W Indicator Light 1 0 W NOTE See your Polaris dealer for jetting and clutching specifications 105 POLARIS PRODUCTS
13. 0000004 35 Break In Period 32 Breather Filter 76 Burning Belts 107 Cc Capacity Weight 45 Carburetor 000 77 Carburetor Adjustment 77 Calton Eeh Gian eatin onan tein Sek 44 45 Cargo Box Dumping 46 Changing Coolant 69 Changing Gears 29 Cc Changing Oil Engine lsrs vc pach gutters 60 Front Gearcase 65 Rear Gearcase 66 Transmission Main Gearcase 64 Chart Gearcase Specifications 63 Chart Periodic Maintenance 52 56 Checking Oil Engin 24 3 ee Nenana 59 Front Gearcase 65 Rear Gearcase 66 Transmission Main Gearcase 63 Chrome Wheel Care 98 Cleaning and Storage 96 100 Cleaning the Air Filter 75 Cleaning the Exhaust System 78 Cleaning the Fuel Filter 75 Cleaning the Spark Arrestor 78 Component Locations 22 25 Condition Spark Plugs 68 Console niece eee ese eae eke tae 28 Coolant Level 70 Coolant Level Radiator 71 Coolant Adding or Changing 69 Cooling Fan 70 Cooling System 70 71 Cooling System Operation 69 Corrosion Removal Chrome 98 Cover for Storage 100 Crankcase Emission Control System 51 Cylinder Head 80 D Defin
14. 66 MAINTENANCE Spark Plugs CAUTION Using non recommended spark plugs can result in serious engine damage Always use Polaris recommended spark plugs Refer to the specifications section beginning on page 102 Spark Plug Gap Torque Model Electrode Gap New Plug Used Plug Torque Torque RANGER 4X4 036 9 mm 9 11 ft Ibs 9 11 ft Ibs RANGER 2X4 12 15 Nm 12 15 Nm Spark plug condition is indicative of engine operation The spark plug firing end condition should be read after the engine is warmed up and the vehicle is driven at higher speeds Immediately check the spark plug for correct color See page 68 A WARNING A hot exhaust system and engine can cause serious burns Wear protective gloves when removing a spark plug for inspection 67 MAINTENANCE Spark Plugs Spark Plug Condition 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 indi cates the proper type and heat range for the engine and the service NOTE The tip should not be white A white insulator tip indicates overheating caused by use of an improper spark plug or incorrect carburetion 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 foulin
15. 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 owners We proudly produce an exciting line of utility and recreational products e Snowmobiles e All terrain vehicles ATVs e RANGER utility vehicles e Victory motorcycles We believe Polaris sets a standard of excellence for all utility and recre ational vehicles manufactured in the world today Many years of experi ence have gone into the engineering design and development of your Polaris vehicle making it the finest machine we ve ever produced For safe and enjoyable operation of your vehicle be sure to follow the instructions and recommendations in this owner s manual Your manual contains instructions for minor maintenance but information about major repairs is outlined in the Polaris Service Manual and should be performed only by a Factory Certified Master Service Dealer MSD Technician Your Polaris dealer knows your vehicle best and is interested in your total satisfaction Be sure to return to your dealership for all of your ser vice needs during and a
16. 100 H 12M Inspect clean external in applicable surfaces gt Cooling Hoses 100 H 12M Inspect for leaks gt Engine mounts 100 H 12M Inspect Exhaust muffler 100 H 12M Inspect pipe gt Spark plug 100 H 12M Inspect replace as needed E Ignition timing 100 H 12M Inspect gt Wiring 100 H 12 M Inspect for wear routing security apply dielectric grease to connectors subjected to water mud etc E Clutches drive 100H 12M Inspect clean replace worn and driven parts Front wheel 100 H 12M Inspect replace as needed bearings E Brake fluid 200 H 24M Change every two years Spark arrestor 300 H 36M Clean out Idle speed Adjust as needed E Toe adjustment Inspect periodically adjust when parts are replaced E Auxiliary brake if Inspect daily adjust as gt equipped needed Headlight aim Adjust as needed gt Perform these procedures more often for vehicles subjected to severe use E Emission Related Service m Have an authorized Polaris dealer perform these services 56 MAINTENANCE Lubrication Recommendations Check and lubricate all components at the intervals outlined in the Peri odic Maintenance Chart beginning on page 52 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 Polaris Premium 4 Synthetic See
17. 19 4 Nm Gearcase Lube Main Gearcase Premium AGL 18 2 oz 14 ft Ibs 14 ft Ibs Transmission Synthetic 540 ml 19 4 Nm 19 4 Nm Gearcase Lube Front Gearcase Premium Demand 5 oz 8 10 ft Ibs 11 ft Ibs 4X4 Drive Hub Fluid 150 ml 11 13 6 Nm 15 Nm Rear Gearcase Premium ATV 18 oz 40 50 ft Ibs 30 45 in Ibs 2X4 4X4 Angle Drive Fluid 532 ml 54 68 Nm 3 5 Nm Transmission Main Gearcase Always check and change the transmission oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 52 Maintain the oil level even with the bottom of the fill plug hole Refer to the Gearcase Specifications Chart for recommended lubricants capacities and torque specifications See page 106 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 Remove the fill plug 3 Check the oil level 4 Add the recommended oil as needed 5 Reinstall the fill plug Torque to specification Fill Plug 63 MAINTENANCE Gearcases Transmission Main Gearcase 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 pan under the drain plug 3 Remove the drain plug Drain the oil 4 Wipe the magnetic end of the drain plug clean to remove accumula
18. ROAD UTILITY VEHICLE DOES NOT MEET FEDERAL MOTOR VEHICLE SAFETY STANDARDS FOR ON ROAD VEHICLES SAFETY Operator Safety A WARNING Failure to follow the warnings contained in this manual can result in severe injury or death A Polaris RANGER is not a toy and can be hazardous to operate This vehicle handles differently than other vehicles such as motorcycles and cars A collision or rollover can occur quickly even during routine maneuvers like turning or driving on hills or over obstacles if you fail to take proper precautions Read and understand your owner s manual and all warnings before operating the vehicle Age Restrictions This vehicle is an ADULT VEHICLE ONLY Operation is prohibited for anyone under 16 years of age No person under the age of 5 may ride as a passenger in this vehicle Know Your Vehicle As the operator of the vehicle you are responsible for your personal safety the safety of others and the protection of our environment Read and understand your owner s manual which includes valuable informa tion about all aspects of your vehicle including safe operating proce dures The RANGER is an off road vehicle Familiarize yourself with all laws and regulations concerning the operation of this vehicle in your area We strongly advise you to strictly follow the recommended maintenance program outlined in your owner s manual This preventive maintenance program is designed to ensure that a
19. alert to changing terrain conditions when operating the vehicle You may come upon hidden rocks bumps or holes suddenly without enough time to react 18 SAFETY Operator Safety A WARNING POTENTIAL HAZARD Failure to follow the minimum age recommendations for this vehicle WHAT CAN HAPPEN Serious injury or death the child or others HOW TO AVOID THE HAZARD Even though a child may be within the age group for which some vehicles are recommended he or she may not have the skills abilities or judgment needed to operate the vehicle safely and may be involved in a serious accident Only persons with a valid driver s license should operate a Polaris RANGER A WARNING POTENTIAL HAZARD Operating this vehicle with improper tires or with improper or uneven tire pressure WHAT CAN HAPPEN Loss of control accident and or overturn HOW TO AVOID THE HAZARD Always use the size and type of tires specified in the Owner s Manual for this vehicle Always maintain proper tire pressure as described on the decal and in the Owner s Manual See pages 5 and 102 19 SAFETY Operator Safety A WARNING Leaving the keys in the ignition can lead to unauthorized use of the vehicle resulting in serious injury or death Always remove the ignition key when the vehicle is not in use A WARNING After any overturn or accident have a qualified service dealer inspect the entire vehicle for possible
20. speed and travel with caution in unfamiliar terrain 41 OPERATION Driving Safely Driving in Reverse Follow these guidelines when operating in reverse Back slowly Apply the brakes lightly for stopping Avoid turning at sharp angles Always avoid backing downhill Never open the throttle suddenly while backing ON ON ee Always inspect left and right fields of vision before backing A WARNING Failure to use caution when operating in reverse can result in serious injury or death Before shifting into reverse always check for obstacles or people behind the vehicle and follow the reverse operation procedures outlined in this manual Always back slowly 42 OPERATION Driving Safely Parking on an Incline Avoid parking on an incline if possible If it s unavoidable follow these precautions 1 Place the transmission in gear 2 Engage the park brake 3 Turn the engine off 4 Block the rear wheels on the downhill side A WARNING A rolling vehicle can cause property damage and serious injury Always engage the park brake after stopping the engine Always block the downhill side of the wheels if leaving the vehicle on a hill or park the vehicle in a sidehill position instead Operating the vehicle while the park brake is engaged could cause loss of control and result in serious injury or death Always disengage the park brake before operating the vehicle
21. the drain plug Reinstall the drain plug Torque to specifica tion 7 Add the recommended oil 8 Reinstall the fill plug Torque to specification 9 Check for leaks 10 Discard used oil properly 65 MAINTENANCE Gearcases Rear Gearcase Always check and change the rear gearcase oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 52 Refer to the Gearcase Specifications Chart on page 63 for recommended lubricants capacities and torque specifications See page 106 for the part numbers of Polaris lubrication products Oil Check The rear gearcase fill plug is on the driver s side of the rear gearcase Maintain the oil level 3 4 of an inch 19 mm below the bottom thread of the fill plug hole Use a light colored non absorbent measuring instru ment such as a white cable tie to measure the depth 1 Position the vehicle ona level surface Fill Plug 2 Remove the fill plug Check the oil level 3 Add the recommended oil y as needed jf 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 Drain the oil 4 Clean the drain plug Reinstall Drain Plug the drain plug Torque to specification Add the recommended oil Reinstall the fill plug Torque to specification Check for leaks Dispose of used oil properly OO Sn
22. vehicle without proper instruction WHAT CAN HAPPEN Loss of control accident a HOW TO AVOID THE HAZARD The risk of an accident is greatly increased if the operator does not know how to operate the vehicle properly in different situations and on different types of terrain All operators must read and understand the Owner s Manual and all warning and instruction labels before operating the vehicle A WARNING POTENTIAL HAZARD Operating this vehicle on public streets roads or highways WHAT CAN HAPPEN Collision with another vehicle HOW TO AVOID THE HAZARD Never operate this vehicle on any public street road or highway including dirt or gravel In many states it s illegal to operate vehicles of this type on public streets roads and highways 15 SAFETY Operator Safety A WARNING POTENTIAL HAZARD Operating this vehicle after consuming alcohol or drugs e WHAT CAN HAPPEN Could seriously affect your judgment Could cause you to react more slowly Could affect your balance and perception Could result in an accident HOW TO AVOID THE HAZARD Driving a RANGER requires your full attention DO NOT drink alcohol or use drugs or medications before or while driving They will reduce your alertness and slow your reaction time In most states and provinces it s prohibited by law to drive while intoxicated or under the influence of drugs A WARNING POTENTIAL HAZARD Operating th
23. will void all manufacturer warranties and may violate laws governing the registration and operation of this vehicle Electromagnetic Interference This spark ignition system complies with Canadian ICES 002 This vehicle complies with European directives 97 24 EC and 89 336 EEC 51 MAINTENANCE Periodic Maintenance Chart Careful periodic maintenance will help keep your vehicle in the safest most reliable condition Inspection adjustment and lubrication of important components are explained in the periodic maintenance chart Inspect clean lubricate adjust and replace parts as necessary When inspection reveals the need for replacement parts use genuine Polaris parts available from your Polaris dealer Record maintenance and service in the Maintenance Log beginning on page 121 NOTE Service and adjustments are important for proper vehicle operation If you re not familiar with safe service and adjustment procedures have a qualified dealer perform these operations Maintenance intervals in the following chart are based upon average riding conditions and an average vehicle speed of approximately ten 10 miles per hour Vehicles subjected to severe use must be inspected and serviced more frequently Severe Use Definition e Frequent immersion in mud water or sand e Racing or race style high RPM use Prolonged low speed heavy load operation Extended idle Short trip cold weather operation Pay special attenti
24. OTING Drive Belt Wear Burn Possible Cause Driving onto a pickup or tall trailer in high range Solution Use low range during loading Starting out going up a steep incline Use low range See warnings on page 38 Driving at low RPM or ground speed 3 7 MPH Drive at a higher speed or use low range more frequently See page 72 Insufficient warm up at low ambient tempera tures 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 flex ible and prevent belt burning Slow easy clutch engage ment 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 throttle application to engage clutch WARNING Excessive throttle may cause loss of control and vehicle overturn 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 overturn Belt slippage from water or snow ingestion into the PVT system Dry out the PVT See page 73 Inspect clutch seals for damage if repeated leaking occurs Clutch
25. Part Number Description Engine Lubricant 2870791 Fogging Oil 12 oz Aerosol 2871281 Premium 4 Synthetic OW 40 4 Cycle Engine Oil qt 2871844 Premium 4 Synthetic OW 40 4 Cycle Engine Oil gal Gearcase Transmission Lubricants 2873602 Premium AGL Synthetic Gearcase Lubricant qt 2873603 Premium AGL Synthetic Gearcase Lube gal 2871653 Premium ATV Angle Drive Fluid 8 oz 2872276 Premium ATV Angle Drive Fluid 2 5 gal 2870465 Pump for Gallon Jug 2871654 Premium Demand Drive Hub Fluid 8 oz 2872277 Premium Demand Drive Hub Fluid 2 5 gal Coolant 2871323 60 40 Coolant gal 2871534 60 40 Coolant qt Grease Specialized Lubricants 2871312 Grease Gun Kit Premium All Season 3 oz 2871322 Premium All Season Grease 3 oz cartridge 2871423 Premium All Season Grease 14 oz cartridge 2871460 Starter Drive Grease 2 oz 2871515 Premium U Joint Lube 3 oz 2871551 Premium U Joint Lube 14 oz 2871329 Dielectric Grease Nyogel 2872073 Chain Lube Aerosol 6 25 oz 2872348 Chain Lube Aerosol 16 oz Additives Miscellaneous 2872889 Brake and Clutch Cleaner 2871326 Carbon Clean Plus 12 oz 2870652 Fuel Stabilizer 16 oz 2872189 DOT 4 Brake Fluid 2870990 DOT 3 Brake Fluid 2872893 Engine Degreaser 12 oz 2871956 Loctite 565 Thread Sealant 2871076 Polaris Battery Tender Charger 106 TROUBLESHO
26. Polaris limited warranty excludes any failures that are not caused by a defect in material or workmanship This warranty does not cover accidental damage normal wear and tear abuse or improper handling This warranty also does not cover any vehicle that has been altered structurally modified neglected improperly maintained used for rac ing or used for purposes other than for which it was manufactured or for any damages which occur during trailer transit or as a result of unauthorized service or the use of unauthorized parts In addition this warranty does not cover physical damage to paint or finish stress cracks tearing or puncturing of upholstery material corrosion or defects in parts components or the vehicle due to fire explosions or any other cause beyond Polaris control This warranty does not cover the use of unauthorized lubricants chemicals or fuels that are not compatible with the vehicle The exclusive remedy for breach of this warranty shall be at Polaris exclusive option repair or replacement of any defective materials or components or products THE REMEDIES SET FORTH IN THIS WARRANTY ARE THE ONLY REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF THIS WARRANTY POLARIS SHALL HAVE NO LIABILITY TO ANY PERSON FOR INCIDENTAL CONSEQUENTIAL OR SPECIAL DAMAGES OF ANY DESCRIP TION WHETHER ARISING OUT OF EXPRESS OR IMPLIED WARRANTY OR ANY OTHER CONTRACT NEGLIGENCE OR OTHER TORT OR OTHERWISE Some states do not permit the exclu
27. S yy J levers Fuel Tank Cap 22 FEATURES AND CONTROLS Component Locations Headlights Radiator if equipped Hood Hold Down Strap Front Bumper Brush Guard 23 FEATURES AND CONTROLS Component Locations Tailgate Latch Release Taillights Tailgate a IF TREA j ee o RLN Air Box CV Boot Rear Caliper Receiver Hitch Muffler Spark Arrestor 24 FEATURES AND CONTROLS Component Locations Indicator Lights The indicator light panel is located on the console See page 28 Reverse Low Gear Brakes Gear if equipped Trailer Hitch Bracket This vehicle is equipped with a receiver hitch bracket for a trailer hitch Trailer towing equipment is not supplied with this vehicle To avoid injury and property damage always heed the warnings and towing capacities outlined on pages 44 47 Auxiliary Outlet The 12 volt receptacle has spade connections on the back that may be used to power an auxiliary light or other optional accessories or lights The connections are behind the console under the hood Auxiliary Outlet 25 FEATURES AND CONTROLS Seat Removal Pull up on the front of the seat and slide it toward the front of the vehicle Install the seat by sliding the tabs into the rear of the seat base Push down firmly on the front of the seat until the pins are fully seated into the grommets
28. WD Differential Switch has three positions All Wheel Drive AWD Differential Lock Two Wheel Drive 2WD and Off 1WD turf mode Press the top of the rocker switch to engage All Wheel Drive AWD See page 50 for AWD operating instructions Move the rocker switch to the center position to lock the differential and operate in two wheel drive 2WD See page 49 for Differential Lock operating instructions Press the bottom of the switch to unlock the differential and allow the rear drive wheels to operate independently 1 WD This mode of opera tion is well suited to turf driving or when active traction is not needed 31 OPERATION Vehicle Break In Period The break in period for your new Polaris RANGER is the first twenty hours of operation or the time it takes to use the first two tanks full of gasoline No single action on your part is as important as a proper break in period Careful treatment of a new engine will result in more efficient performance and longer life for the engine Perform the following pro cedures carefully CAUTION Excessive heat build up during the first three hours of operation will damage close fitted engine parts Do not operate at full throttle or high speeds for extended periods during the first three hours of use Use of any oils other than those recommended by Polaris may cause serious engine damage We recommend the use of Polaris Premium 4 Synthetic Oil for your 4 cy
29. a guest to operate this vehicle unless the guest has read this manual and all product labels e To reduce tipover risk be especially careful when encountering obstacles and slopes and when braking on hills or during turns e This vehicle is for off road use only Never operate on public roads Always avoid paved surfaces e Helmets are recommended whenever driving this vehicle in an aggressive manner Eye protection is recommended at all times e Never consume alcohol or drugs before or while operating this vehicle e 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 e Always inspect your vehicle each time you use it to make sure it s in safe operating condition Always follow the inspection and maintenance procedures and schedules described in this manual e Always keep both hands on the steering wheel and both feet on the floorboards of the vehicle during operation e Always travel slowly and use extra caution when operating on unfamiliar terrain Be alert to changing terrain e Never operate on excessively rough slippery or loose terrain 10 SAFETY Operator Safety Always follow proper procedures for turning as described in this manual Practice turning at slow speeds before attempting to turn at faster speeds Never turn at excessive speeds Always have this vehicle checked by an auth
30. a trailer to any other location or you may lose control of the vehicle Never tow a trailer on a grade steeper than 15 Model Total Towed Total Towed Total Hitch Maximum Load Weight Load Weight Vertical Towin Level Ground 15 grade Weight Spee RANGER 4X4 1500 Ibs 850 Ibs 150 lbs 10 mph 681 kg 386 kg 68 1 kg 16 km h RANGER 2X4 1500 Ibs 850 Ibs 150 lbs 10 mph 681 kg 386 kg 68 1 kg 16 km h Belt Life To extend belt life use the lowest gear possible when hauling or towing heavy cargo 47 OPERATION Driving Safely Parking the Vehicle A WARNING A rolling vehicle can cause property damage and serious injury Always engage the park brake after stopping the engine Stop the vehicle on a level surface Turn the engine off Engage the park brake fies a Remove the ignition switch key to prevent unauthorized use A WARNING Gasoline is extremely flammable and can be explosive under certain conditions When parking inside a garage or other structure be sure that the structure is well ventilated and that the vehicle is not close to any source of flame or sparks including any appliance with pilot lights 48 OPERATION Differential Operation Modes The rear axle is equipped with a lockable differential that allows the operator to choose between an open differential or a closed differential On 4X4 models engaging AWD locks the front diff
31. aled battery is already filled with electrolyte and has been sealed and fully charged at the factory Never pry the sealing strip off or add any other fluid to this battery The single most important thing about maintaining a sealed battery is to keep it fully charged Since the battery is sealed and the sealing strip cannot be removed you must use a voltmeter or multimeter to measure DC voltage A 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 Ifthe voltage is less than 12 8 volts recharge the battery at 1 2 amps or less until battery voltage is 12 8 or greater NOTE When using an automatic charger refer to the charger manufacturer s instructions for recharging When using a constant current charger use the guidelines on the next page for recharging 94 Battery MAINTENANCE Battery Charging Sealed Battery NOTE Always verify battery condition before and 1 2 hours after the end of charging State of Charge Time Voltage Action Using constant current Charge charger standard amps specified on top of battery 100 12 8 13 0 volts None check at 3 None req
32. aler If you move or are traveling within the country where your vehicle was purchased Warranty or Service Bulletin repairs may be requested from any authorized Polaris dealer who sells the same line as your vehicle Outside the Country where your vehicle was purchased If you are traveling temporarily outside the country where your vehicle was purchased you should take your vehicle to an authorized Polaris dealer You must show the dealer photo identification from the country of the selling dealer s authorized location as proof of residence Upon residence verification the servicing dealer will be authorized to per form the warranty repair If You Move If you move to another country be sure to contact Polaris Customer Assistance and the customs department of the destination country before you move Vehicles importation rules vary considerably from country to country You may be required to present docu mentation of your move to Polaris Industries in order to continue your warranty cover age You may also be required to obtain documentation from Polaris Industries in order to register your vehicle in your new country If Purchased From A Private Party If you purchase a Polaris product from a private citizen outside of the country in which the vehicle was originally purchased all warranty coverage will be denied Notice If your vehicle is registered outside of the country where it was purchased and you have not followed the procedu
33. and equipped at the time of manufacture so as to conform with the applicable regulations of the California Air Resources Board and 2 is free from defects in materials and workmanship which may cause it to fail to conform with those regulations as applicable according to the terms and conditions stated below Warranty Period This warranty period begins on the date which the LSI engine is delivered to the origi nal retail purchaser and ends two years after that date During this two year period POLARIS warrants to the original retail purchaser and each subsequent purchaser that the LSI engine is free from defect in material and workmanship that can cause the fail ure of a warranted emission related part What is Covered Under This Warranty Repair and or replacement of any warranted emission related part will be performed at no charge provided the work is performed at an authorized dealer There will also be no charge for any diagnostic labor performed at an authorized dealer which leads to the determination that a warranted emission related part is defective Any warranted part which is not scheduled for replacement as required maintenance or which is scheduled only for regular inspection to the effect of repair or replace as nec essary shall be warranted for the warranty period Any warranted part which is sched uled for replacement as required maintenance shall be warranted for the period of time up to the first scheduled replacemen
34. apply them lightly several times to let friction dry out the pads Always be sure there are no obstacles or people behind your vehicle when operating in reverse When it s safe to proceed in reverse move slowly Avoid turning at sharp angles in reverse Always use the proper size and type of tires specified in this manual Always maintain proper tire pressure as specified on page 5 and in the specifications section beginning on page 102 11 SAFETY Operator Safety Never modify this vehicle through improper installation or use of accessories Never exceed the stated load capacity for this vehicle Cargo should be properly distributed and securely attached Reduce speed and fol low the instructions in this manual for hauling cargo or pulling a trailer Allow a greater distance for braking Always wear the seat belts when operating this vehicle Seat belts reduce the severity of injury in case of a sudden stop or collision Always keep arms and legs inside the cab frame while the vehicle is in motion Always engage the park brake before getting out of the vehicle See page 30 Always apply the brakes before releasing the park brake Always turn off the engine before refueling Make sure the refueling area is well ventilated and free of any source of flame or sparks Gas oline is extremely flammable See page 21 for fuel safety warnings Always remove the ignition key when the vehicle is not in use to pre vent unauthorized use or ac
35. aris Premium 60 40 anti freeze coolant or a 50 50 mixture of high quality aluminum compatible anti freeze coolant and distilled water Polaris Premium 60 40 is already premixed and ready to use Do not dilute with water See page 106 for the part numbers of Polaris prod ucts NOTE 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 69 MAINTENANCE Cooling System Radiator and Cooling Fan Always check and clean the screen and radiator fins at the intervals out lined in the Periodic Maintenance Chart beginning on page 52 Do not obstruct or deflect air flow through the radiator by installing unautho rized accessories in front of the radiator or behind the cooling fan Inter ference with the radiator air flow can lead to overheating and consequent engine damage CAUTION Washing the vehicle with a high pressure hose could damage the radiator fins and impair the radiator s effectiveness Using a high pressure system is not recommended Coolant Level Always check and change the coolant at the intervals outlined in the Periodic Maintenance Chart beginning on page 52 Maintain the coolant level between the minimum and maximum marks on the bottle when the fluid is cool The ov
36. arranty also does not cover physical damage corrosion or defects caused by fire explosions or other similar causes beyond the control of Polaris If you have any questions regarding your warranty rights and responsibilities you should contact the Polaris Warranty Department at 1 763 417 8650 114 WARRANTY California Emission Control Warranty Statement Your Warranty Rights and Obligations The California Air Resources Board and Polaris Industries Inc 2100 Highway 55 Medina Minnesota 55340 herein POLARIS are pleased to explain the emission con trol system warranty on your 2005 and later Large Spark Ignition Engine herein LSI engine The California Air Resources Board has designated this engine for this vehi cle as an LSI engine which produces 25 and greater horsepower and the vehicle has a six 6 or four 4 wheel drive and or a round steering wheel In California this LSI engine must be designed built and equipped to meet the state s stringent anti smog standards Polaris must warrant the emission control system on your LSI engine for the period of time described below provided there has been no abuse neglect or improper mainte nance of your LSI engine Your emission control system includes parts such as the carburetor and the ignition sys tem Also included may be hoses connectors and other emission related assemblies Where a warrantable condition exists POLARIS will repair your LSI engine at no cost to you inclu
37. arranty seerste nanni ee ee ae 111 Maintenance Log 0000ee0es 121 NAEK corae ea ei ee eee eee 123 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 Key Number V f p SOLARIS Engine Serial Number J h Vehicle Model Number Frame VIN Engine Serial Number Key Number SAFETY Safety Decals and Locations Warning decals have been placed on the vehicle for your protection Read and follow the instructions of the decals on the vehicle carefully If any of the decals depicted in this manual differ from the decals on your vehicle always read and follow the instructions of the decals on the vehicle If any decal becomes illegible or comes off contact your Polaris dealer to purchase a replacement Replacement safety decals are provided by Polaris at no charge The part number is printed on the decal Container Passenger Tire Pressure Warning WARNING Remove flammable material containers from box before filling e Passengers can be thrown off This can cause serious injury or death e Never carry pass
38. ate or federal law all other warranty terms will remain in effect Lubricants 1 Mixing oil brands or using non recommended oil may cause engine damage We rec ommend the use of Polaris engine oil 2 Damage resulting from the use of non recommended lubricants may not be covered by warranty SPARK ARRESTOR Polaris warrants that the spark arrestor in this vehicle will meet the efficiency require ments of 43 CFR 8343 1 c for at least 1000 hours when subjected to normal use and when maintenance and installation are in accordance with Polaris recommendations 112 WARRANTY Exported Vehicles EXCEPT WHERE SPECIFICALLY REQUIRED BY LAW THERE IS NO WAR RANTY OR SERVICE BULLETIN COVERAGE ON THIS VEHICLE IF IT IS SOLD OUTSIDE THE COUNTRY OF THE SELLING DEALER S AUTHORIZED LOCA TION This policy does not apply to vehicles that have received authorization for export from Polaris Industries Dealers may not give authorization for export You should consult an authorized dealer to determine this vehicle s warranty or service bulletin coverage if you have any questions This policy does not apply to vehicles registered to government officials or military per sonnel on assignment outside the country of the selling dealer s authorized location This policy does not apply to Safety Recalls How to Get Service In the Country where your vehicle was purchased Warranty or Service Bulletin repairs must be done by an authorized Polaris de
39. attery electrolyte is poisonous It contains sulfuric acid Serious burns can result from contact with skin eyes or clothing Antidote External Flush with water Internal Drink large quantities of water or milk Follow with milk of magnesia beaten egg or vegetable oil Call physician immediately Eyes Flush with water for 15 minutes and get prompt medical attention Batteries produce explosive gases Keep sparks flame cigarettes etc away Ventilate when charging or using in an enclosed space Always shield eyes when working near batteries KEEP OUT OF REACH OF CHILDREN 90 MAINTENANCE Battery A WARNING Improperly connecting or disconnecting battery cables can result in an explosion and cause serious injury or death When removing the battery always disconnect the negative black cable first When reinstalling the battery always connect the negative black cable last Battery Removal 1 Open the hood Battery 2 On conventional batteries remove the battery vent tube E 3 Disconnect the black nega gt tive battery cable first ma R f 3 4 Disconnect the red positive ala 2 battery cable last 5 Lift the battery out of the vehicle Be careful not to tip a gt conventional battery side ways which could spill elec trolyte CAUTION If electrolyte spills immediately wash it off with a solution of one tablespoon baking soda and one cup
40. changing adding or removing parts When the LSI engine is being serviced under warranty POLARIS and any of its autho rized dealers shall not be liable for any loss of use of the LSI engine for any damage to goods or loss of time or inconvenience This limited warranty also does not apply to any emission related part which malfunctions fails or is damaged due to failure to follow the maintenance and operating instructions specified in the 2005 and later Owner s Man ual including a Improper or inadequate maintenance of any warranted emission related part b Improper installation adjustment or repair of the LSI engine or any warranted emission related part unless performed by an authorized dealer c Failure to use recommended fuel as specified in the 2005 and later Owner s Manual d Repairs and diagnosis performed outside of an authorized dealer e Use of parts which are not authorized by POLARIS Maintenance Schedule The LSI engine owner is responsible for having all scheduled inspection and mainte nance services performed at the intervals specified in the 2005 and later Owner s Manual and to retain records of these services as having been performed These records should be transferred to each subsequent owner of the LSI engine POLARIS cannot deny a claim solely because there are no records of scheduled maintenance however a war ranty claim may be denied if the failure to perform the scheduled maintenance and inspection resu
41. cidental starting FOR MORE INFORMATION ABOUT SAFETY call Polaris at 1 800 342 3764 12 SAFETY Operator Safety A WARNING Make sure your RANGER is in excellent operating condition at all times We strongly recommend that the operator check all safety components before each ride Polaris RANGERs are designed to provide safe operation when used as directed Failure of critical machine components may result from operation with any modifications especially those that increase speed or power The RANGER may become aerodynamically unstable at speeds higher than those for which it is designed Loss of control may occur at higher speeds Modifications may also create a safety hazard and lead to bodily injury Do not make any modifications to your RANGER Equipment Modifications We are concerned for the safety of our customers and for the general public Therefore we strongly recommend that consumers do not install on a Polaris RANGER any equipment that may increase the speed or power of the vehicle or make any other modifications to the vehicle for these purposes Any modifications to the original equipment of the vehi cle create a substantial safety hazard and increase the risk of bodily injury The warranty on your Polaris RANGER is terminated if any equipment has been added to the vehicle or if any modifications have been made to the vehicle that increase its speed or power NOTE The addition of certain accessori
42. cle should never exceed 10 mph 16 kph while towing a load on a level grass surface Vehicle speed should never exceed 5 mph 8 kph when towing loads in rough terrain while cornering or while ascending or descending a hill 44 Driving Safely Hauling Cargo The RANGER has been designed to carry or tow specific capacities OPERATION Always read and understand the load distribution warnings listed on the warning labels Never exceed the following capacities 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 Model Maximum Capacities Cargo Box Level Ground RANGER 4X4 1500 Ibs 681 kg 1000 Ibs 454 kg RANGER 2X4 1350 Ibs 613 kg 850 Ibs 386 kg A WARNING Driving with 45 OPERATION Driving Safely Dumping the Cargo Box A WARNING Operating the vehicle while the cargo box is raised could result in severe injury The box could close unexpectedly and cause injury to the driver or passenger The rear tires will also catch the rear of a raised box damaging the vehicle and creating hazardous driving conditions Never operate this vehicle with the cargo box in the raised position 1 Select a level site to dump the cargo box Do not attempt to dump or unload the vehicle while parked T Y on an incline 2 Engag
43. cle engine 1 Fill the fuel tank with gasoline Heed the gasoline warnings on page 21 2 Check the oil level See page 59 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 famil iarize 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 33 6 Pull only light loads 7 During the break in period change both the oil and the filter at 25 hours 32 OPERATION Pre Ride Inspection A WARNING proper operating condition If a proper inspection is not done before each use severe injury or death could result Always inspect the vehicle before each use to ensure it s in Item Remarks Page Brake system pedal travel Ensure proper operation oF Brake fluid Ensure proper level 81 Front suspension Inspect lubricate if necessary 57 Rear suspension Inspect lubricate if necessary 57 Steering Ensure free operation 83 Tires Inspect condition and pressure 5 2 Wheels fasteners Inspect ensure fastener tightness 85 Frame nuts bolts fasteners Inspect ensure tightness Fuel and oil Ensure proper levels Ze Coolant level Ensure proper level a Coolant hoses Inspect for leak
44. 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 Condition Range to Use Operating at speeds less than 7 MPH 11 km h Low Towing heavy loads Low Operating in rough terrain swamps mountains etc Low Operating at speeds greater than 7 MPH 11 km h High 72 MAINTENANCE PVT System PVT Drying There may be some instances when water is ingested into the PVT sys tem Use the following instructions to dry it out before operating l 2 Loosen the bottom screws that secure the clutch cover Allow the water to drain Tighten the screws Apply the brakes Start the engine Engage the park brake Shift the transmission to neutral Apply varying throttle for 10 15 seconds to expel the moisture and air dry the belt and clutches Do not hold the throttle wide open for more than 10 seconds Allow the engine RPM to settle to idle speed Apply the service brakes Release the park brake and shift the transmission to the low est 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 73 MAINTENANCE Vehicle Immersion CAUTION 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
45. d cloths and pads may contain dirt particles that will scratch the finish 96 MAINTENANCE Cleaning and Storage Washing the Vehicle If a high pressure water system is used for cleaning not recommended exercise extreme caution The water may damage components and could remove paint and decals Avoid directing the water stream at the follow ing items e Wheel bearings e Radiator e Transmission seals e Brakes e Cab and body panels e Labels and decals e Electrical components and wiring NOTE If warning and safety labels are damaged contact your Polaris dealer for free replacement 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 Polishing the Vehicle Polaris recommends the use of common household aerosol furniture polish for polishing the finish on your Polaris vehicle Follow the instructions on the container Polishing Tips e Avoid the use of automotive products some of which can scratch the finish of your vehicle e 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 97 MAINTENANCE Cleaning and Storage Chrome Wheel Care if equipped Proper maintenance will protect chrome wheels from corrosion pre serve wheel life and ensure a like new appearance for many years NOTE Chrome wheels e
46. d warranty is the responsibility of the owner including the parts labor and other costs associated with recommended maintenance The exclusive remedy for breach of this limited warranty shall be at the exclusive option of Polaris repair or replacement of any defective materials components or prod ucts THE REMEDIES SET FORTH IN THIS LIMITED WARRANTY ARE THE ONLY REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF THIS WAR RANTY POLARIS SHALL HAVE NO LIABILITY TO ANY PERSON FOR INCI DENTAL CONSEQUENTIAL OR SPECIAL DAMAGES OF ANY DESCRIPTION WHETHER ARISING OUT OF EXPRESS OR IMPLIED WAR RANTY OR ANY OTHER CONTRACT NEGLIGENCE OR OTHER TORT OR OTHERWISE ALL IMPLIED WARRANTIES INCLUDING BUT NOT LIMITED TO ANY IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PAR TICULAR PURPOSE ARE LIMITED IN DURATION TO THE WARRANTY PERIOD DESCRIBED HEREIN POLARIS DISCLAIMS ALL EXPRESS WARRAN TIES 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 incon sistent with the controlling state law This limited warranty excludes failures not caused by a defect in material or workman ship This limited warranty does not cover damage due to accidents abuse or improper handling maintenance or use This limited warranty also does not cover any engine that has been structurally altered or any engine that has been used in racing competition This limited w
47. damage including but not limited to brakes throttle and steering systems A WARNING Exhaust system components are very hot during and after use of the vehicle Hot components can cause serious 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 20 SAFETY Fuel Safety A WARNING Gasoline is highly flammable and is explosive under certain conditions Always exercise extreme caution whenever handling gasoline Always stop the engine when refueling Always refuel outdoors or in a well ventilated area Do not smoke or allow open flames or sparks in or near the refueling area or where gasoline is stored Do not over fill the tank Do not fill the tank neck If gasoline spills on your skin or clothing immediately wash it off with soap and water and change clothing Never start the engine or let it run in an enclosed area Gasoline powered engine exhaust fumes are poisonous and can cause loss of consciousness and death in a short time 21 FEATURES AND CONTROLS Component Locations Some Polaris vehicles are equipped with special features such as the cab frame Not all models come with all features Refer to the specifications section beginning on page 102 Cab Frame if Equipped Console Battery under hood Cargo Box vd D
48. ding diagnosis parts and labor Manufacturer s Warranty Coverage The 2005 and later LSI engines are warranted for two 2 years If any emission related part on your LSI engine is defective the part will be repaired or replaced by POLARIS Owner s Warranty Responsibilities e As the LSI engine owner you are responsible for the performance of the required maintenance listed in your Owner s Safety and Maintenance Manual herein Owner s Manual POLARIS recommends that you retain all receipts covering maintenance on your LSI engine but POLARIS cannot deny warranty solely for the lack of receipts or for your failure to ensure the performance of all scheduled maintenance As the LSI engine owner you should however be aware that POLARIS may deny you warranty coverage if your LSI engine or a part has failed due to abuse neglect improper maintenance or unapproved modifications You are responsible for presenting your LSI engine to a dealer authorized by POLARIS as soon as a problem exists The warranty repairs should be completed in a reasonable amount of time not to exceed 30 days If you have any questions regarding your warranty rights and responsibilities you should contact the Polaris Warranty Department at 1 763 417 8650 115 WARRANTY California Emission Control Warranty Statement Limited Warranty California Only POLARIS warrants to the owner of 2005 and later LSI engines that the LSI engine 1 has been designed built
49. e engine 3 Remove the seat See page 26 4 Remove the dipstick Wipe it dry with a clean cloth 5 Reinstall the dipstick A Screw it in completely iA NOTE The dipstick must be JE st screwed in completely to Add Full keep the angle and depth of the stick consis tent Remove the dipstick Make sure that the oil level is between the full and add marks Add oil if necessary Do not overfill NOTE Arising oil level between checks in cool weather driving can indicate moisture collecting in the oil reservoir If the oil level is above the full mark change the oil Safe Range 59 MAINTENANCE Engine Oil Oil and Filter Change CAUTION Hot oil can cause serious burns to skin Do not allow hot oil to come into contact with skin Always change the oil and filter at the intervals outlined in the Periodic Maintenance Chart beginning on page 52 Always change the oil filter whenever changing oil 1 Position the vehicle on a level surface 2 Run the engine for two to three minutes until warm Stop the engine 3 Clean the area around the Drain drain plug 4 Place a drain pan beneath oil tank 5 Remove the drain plug Sealing Fitting Allow the oil to drain com Washer pletely 6 Install a new sealing washer on the drain plug NOTE The sealing surfaces on Orientation drain plug and oil tank Mark LDH Bee oF should be clean and free of QUK N ee burrs nicks
50. e level requirements Operation on Public Lands in the U S A Your Polaris vehicle has a spark arrestor that was tested and qualified to be in accordance with the USDA Forest Service Standard 5100 1C Fed eral law requires that this spark arrestor be installed and functional when the vehicle is operated on public lands Operation of off road vehicles on public lands in the U S A Is regulated by 43 CFR 8343 Violations are subject to monetary penalties Federal regulations can be viewed online at www gpoaccess gov 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 The emissions from the exhaust of this vehicle are controlled by engine design including factory set fuel delivery and ignition The engine and related components must be maintained at Polaris specifications to achieve optimal performance Engine idle speed is the only adjustment Polaris recommends that the operator perform Any other adjustments should be performed by an authorized Polaris dealer The emissions label is located on either the recoil cover or stator hous ing Remove the seat and look through the gap in the aluminum exhaust shield to view the label NOTE The installation of devices that effectively increase exhaust emissions beyond their legal limits
51. e the arrestor clean out plugs located on the bottom of the muffler 2 Shift the transmission to neutral Apply the brakes Start the engine 3 Purge accumulated carbon from the system by momentarily rev ving the enging several times Outlet Cl an Out 4 Ifcarbon is expelled cover or Plugs plug the exhaust outlet and rap on the pipe around the clean out plugs while revving the engine several more times 5 Ifparticles are still suspected to be in the muffler elevate the rear of the vehicle one foot higher than the front Engage the park brake Block the wheels Make sure the transmission is in neutral and repeat steps 3 and 4 until no more particles are expelled when the engine is revved 6 Stop the engine Allow the arrestor to cool 7 Reinstall the arrestor plugs and remove the outlet cover or plug 78 MAINTENANCE Throttle System A WARNING Failure to check or maintain proper operation of the throttle system can result in an accident and lead to serious injury or death if the throttle pedal sticks during operation 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 If the throttle pedal has excessive play due to cable stretch or mis adjustment
52. e the park ss N brake 3 Dismount the vehicle lt Nes Ensure that the cargo eleas Lever Noa is positioned evenly or toward the front of the cargo box IC wa Release the tailgate by pulling up on the tailgate latch Stand clear and pull up on the cargo box release lever Lift the front of the cargo box to dump the cargo Sym Lower the cargo box and push down securely to latch A 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 46 OPERATION Driving Safely Towing Loads A WARNING Towing improperly can alter vehicle handling and may cause loss of control or brake instability which can result in serious injury or death Always follow these precautions when towing Never load more than the recommended vertical tongue weight on the towing bracket Do not operate the vehicle faster than 10 mph 16 km h when towing See 102 page 44 Towing a trailer increases braking distance Do not tow more than the recommended weight for the vehicle See the towing capacity chart below and the specifications charts beginning on page Attach a trailer to the trailer hitch bracket only Do not attach
53. each month during storage and recharge as needed to maintain a full charge See page 94 NOTE Battery charge can be maintained by using a Polaris Battery Tender charger or by charging about once a month to make up for normal self discharge Battery Tender can be left connected during the storage period and will automatically charge the battery if the voltage drops below a pre determined point See page 106 for the part numbers of Polaris products Battery Fluid Conventional Battery A poorly maintained battery will Lower Upper deteriorate rapidly Check the bat Mark Mark tery 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 93 MAINTENANCE Battery Battery Charging Conventional Battery 1 Remove the battery from the vehicle to prevent damage from leak ing or spilled electrolyte during charging See page 91 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 grav ity to 1 270 or greater 3 Reinstall the battery See page 92 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 installa tion of a sealed battery Read all instructions before proceeding with the installation of this battery The se
54. eadily start intermittent use of the choke half way out may be necessary If the engine is over choked when warm depress the throttle pedal fully while cranking to aid in starting Release the throttle pedal immediately after the engine starts If the engine does not start and all conditions are favorable change the spark plug and try again 34 OPERATION Starting the Engine 8 After the engine starts push the choke knob in half way 9 Vary the engine RPM slightly with the throttle to aid in warm up until the engine idles smoothly 10 Push the choke knob in CAUTION 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 brake A WARNING A rolling vehicle can cause property damage and serious injury Always engage the park brake after stopping the engine Braking 1 Release the throttle pedal completely 2 Press on the brake pedal evenly and firmly NOTE Practice starting and stopping using the brakes until you re familiar with the controls NOTE When the throttle pedal is released completely and the engine speed drops near an idle the vehicle has no engine braking A WARNING Failure to allow for increased braking distance when hauling cargo o
55. eeplay Adjustment 80 Throttle Freeplay Inspection 79 Throttle Freeplay Freeplay Throttle i Throttle Pedal 00 Throttle System 79 80 Tire Pressure 0 0005 5 Tire Tread Depth 85 Diresse Gale outst fost ey ey le Ws gn 85 86 Torque Axle Nuts 85 Torque Spark Plug 67 Torque Wheel Nut 85 126 T Towing Loads 47 Towing Speed 0 47 Trailer Hitch Bracket 25 Transmission Lubrication 63 Oil Change 64 Oil Check 00 63 Operation c g veers cadet dasa 72 System 00 00 73 Dry oregon aoea vase esti uo 73 Transporting the Vehicle 101 Tread Depth 85 V Vehicle Break In 32 Vehicle Identification Numbers 4 Vehicle Immersion 74 Vehicle Transport 101 WwW Warning Symbols 9 Washing the Vehicle 96 97 Water Immersion of Vehicle 74 Wear Drive Belt 107 Weight Capacity 45 Weight Hitch 47 Wheel Installation 86 Wheel Nut Torque 85 Wheel Removal 86
56. engers in cargo box Maximum 2X4 Box Load 850 Ibs Maximum 4X4 Box Load 1000 Ibs Maximum 6X6 Box Load 1200 Ibs IMPROPER TIRE PRESSURE OR OVERLOADING can cause loss of control resulting in SEVERE INJURY OR DEATH TIRE PRESSURE PSI RANGER 2X4 and 4X4 FRONT 10 REAR 10 RANGER 6X6 FRONT 10 CENTER 10 REAR 10 MAXIMUM WEIGHT CAPACITY Gross Vehicle Weight INCLUDING MACHINE DRIVER AND CARGO RANGER 2X4 and 4X4 is 2750 LBS RANGER 6X6 is 2900 LBS Reduce speed and allow greater distance for braking when carrying cargo Overloading or carrying tall off center or unsecured loads will increase your risk of losing control Loads should be centered and carried as low as possible in box For stability on rough or hilly terrain reduce speed and cargo Be careful if load extends over the side of the box Read Owner s Manual for more detailed loading information SAFETY Safety Decals and Locations Cab Frame Seat Belt Warning Clutch Cover Q Warning Clutch Cover Warning WARNING NO STEP e 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 Cab Frame Seat Belt Warning WARNING VEHICLE ROLLOVER could cause severe injury or death This cab frame is not designed or inte
57. erential and the rear differential AWD 4X4 Press the top of the rocker switch to engage All Wheel Drive AWD When in AWD the rear wheels rotate at the same speed The front wheels also rotate at the same speed See page 50 for AWD operating instructions 2WD Rear Differential Locked Move the rocker switch to the center position to lock the differential and oper ate in two wheel drive 2WD Locking the differential in slippery or low traction conditions helps improve traction When the rear differential is locked both rear wheels rotate at the same speed T OFF Differential Unlocked Press the bottom of the switch to unlock the differential and allow the rear drive wheels to operate independently 1 WD When the rear differ ential is unlocked the rear wheels can rotate at different speeds Unlock the differential to make maneuvering easier and minimize damage to turf CAUTION Damage to the differential can occur if it is engaged while the vehicle is traveling at high speeds or while the rear wheels are spinning Slow the vehicle to nearly stopped before engaging the differential 49 OPERATION All Wheel Drive AWD 4X4 Models The illuminated amber AWD AWD Switch switch indicates that the vehi cle is in AWD When the AWD switch is on the front gearcase will auto matically engage any time the rear wheels lose traction When the rear wheels regain traction the front gearcase w
58. erflow 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 3 Ifthe coolant level is below the safe operating range lift the hood and locate the overflow bottle lid Remove the lid and use a funnel to add coolant through the filler opening Reinstall the cap Overflow Bottle NOTE 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 70 MAINTENANCE Cooling System Radiator Coolant Level Always check and clean the screen and radiator fins at the intervals out lined in the Periodic Maintenance Chart beginning on page 52 Do not obstruct or deflect air flow through the radiator by installing unautho rized accessories in front of the radiator or behind the cooling fan Inter ference with the radiator air flow can lead to overheating and consequentially engine damage A WARNING Escaping steam can cause severe burns Never remove the pressure cap while the engine is warm or hot Always allow the engine to cool before removing the pressure cap 1 Lift the hood 2 Slowly remove the radi ator cap 3 View the coolant level through the opening 4 Use a funnel and slowly add coolant as needed NOTE This procedure is required only if the cooling system has been drained for mainte
59. es including but not limited to mow ers 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 13 SAFETY Operator Safety A WARNING POTENTIAL HAZARD Stalling rolling backwards while climbing a hill WHAT CAN HAPPEN Vehicle overturn HOW TO AVOID THE HAZARD Maintain a steady speed when climbing a hill If you lose all forward speed Apply the brakes Engage the park brake after fully stopped If you begin rolling backwards Never apply engine power Apply the brakes gradually When fully stopped engage the park brake In the event of an accident have a qualified service dealer check the complete vehicle for possible damage including but not limited to brakes throttle and steering A WARNING POTENTIAL HAZARD Operating this vehicle on paved surfaces WHAT CAN HAPPEN Loss of control HOW TO AVOID THE HAZARD This vehicle s tires are designed for off road use only not for use on pavement Paved surfaces may seriously affect handling and control of the vehicle and may cause the vehicle to go out of control Avoid operating the vehicle on pavement If you must operate on a paved surface travel slowly and do not make sudden turns or stops 14 SAFETY Operator Safety A WARNING POTENTIAL HAZARD Operating this
60. f the AWD is engaged while the wheels are spinning Always allow the wheels to stop spinning before engaging AWD A WARNING Failure to exercise care when operating on slippery surfaces can result in loss of tire traction and cause loss of control accident and serious injury or death Never apply the brakes during a skid Do not operate on excessively slippery surfaces Always reduce speed and use additional caution when operating on slippery surfaces 37 OPERATION Driving Safely Driving Uphill Whenever traveling uphill follow these precautions 1 Always travel straight uphill 2 Avoid steep hills 15 maximum 3 Keep both feet on the floor 4 Proceed at a 15 maximum steady rate of speed and throttle opening A WARNING Climbing hills improperly can cause loss of control or vehicle overturn Always check the terrain carefully before climbing a hill Braking and handling are greatly affected when operating in hilly terrain Improper procedure could cause loss of control or overturn and result in serious injury or death Avoid climbing steep hills 15 maximum Use extreme caution when operating on hills and follow proper operating procedures outlined in the owner s manual Never climb hills with excessively slippery or loose surfaces Never open the throttle suddenly Never go over the crest of a hill at high speed An obstacle a sharp drop or another vehicle or perso
61. for excessive travel or a spongy feel 3 Check the friction pads for wear damage and looseness 4 Inspect the brake disc spline and pad wear surface for excessive wear 5 Change pads when worn to 3 64 1 mm Park Brake Inspection 1 Slowly push the park brake pedal down with your foot 2 After 8 to 12 clicks of pedal travel check the vehicle for movement The vehicle should not roll while parked If the vehicle moves adjust the park brake Park Brake Adjustment 1 Position the vehicle on a level surface Park Brake Pedal 2 Shift the transmission to neutral 3 Loosen or tighten the nuts on the pedal end of the park brake cable as needed 82 MAINTENANCE 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 52 1 Position the vehicle on a level surface 2 Lightly turn the steering wheel left and right 3 There should be 0 8 1 0 20 25 mm of freeplay 4 If there is excessive freeplay or strange noises or the steering feels rough or catchy have the steering system inspected by an autho rized Polaris dealer Suspension Adjustment The rear suspension may 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
62. fter the warranty period We also take great pride in our complete line of apparel parts and acces sories available through our online store at www purepolaris com Have your accessories and clothing delivered right to your door POLARIS The Way Out POLARIS and POLARIS THE WAY OUT are registered trademarks of Polaris Indus tries Inc Copyright 2006 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 discrep ancies may result between the actual vehicle and the information presented in this publi cation Depictions and or procedures in this publication are intended for reference use only No liability can be accepted for omissions or inaccuracies Any reprinting or reuse of the depictions and or procedures contained within whether whole or in part is expressly prohibited Printed in U S A 2007 RANGER 2X4 RANGER 4X4 Owner s Manual P N 9920634 2 TABLE OF CONTENTS Vehicle Identification Numbers 4 DAlCly irr nites SSS Re eeS ost ose 5 Features and Controls 2 005 22 Operation c6 2 23 eed rele er ee ee 32 Emission Control Systems 51 Maintenance 2 000e eee eee eee 52 SpecificationS 000e eee 102 Polaris Products 02000e cease 106 Troubleshooting 0000ee eee eee 107 W
63. g are excessive oil use of non recommended oil improper use of the choke or incorrect throt tle body carburetor adjustments Spark Plug Removal and Replacement 1 Remove the seat to access the engine compartment 2 Remove the spark plug cap Using the spark plug wrench provided in the tool kit remove the plug by rotating it counterclockwise 3 Reverse the procedure for spark plug installation Torque to specifi cation See page 67 68 MAINTENANCE Cooling System Operation The engine coolant level is controlled or maintained by the recovery system The recovery system components are the overflow bottle radia tor filler neck radiator pressure cap and connecting hose As coolant operating temperature increases the expanding heated excess coolant is forced out of the radiator past the pressure cap and into the overflow bottle As engine coolant temperature decreases the contracting cooled coolant is drawn back up from the tank past the pressure cap and into the radiator NOTE Some coolant level drop on new vehicles is normal as the system is purging itself of trapped air Observe coolant levels and maintain as recommended by adding coolant to the overflow bottle Adding or Changing Coolant To ensure that the coolant maintains its ability to protect the engine we recommend that the system be completely drained every two years and a fresh mixture of antifreeze and water added Polaris recommends the use of Pol
64. ill automatically disengage There is no limit to the length of time the vehicle may remain in AWD Initially the vehicle s electronic system will not enable the AWD until the engine RPM is below 3100 Once enabled the AWD remains enabled until the AWD switch is turned off If the switch is turned off while the front gearcase is moving it will not disengage until the rear wheels regain traction Engage the AWD before getting into conditions where front wheel drive may be needed If the rear wheels are spinning release the throttle before switching to AWD CAUTION Switching to AWD while the rear wheels are spinning may cause severe drive shaft and clutch damage Always switch to AWD while the rear wheels have traction or are at rest Disengaging AWD Under certain conditions it may be possible for the front gearcase to remain locked unnecessarily This condition causes increased steering effort and some vehicle speed restriction If the front gearcase remains locked after following these instructions return the vehicle to your dealer for service 1 Stop the vehicle 2 Operate in reverse for at least 10 feet 3 Stop completely 4 Shift into low gear and drive forward 50 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 nois
65. injury or death Always ensure that all nuts are torqued to specification Do not service axle nuts that have a cotter pin installed See your Polaris dealer Wheel Removal 1 4 Stop the engine Place the transmission in gear Engage the park brake Loosen the wheel nuts slightly Elevate the side of the vehicle by placing a suitable stand under the frame Remove the wheel nuts and washers Remove the wheel Wheel Installation l 2 86 Place the transmission in gear Engage the park brake Place the wheel in the correct position on the wheel hub Be sure the valve stem is toward the outside and rotation arrows on the tire point toward forward rota tion d Attach the wheel nuts and washers and finger tighten Carefully lower the vehicle to the ground Torque the wheel nuts to specification See page 85 MAINTENANCE Lights When servicing a halogen lamp don t touch the lamp with bare fingers Oil from your skin leaves a residue causing a hot spot that will shorten the life of the lamp A WARNING Poor lighting while driving can result in severe injury or death Headlight and taillight lenses become dirty during normal operation Wash the headlights frequently to maintain lighting quality Hot components can cause serious burns to skin Do not service the headlamps until they ve cooled sufficiently Headlight Lamp Replacement 1 Open the hood 2 Unplug the headla
66. injury or death No one under the age of 16 may operate this vehicle No one under the age of 5 may ride as a passenger in this vehicle 84 MAINTENANCE Tires A WARNING Operating your vehicle with worn tires will increase the possibility of skidding loss of control and an accident which could result in serious injury or death Always replace tires when the tread depth measures 1 8 3 mm or less Improper tire inflation or the use of non standard size or type of tires may adversely affect vehicle handling which could result in vehicle damage or personal injury Always maintain proper tire pressure When replacing tires always use original equipment size and type Tire Tread Depth Always replace tires 1 8 3 mm when tread depth is worn to 1 8 3 mm less or less A NS Axle and Wheel Nut Torque Specifications Inspect the following items occasionally for tightness and if they ve been loosened for maintenance service Nut Type Location Nut Torque Lug Nut Front and Rear 90 ft Ibs 122 Nm 2 Piece Flange a Front and Rear 35 ft Ibs 47 Nm Nut O Spindle Nut Front 70 ft Ibs 95 Nm Hub Retaining Nuts Center and Rear 110 ft Ibs 150 Nm NOTE Do not lubricate the stud or the lug nut 85 MAINTENANCE Tires A WARNING Improperly installed wheels can adversely affect tire wear and vehicle handling which can result in serious
67. is vehicle at excessive speeds WHAT CAN HAPPEN Loss of control accident HOW TO AVOID THE HAZARD Always travel at a speed proper for the terrain visibility and operating conditions and your experience 16 SAFETY Operator Safety A WARNING POTENTIAL HAZARD Attempting jumps and other stunts WHAT CAN HAPPEN Loss of control accident and or vehicle overturn HOW TO AVOID THE HAZARD Never attempt jumps and other stunts Avoid exhibition driving A WARNING POTENTIAL HAZARD Operating on frozen bodies of water WHAT CAN HAPPEN Severe injury or death can result if the vehicle and or the operator fall through the ice HOW TO AVOID THE HAZARD Never operate the RANGER on a frozen body of water 17 SAFETY Operator Safety A WARNING POTENTIAL HAZARD Failure to inspect the vehicle before operating Failure to properly maintain the vehicle WHAT CAN HAPPEN Accident equipment damage HOW TO AVOID THE HAZARD Always inspect your RANGER before each use to make sure it s in safe operating condition Always follow the inspection and maintenance procedures and schedules described in the Owner s Manual A WARNING POTENTIAL HAZARD Failure to use extra caution when operating this vehicle on unfamiliar terrain WHAT CAN HAPPEN Loss of control vehicle overturn HOW TO AVOID THE HAZARD Travel slowly and use extra caution when operating on unfamiliar terrain Always be
68. 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 52 Adjust the freeplay if necessary Throttle Freeplay Inspection 1 Engage the park brake Shift the transmission to neutral 2 Apply the brakes Start the engine Allow it to warm up thoroughly 3 Measure the distance the throttle pedal moves before the engine begins to pick up speed Freeplay should be 1 16 to 1 8 inches 1 6 3 2 mm 79 MAINTENANCE Throttle System Throttle Freeplay Adjustment 1 Remove the seat 2 Locate the throttle cable adjuster 3 Squeeze the end of the rub ber boot and slide it far enough to expose the end of the inline cable adjuster Bdot 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 Lock Nul Adjuster pedal See page 79 NOTE 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 adjuster to its original position Cylinder Head Cylinder Base Fastener Torque Have your dealer check the cylinder head and cylinder base fasteners for proper torque at the fi
69. ition Severe Use 52 Depth Treads iua susia minari aens 85 Differential Lock Switch 31 Differential Operation 49 Disengaging AWD 50 Drive Belt Wear 107 Driving Downhill 39 Driving in Reverse 42 Driving on a Sidehill 39 Driving on Slippery Surfaces 37 Driving Over Obstacles 4 Driving Procedure 36 Driving Safely 36 48 Driving Through Water 40 Driving Uphill 38 Driving After Driving in Water 73 Drying the Transmission 73 Dumping the Cargo Box 46 123 INDEX E Electromagnetic Interference 51 Emission Control Crankcase 51 Emission Control Exhaust 51 Emission Control Noise 51 Emissions Limited Warranty 114 Engine Fogging 100 Engine Idle RPM Adjustment 77 Engine Oil 58 62 Engine Starting 34 35 Engine Stopping 35 Equipment Modifications 13 Exhaust Cleaning 78 Exhaust Emission Control System 51 Exhaust System Waring 78 F Fan Cooling 0 70 Fastener Cylinder Head Base 80 Filling the Battery 93 Filter 7 Ak eee nA i 75 Breather 76 Care During Storage 99 Change esta sass a 60 Cleaning Air 75 Cleaning Fuel
70. ive film of fresh oil Treat the fuel system with Polaris Carbon Clean See page 99 If Polaris fuel system additive is not used fuel tank fuel lines and carburetor should be completely drained of gasoline To eliminate any fuel remaining in the carburetor run the engine until it stops Battery Maintenance See pages 93 95 for storage and charging procedures Storage Area Covers Be sure the storage area is well ventilated Cover the vehicle with a gen uine Polaris cover NOTE Do not use plastic or coated materials They do not allow enough ven 100 tilation to prevent condensation and may promote corrosion and oxi dation MAINTENANCE Removal from Storage l 3 4 Check the battery electrolyte level and charge the battery if neces sary 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 33 NOTE Tightness of the bolts nuts and other fasteners should be checked by 5 an authorized Polaris dealer Lubricate at the intervals outlined in the Periodic Maintenance Chart beginning on page 52 A WARNING Engine exhaust contains poisonous carbon monoxide and can cause loss of consciousness or death Never run an engine in an enclosed area Transporting the RANGER Follow
71. l adjustment proce dures Park Brake Pedal Engage the park brake when parking the vehicle to help prevent the vehicle from rolling To engage the park brake apply the brakes then push the park brake pedal down firmly and fully with your foot Park Brake Release Always apply the service brakes before releasing the park brake To release the park brake pull the park brake release handle Make sure the park brake pedal is functioning properly before each operation 30 FEATURES AND CONTROLS Switches Light Switch AWD Differential Switch AWD 2WD OFF Ignition Switch Ignition Switch The ignition switch is a three position key operated switch The key can be removed from the switch when it is in the OFF position OFF The engine is off Electrical circuits are off except Acc 12V ON Electrical circuits are on Electrical equipment 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 A WARNING Leaving the keys in the ignition can lead to unauthorized use of the vehicle resulting in serious injury or death Always remove the ignition key when the vehicle is not in use Light Switch The ignition switch key must be in the ON RUN position to operate the headlights The light switch has three positions high beam low beam and off AWD Differential Lock Switch The A
72. l travel If the light doesn t come on check the bulb Indicator Lamp Replacement 1 Lift the hood Release 2 Reach in behind the console Tab panel and lift the release to unplug the light from the harness 3 Usinga flathead screwdriver press on the tab on the top of the light to remove the indi cator light assembly from the console panel 4 Locate the expired lamp Using a screwdriver rotate the lamp 1 4 turn counterclockwise 5 Grip the lamp with a needle nose pliers and remove it from the assembly 6 Install the new lamp Using a screwdriver rotate the lamp 1 4 turn clockwise to seat it 7 Snap the assembly back into the console panel Reconnect the har ness 8 Close the hood 89 MAINTENANCE Battery Your vehicle may have either a sealed battery which requires little maintenance or a conventional battery A sealed battery can be identi fied by its flat covers on the top of the battery A conventional battery has six filler caps on the top of the battery Conventional 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 A WARNING B
73. ll critical components on your vehi cle are thoroughly inspected at specific intervals SAFETY Operator Safety The following signal words and symbols appear throughout this manual and on your vehicle Your safety is involved when these words and sym bols are used Become familiar with their meanings before reading the manual A The safety alert symbol on your vehicle or in this manual alerts you to the potential for injury A WARNING The safety alert warning indicates a potential hazard that may result in serious injury or death A CAUTION The safety alert caution indicates a potential hazard that may result in minor injury or damage to the vehicle CAUTION A caution indicates a situation that may result in damage to the vehicle NOTE A note will alert you to important information or instructions SAFETY Operator Safety A WARNING Serious injury or death can result if you do not follow these instructions and procedures which are outlined in further detail within your owner s manual e Read this manual and all labels carefully Follow the operating procedures described e Never allow anyone without a valid driver s license to operate this vehicle e Minimum age recommendation for passengers is five years old Passengers under five years of age require special restraints which are not available with this vehicle Driver and passenger should wear their seat belts at all times e Never permit
74. lling 5 Inspect the air box for oil or water deposits If present drain them into a suitable container NOTE Service the air filter more frequently if the vehicle is operated in wet conditions or at high throttle openings for extended periods Fuel Filter Your Polaris vehicle is equipped with an in line fuel filter Have your dealer replace it after every 100 hours of operation Do not attempt to clean the fuel filter 75 MAINTENANCE Filter Systems Breather Filter and Hoses 1 Lift the cargo box and locate the air box Breather Line Breather Filter 2 Follow the right hand breather line out the side of the air box and locate the filter 3 Remove and inspect the filter for debris Blow gently through the filter in the direction of the arrow to check for clogging Replace as needed 4 Check hoses for cracks deterioration abrasion or leaks Replace as needed 5 Reinstall the filter with the arrow pointing toward the engine Secure the clamps CAUTION Operation of the vehicle without a breather filter can cause engine damage Always reinstall the breather filter after removing it for service 76 MAINTENANCE Carburetor The idle speed adjustment should be performed as outlined in the Peri odic Maintenance Chart or whenever the idle speed is changed Recom mended engine idle RPM for the RANGER 2X4 and 4X4 is 1200 200 If the engine idle speed is not satisfactory and all
75. loor boards Follow these procedures when oper ating through water 1 Always determine water depths and current before entering 2 Choose a crossing where both banks eas Floorboard have gradual E on aa ta t inclines DA LOS D 3 Proceed slowly avoiding rocks and obstacles 4 After leaving water always dry the brakes by applying light pres sure to the pedal repeatedly until braking action is normal NOTE After running your vehicle in water it s critical that you perform the ser vices outlined in the Periodic Maintenance Chart beginning on page 52 Give special attention to engine oil transmission oil front and rear gearcases and all grease fittings CAUTION Immersion can result in major damage if the vehicle isn t serviced correctly and promptly After immersion always take the vehicle to your dealer service Do not start the engine If it s impossible to bring the vehicle to your dealer before starting the engine perform the service outlined on page 74 and take the vehicle to your dealer at the first opportunity 40 OPERATION Driving Safely Driving Over Obstacles Be alert Look ahead and learn to read the terrain you re traveling on Watch for hazards such as logs rocks and low hanging branches A WARNING Severe injury or death can result if your vehicle suddenly comes in contact with a hidden obstacle Not all obstacles are immediately visible Reduce
76. lted in the failure of a warranted emission related part As a minimum the LSI engine owner is responsible for the scheduled inspection and maintenance described below which are based on the procedures described in the Owner s Manual 118 WARRANTY California Emission Control Warranty Statement NOTE gt More often under severe use such as dirty or wet conditions m Due to the nature of these adjustments it is recommended that an authorized Polaris dealer perform service Do not attempt to perform this work unless you are familiar with mechanical repair Maintenance Schedule Item Maintenance Interval Remarks whichever comes first Hours Calendar Miles Km gt Air filter Daily Inspect clean pre cleaner gt Air filter Weekly Inspect replace if necessary main element gt Engine breather 20H Monthly Inspect replace annually and filter as needed gt Engine oil level 100 H 6M Check level daily break in change service at 1 month Change oil more often in cold weather use gt Oil filter 100 H 6M Replace with oil change Engine breather 100 H 6M Inspect hose Choke enricher 50 H 6M Inspect adjust lubricate cable replace if necessary Spark plug 100 H 12M Inspect replace if necessary E Ignition timing 100 H 12M Inspect and adjust as needed E Fuel system 100 H 12M Check for leaks at tank cap lines fuel valve filter pump carbure
77. 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 32 and 72 107 TROUBLESHOOTING Engine Doesn t Turn Over Possible Cause Low battery voltage Solution Recharge the battery to 12 8 VDC Loose battery connections Check all connections and tighten Loose solenoid connections Check all connections and tighten Tripped circuit breaker Reset the breaker Engine Turns Over Fails to Start Possible Cause Out of fuel Solution Refuel Clogged fuel filter Inspect and clean or replace Water is present in fuel Drain the fuel system and refuel Old or non recommended fuel Replace with fresh recommended fuel Fouled or defective spark plugs Inspect plugs and replace if necessary No spark to spark plug Inspect plugs and replace if necessary Water or fuel in crankcase Immediately see your Polaris dealer Overuse of choke Low battery voltage Inspect clean and or replace spark plug Recharge the battery to 12 8 VDC Mechanical failure See y
78. mounting bolts Torque to 30 ft Ibs 40 Nm Outside Mounting Holes Inside Mounting Holes Rear Spring Adjustment The rear shock absorber springs are adjusted by rotating the adjustment cam either clockwise or counterclockwise to increase or decrease spring tension 83 MAINTENANCE Seat Belts Inspect all three seat belts for proper operation before each use of the vehicle 1 Push the latch plate into the buckle until it clicks The latch plate must slide smoothly into the buckle A click indicates that it s securely latched 2 Push the red button in the middle of the buckle to make sure it releases freely 3 Check the belt webbing for wear cuts or damage If any irregularities are found have the seat belt system checked and or replaced by an authorized Polaris dealer The RANGER seat belt is adjustable and should be adjusted for both the operator and passengers before driv ing Although having the belt at 30 is typical for many peo ple it will not accommodate all body sizes and shapes Make sure the seat belt is adjusted to the lowest possible lap position before riding 1 To adjust loosen the bolts 2 Reposition both the buckle and retractor Tighten the bolts NOTE The center belt does not self adjust Before riding pull on the strap to secure the belt on the lap of the center passenger A WARNING Failure to follow the age recommendations for this vehicle could result in serious
79. mp from the wiring harness Be sure to pull on the connector not on the wiring 3 Turn the lamp counter clockwise to remove it 4 Install the new lamp NOTE Make sure the tab on the lamp locates properly in the housing 5 Reinstall the harness assembly into the headlight assembly Wiring Harness e 87 MAINTENANCE Lights 1 Place the vehicle on a level surface with the headlight approxi mately 25 ft 7 6 m from a wall 2 Measure the distance from the floor to the center of the headlight and make a mark on the wall at the same height 3 Apply the brakes 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 in step 2 NOTE Include the weight of a rider on the seat while performing this step 5 Ifthe headlight needs adjustment open the hood NOTE The lights are part of the hood assembly 6 Turn the adjustment screw to adjust the beam 7 Close the hood and repeat steps 4 6 until the lamp is properly adjusted View of driver s headlight with hood lifted 88 MAINTENANCE Lights Brake Lights When the brake pedal is depressed the console brake light comes on Check the brake light before each ride 1 Turn the ignition switch to the ON position 2 Depress the brake pedal The brake light should come on after about 10mm 0 4 in of peda
80. n could be on the other side of the hill 38 OPERATION Driving Safely Driving on a Sidehill Sidehilling A WARNING Crossing hillsides or turning on hills can result in loss of control or vehicle overturn resulting in severe injury or death Avoid crossing the side of a hill when possible When unavoidable exercise extreme caution Avoid operating on steep hills 15 maximum Driving Downhill Whenever descending a hill follow these precautions 1 Proceed directly downhill 2 Slow down 3 Apply the brakes slightly to aid in slowing A WARNING Traveling downhill improperly could cause loss of control or vehicle overturn Always check the terrain carefully before descending a hill Never descend a hill at high speed Excessive speed may result in loss of vehicle control and lead to serious injury or death Always operate slowly when traveling downhill Avoid descending a hill at an angle which would cause the vehicle to lean sharply to one side Travel straight downhill when possible 39 OPERATION Driving Safely Driving Through Water A 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 Your Polaris RANGER can operate through water up to a maximum recommended depth equal to the f
81. nance and or repair But if the over flow bottle has run dry the level in the radiator should also be inspected NOTE Use of anon standard pressure cap will not allow the recovery system to function properly See your dealer for the correct replacement part 71 MAINTENANCE Polaris Variable Transmission PVT System A WARNING Failure to comply with the instructions in this warning can result in severe injury or death Do not modify any component of the PVT system Doing so may reduce its strength so that a failure may occur at a high speed The PVT system has been precision balanced Any modification will cause the system to be out of balance creating vibration and additional loads on components The PVT system rotates at high speeds creating large amounts of force on clutch components Extensive engineering and testing has been conducted to ensure the safety of this product However as the owner you have the following responsibilities to make sure this system remains safe Always follow all recommended maintenance procedures See your dealer as outlined in the owner s manual e This PVT system is intended for use on Polaris products only Do not install it in any other product Always make sure the PVT housing is securely in place during operation When To Use Low Range vs High Range Belt slip is responsible for creating excessive heat that destroys belts wears clutch
82. nded to provide rollover protection ALWAYS WEAR YOUR SEAT BELT for maximum protection SAFETY Safety Decals and Locations Shift Caution CAUTION To avoid transmission damage shift only when vehicle is stationary and at idle Discretionary Warning WARNING Improper vehicle use can result in SEVERE INJURY or DEATH NEVER e Operate on public roads A collision can occur with a another vehicle e Carry more than two passengers or passengers under age five e Use ALCOHOL or DRUGS before or while operating this vehicle e Operate at speeds too fast for your skills or the conditions e Operate this vehicle on HILLS Shift Caution Discretionary steeper than 15 degrees 15 Warning To prevent flipover on hilly terrain use throttle and brakes gradually ALWAYS e Avoid paved surfaces which may adversely affect handling and control e Use proper RIDING TECHNIQUES to avoid vehicle overturns on hills and rough terrain and in turns e Wear eye protection REVERSE operation can be dangerous even at low speeds Steering becomes difficult To prevent flipover avoid sharp turns The park emergency brake lever will supply increased braking but should be used as an emergency or parking brake only READ OWNER S MANUAL FOLLOW ALL INSTRUCTIONS AND WARNINGS IF OWNER S MANUAL IS MISSING CONTACT A POLARIS DEALER FOR A REPLACEMENT THIS GENERAL PURPOSE OFF
83. nt Suspension MacPherson strut w 8 in 20 cm of travel Rear Suspension Independent w 9 in 23 cm of travel 102 SPECIFICATIONS RANGER 2X4 Lubrication System Dry Sump Engine Oil 0W 40 Driving System Type PVT Shift Type Single Lever console Gear Reduction Low 8 71 1 Gear Reduction Reverse 5 9 1 Gear Reduction High 3 83 1 Drive Ratio Front N A Drive Ratio Final 3 70 1 Tire Size Front 25x 10 12 Tire Size Rear 25x 11 12 Tire Pressure Front 8 12 psi Tire Pressure Rear 8 12 psi Brakes Front Rear Foot Activated 4 wheel hydraulic disc Brake Park Foot activated mechanical Hood Headlight 2 dual beam 35W quartz halogen Taillights 2 single beam 5W Brake Light 2 single beam 5W Indicator Light 1 0 W NOTE See your Polaris dealer for jetting and clutching specifications 103 SPECIFICATIONS RANGER 4X4 Gross Vehicle Weight 2700 Ibs 1226 kg Dry Weight 1185 Ibs 537 kg Overall Length 113 in 282 cm Overall Width box 60 in 152 4 cm Overall Width tires 58 in 147 3 cm Overall Height 75 in 190 5 cm Wheelbase 76 in 193 cm Cargo Box L x W x H 58 x 42 x 10 in 147 x 106 7 x 25 4 cm Ground Clearance 11 5 in 29 cm Min Turning Radius 132 in 335 3 cm Fuel Capacity 9 gal 34 1 Engine Oil Capacity 2 qts 2 1 1 Coolant Capacity 2 25 qts
84. on to the oil level A rise in oil level during cold weather can indicate contaminants collecting in the oil sump or crank case 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 52 MAINTENANCE Periodic Maintenance Chart Maintenance Chart Key gt Perform these operations more often for vehicles subjected to severe use E Emission Control System Service 4 Cycle California M Have an authorized Polaris dealer perform these services A WARNING Improperly performing the procedures marked with a W could result in component failure and lead to serious injury or death Have an authorized Polaris dealer perform these services 53 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 E Steering Pre Ride Make eg pes leon need 7 z ed See Pre Ride Checklist gt Front suspension Pre Ride on page 33 gt Rear suspension Pre Ride Tires Pre Ride gt Brake fluid level Pre Ride gt Brake pedal travel Brake system Pre Ride Wheels fasteners Pre Ride Frame fasteners Pre Ride gt Engine oil level Pre Ride E gt Air filter p
85. or scratches Se 7 Reinstall the drain plug Torque to 14 ft Ibs 19 Nm 8 Disconnect the lower oil delivery hose and remove the screen fitting from the oil tank Clean the fitting NOTE The fitting threads must be sealed with LOCTITE PST 505 or PTFE seal tape 9 Reinstall the screen fitting and rotate the fitting clockwise a mini mum of 2 1 2 turns into the tank threads Continue to rotate the fit ting until the nipple of the fitting aligns with the mark on the tank NOTE Do not over tighten Maximum torque for the screen fitting is 25 ft Ibs 34 Nm 60 MAINTENANCE Engine Oil Oil and Filter Change 10 Reattach the oil line 11 Place shop towels beneath the oil filter Using an oil fil ter wrench turn the filter counterclockwise to remove it 12 Using a clean dry cloth clean the filter sealing sur face on the crankcase 13 Lubricate the gasket on the new filter with a film of new engine oil Make sure the iT l gasket is in good condition Oil Filter Make sure the gasket from the old filter is not still on the engine 14 Install the new filter and turn by hand until the filter gasket contacts the sealing surface then turn and additional 1 2 turn 15 Approximately one cup of engine oil will remain in the crankcase To drain remove the drain plug on the lower right side of the crank case NOTE The sealing surfaces on the drain plug and crankcase should be clean and free of burrs nick
86. orized Polaris dealer if it has been involved in an accident Never operate this vehicle on hills too steep for the vehicle or for your abilities Practice on smaller hills before attempting larger hills Always follow proper procedures for climbing hills as described in this manual Check the terrain carefully before attempting to climb a hill Never climb hills with excessively slippery or loose surfaces Never open the throttle suddenly or make sudden gear changes Never go over the top of a hill at high speed Always follow the proper procedures outlined in this manual for trav eling downhill and for braking on hills Check the terrain carefully before descending a hill Never travel downhill at high speed Avoid going downhill at an angle which would cause the vehicle to lean sharply to one side Travel straight down the hill where possible Always check for obstacles before operating in a new area Never attempt to operate over large obstacles such as rocks or fallen trees Always follow the proper procedures outlined in this manual when operating over obstacles Always be careful of skidding or sliding On slippery surfaces such as ice travel slowly and exercise caution to reduce the chance of skid ding or sliding out of control Never operate your vehicle in fast flowing water or in water deeper than that specified in this manual Wet brakes may have reduced stop ping ability Test your brakes after leaving water If necessary
87. other conditions are favorable the carburetor can be adjusted with the following procedure Carburetor Engine Idle RPM Adjustment Recommended engine idle RPM is 1200 200 If the engine idle speed is unsatisfactory and all other conditions are favorable the carbu retor can be adjusted 1 Engage the park brake 2 Shift the transmission to neutral 3 Start the engine and allow it to warm up for approximately five minutes 4 Remove the seat Locate the idle adjust screw 5 Place the transmission in gear 6 Turn the screw in clockwise to raise RPM Turn the screw out counter clockwise to lower RPM Idle Adjust Screw 77 MAINTENANCE Spark Arrestor A WARNING Failure to heed the following warnings while servicing the spark arrestor could result in serious injury or death Do not perform service on the spark arrestor while the system is hot Exhaust system temperatures can reach 1000 F Allow components to cool sufficiently before proceeding Remove any combustible materials from the area Wear eye protection and gloves Do not stand behind or in front of the vehicle while purging Never run the engine in an enclosed area Exhaust contains poisonous carbon monoxide gas that can cause loss of consciousness or death ina very short time Never go under the vehicle while it s inclined Use the following procedure to periodically purge accumulated carbon from the exhaust pipe 1 Remov
88. our dealer Engine Backfires Possible Cause Weak spark from spark plug Solution Inspect clean and or replace spark plugs Incorrect spark plug gap or heat range Set gap to specs or replace plugs Old or non recommended fuel Replace with fresh recommended fuel Incorrectly installed spark plug wires See your dealer 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 108 Engine Pings or Knocks TROUBLESHOOTING Possible Cause Poor quality or low octane fuel Solution Replace with recommended fuel Incorrect ignition timing See your dealer Incorrect spark plug gap or heat range Set gap to specs or replace plugs Engine Runs Irregularly Stalls or Misfires Possible Cause Fouled or defective spark plugs Solution 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 replace plugs Loose ignition connections Check all connections and tighten Water present in fuel Replace with new fuel Low battery voltage Recharge battery to 12 8 VDC Kinked or plugged fuel tank vent line Inspect and replace Incorrect fuel Replace with recommended fuel
89. page 59 ow40 Brake Fluid DOT 3 or DOT 4 See page 81 Main Gearcase Oil Premium AGL Synthetic See page 63 Transmission Gearcase Lube Front Gearcase Oil Premium Demand Drive Hub See page 65 Fluid Rear Gearcase Oil Premium ATV Angle Drive See page 66 Fluid Prop Shaft U joints Polaris Premium U Joint Lube Locate fittings and grease See above Front Prop Shaft Yoke 4X4 Polaris Premium U Joint Lube Locate fittings and grease 3 pumps maximum Ball Joint Polaris Premium all Season Locate fitting back side of Grease or grease conform struts grease with grease gun ing to NLGI No 2 Swing Arm Polaris Premium all Season Locate fittings on swing arm and Bushings Grease or grease conform grease with grease gun ing to NLGI No 2 4X4 Prop Shaft U Joint 57 MAINTENANCE Engine Oil Always check and change the engine oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 52 Always change the oil filter whenever changing oil Premium 4 Synthetic Oil Polaris Premium 4 All Season Synthetic engine oil has been specially formulated for use in Polaris 4 cycle engines It s a fully synthetic high performance multi viscosity oil designed to provide the ultimate in lubrication performance and protection See page 106 for the part num bers of Polaris products Premium 4 possesses unsurpassed film strength over the widest possible temperature range It
90. r for the recommended amount NOTE Carbon Clean removes water from fuel systems stabilizes fuel and removes carbon deposits from pistons rings valves and exhaust sys tems 2 Allow the engine to run for 15 20 minutes to allow the stabilizer to disperse through the fuel in the tank and carburetor 3 Drain the carburetor bowl Oil and Filter Change the oil and filter See page 60 Air Filter Air Box Inspect and clean or replace the pre cleaner and air filter See page 75 Clean the air box Drain the sediment tube Fluid Levels Inspect the fluid levels Add or change fluids as recommended in the Periodic Maintenance Chart beginning on page 52 Front and rear gearcase fluid Transmission fluid e Brake fluid change every two years and any time the fluid looks dark or contaminated e Coolant test strength fill Inspect and Lubricate Inspect all cables and lubricate all areas of the vehicle as recommended in the Periodic Maintenance Chart beginning on page 52 99 MAINTENANCE Cleaning and Storage Storage Tips Fog the Engine l 6 Remove the spark plug and add 2 3 tablespoons of Premium 4 Syn thetic OW40 engine oil Reinstall the spark plug Torque to specification See page 67 Apply dielectric grease to the inside of the spark plug cap Reinstall the cap Turn the engine over several times Oil will be forced in and around the piston rings and ring lands coating the cylinder with a protec t
91. r towing a trailer may result in accident and injury Always slow down and allow additional braking distance when towing or hauling cargo 35 OPERATION Driving Safely Driving Procedure 5 6 Sit in the driver s seat and fasten the seat belt After starting the engine and allowing it to warm up apply the ser vice brakes and shift the transmission into gear Check your surroundings and determine your path of travel Release the park brake Keeping both hands on the steering wheel slowly release the brakes and depress the throttle with your right foot to begin driving Drive slowly Practice maneuvering and using the throttle and brakes on level surfaces NOTE Low gear is the primary range for operating the RANGER High gear is 36 intended for use on hard packed surfaces with light loads OPERATION Driving Safely Driving On Slippery Surfaces When driving on slippery surfaces such as wet trails loose gravel or ice be alert for the possibility of skidding and sliding Under these con ditions follow these precautions 1 Slow down when entering slippery areas 2 Maintain a high level of alertness reading the trail and avoiding quick sharp turns which can cause skids 3 Correct a skid by turning the steering wheel in the direction of the skid 4 Drive with AWD engaged if equipped to assist in controlling the vehicle CAUTION Severe damage to the drive train may occur i
92. re filter Daily Inspect clean often replace E as needed gt Air box sediment Daily Drain deposits when visible tube Coolant Daily Check level daily change if applicable coolant every 2 years Headlamp tail Daily Check operation apply lamp dielectric grease if replacing gt Air filter Weekly Inspect replace as needed E main element gt Brake pad wear 10H Monthly Inspect periodically a Battery 20H Monthly Check terminals clean test gt Front Gearcase Oil 25H Monthly Inspect level change yearly if equipped gt Middle Gearcase 25H Monthly Inspect level change yearly Oil if equipped gt Rear gearcase oil 25H Monthly Inspect level change yearly if equipped gt Transmission oil 25H Monthly Inspect level change yearly gt Perform these procedures more often for vehicles subjected to severe use E Emission Related Service m Have an authorized Polaris dealer perform these services 54 Periodic Maintenance Chart MAINTENANCE Item Maintenance Interval Remarks whichever comes first Hours Calendar Miles Km gt Engine breather 20H Monthly Inspect replace if necessary E filter if equipped gt Engine oil change 25H 1M Perform a break in oil change E break in at one month gt General 50 H 3M Lubricate all fittings pivots lubrication cables etc Shift Linkage 50H 6M In
93. re set out above your vehicle will no longer be eligible for war ranty or service bulletin coverage of any kind Vehicles registered to Government offi cials or military personnel on assignment outside of the country where the vehicle was purchased will continue to be covered by the basic warranty For questions call Polaris Customer Assistance United States 1 763 417 8650 Canada 1 204 925 7100 113 WARRANTY U S A EPA Emissions Limited Warranty This All Terrain Vehicle ATV or Off Road Utility Vehicle ORUV emissions limited warranty is in addition to the Polaris standard limited warranty for this vehicle Polaris warrants that this vehicle is 1 designed built and equipped to conform at the time of initial sale with the requirements of 40 CFR 1051 and 2 free from defects in materials and workmanship that may keep it from meeting these requirements The emissions warranty period for this vehicle begins on the date the vehicle is deliv ered to the original retail purchaser and ends 30 months 2 5 years after that date or after 5000 km 3100 miles whichever comes first This emission related warranty covers components whose failure would increase an engine s emissions including electronic controls fuel injection exhaust gas recircula tion aftertreatment or any other system utilized in this vehicle to control emissions Replacing or repairing other components not covered by this emissions warranty or the standar
94. resists viscosity and frictional breakdown in ambi ent temperatures from 40 F to 120 F Its exceptional frictional prop erties result in more efficient operation more power output and lower fuel consumption Although Polaris Premium 4 is the only oil recommended for use in this engine use of any API certified SH oil is allowable as long as it s OW 40 Oil may need to be changed more frequently if Polaris Premium 4 is not used Follow the manufacturer s recommendations for ambient tem perature operation CAUTION Mixing brands or using a non recommended oil may cause serious engine damage We recommend the use of Polaris Premium 4 All Season synthetic oil or API certified SH oil OW 40 Never substitute or mix oil brands Use only OW 40 A 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 58 MAINTENANCE Engine Oil Always check and change the oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 52 We recommend the use of Polaris Premium 4 All Season Synthetic engine oil Oil Check The oil tank is located under the seat 1 Position the vehicle on a level surface 2 Apply the brakes Start the engine and allow it to idle for 20 30 seconds Stop th
95. rst service or after 25 hours 80 Brakes MAINTENANCE The front and rear brakes are hydraulic disc type brakes Press down on the brake pedal to engage the brakes See page 30 Brake Fluid Inspect the brake system rou tinely Inspect the level of the brake fluid before each opera tion Change the brake fluid every two years and any time the fluid becomes contaminated the fluid level is below the minimum or if the type and brand of the fluid in the reservoir are unknown See page 57 for fluid recommenda tions 1 Position the vehicle on a level surface 2 View the brake fluid level at the reservoir under the hood The level should be between Brake Fluid Reservoir the upper MAX and lower MIN level lines 3 Ifthe fluid level is lower than the lower level line add brake fluid to the upper MAX line 4 Apply the brake forcefully for a few seconds and check for fluid leakage around the fittings A 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 81 MAINTENANCE Brakes Brake Inspection 1 Check the brake system for fluid leaks 2 Check the brake pedal
96. s Throttle Ensure proper operation 79 Indicator lights switches Ensure operation 25 Air filter pre filter Inspect clean 75 Air box sediment tube Drain deposits whenever visible 75 Headlamp Check operation apply Polaris dielec 87 tric grease when lamp is replaced Brake light tail lamp Check operation apply Polaris dielec 89 tric grease when lamp is replaced 33 OPERATION Starting the Engine A WARNING Engine exhaust contains poisonous carbon monoxide and can cause loss of consciousness resulting in severe injury or death Never run an engine in an enclosed area 1 Sit in the driver s seat and fasten the seat belt 2 Engage the park brake FULL ON 7 HALF ON D OFF W l SON Choke Knob 3 Shift the transmission to neutral 4 Apply the brakes NOTE Do not use the choke if starting a warm engine Excessive use of the choke can cause spark plugs to become wet fouled 5 Ifthe engine is cold pull the choke knob out until it stops 6 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 BEE NOTE Do not press the throttle pedal while starting the engine 7 Ifthe engine does not start within five seconds release the ignition switch and wait five seconds Repeat steps 6 and 7 until the engine starts NOTE Ifa warm engine has cooled to a point where it does not r
97. s or scratches 16 Reinstall the drain plug Torque to 14 ft Ibs 19 Nm 17 Remove the dipstick and fill the tank with two quarts 1 9 1 of the recommended oil 18 Place the gear selector in neutral and engage the parking brake 19 Prime the oil pump using the procedure on page 62 Then stop the engine and inspect for leaks 20 Check the oil level on the dipstick Add oil as necessary to bring the level to the upper mark on the dipstick 21 Dispose of used filter and oil properly 6l MAINTENANCE Engine Oil Oil and Filter Change Oil Pump Priming This priming procedure must be Tank performed whenever the oil hose connection between the oil tank and pump inlet has been disconnected 1 Clamp or pinch off the vent line approximately 2 5 cm from the oil tank between the end of the oil tank vent fitting and the vent line s pressure relief slit Pressure 2 Start the engine Allow it to idle Relief Slit for 10 20 seconds 3 Remove the vent line clamp If the line is bled properly you should hear a rush of air indicating that the line is properly primed and ready for operation NOTE If you do not hear air the line has not bled Repeat the priming proce dure 62 MAINTENANCE Gearcases Gearcase Specification Chart Gearcase Lubricant Capacity Fill Plug Drain Plug Torque Torque Main Gearcase Premium AGL 15 2 oz 14 ft Ibs 14 ft Ibs Transmission Synthetic 450 ml 19 4 Nm
98. sion or limitation of incidental or consequential damages or implied warranties so the above limitations or exclusions may not apply to you if inconsistent with controlling state law 111 WARRANTY LIMITATIONS OF WARRANTIES AND REMEDIES ALL IMPLIED WARRANTIES INCLUDING BUT NOT LIMITED TO THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PAR TICULAR PURPOSE ARE LIMITED IN DURATION TO THE ABOVE SIX MONTH WARRANTY PERIOD POLARIS FURTHER DISCLAIMS ALL EXPRESS WARRANTIES NOT STATED IN THIS WARRANTY Some states do not allow limi tations on how long an implied warranty lasts so the above limitation may not apply to you if inconsistent with controlling state law HOW TO OBTAIN WARRANTY SERVICE If your vehicle requires warranty service you must take it to a Polaris Servicing Dealer When requesting warranty service you must present your copy of the Warranty Registra tion form to the dealer THE COST OF TRANSPORTATION TO AND FROM THE DEALER IS YOUR RESPONSIBILITY Polaris suggests that you use your original selling dealer however you may use any Polaris Servicing Dealer to perform warranty service Please work with your dealer to resolve any warranty issues Should your dealer require any additional assistance they will contact the appropriate person at Polaris This warranty gives you specific legal rights and you may also have other rights which vary from state to state If any of the above terms are void because of st
99. smission 63 Oil Pump Priming 62 Oil Engine 58 62 Oil Synthetic 0 58 Operation on Public Lands 51 Operation Cooling System 69 Operation Transmission 72 Operator Safety 8 20 Outlet Auxiliary 25 P Park Brake Adjustment 82 Inspection 82 Release onare va sae eni epia 30 Parking on an Incline 43 Parking the Vehicle 48 Periodic Maintenance Chart 52 56 Plug Condition 68 AP aerar EESE AES 67 TOTQUCs aapa aen aes g acho aia partes 67 Fouled y reae na r gars 68 Spark Plug 67 Polaris Products 106 P Polishing the Vehicle 97 Premium 4 Synthetic Oil 58 Pre Ride Inspection 33 Pressure Tire 0 0005 5 Public Lands 51 PVT Drying 73 PVT System 04 13 PVT System Operation 72 R Radiator saien tae hath eee es 70 Radiator Coolant Level 71 Rear Gearcase Lubrication 66 Oil Change 66 Oi Cheek us eseat dane 66 Rear Spring Adjustment 83 Rear Suspension Adjustment 83 Release Park Brake 30 Removing the Vehicle from Storage 101 Replacement Headlight Lamp 87 Reverse i es ee rs ake aad oa 42 S Safety Decals
100. spect lubricate adjust E Steering 50H 6M Lubricate gt Front Suspension 50 H 6M Lubricate gt Rear Suspension 50 H 6M Lubricate Carburetor float 50 H 6M Drain bowl periodically and bowl prior to storage E Throttle cable 50 H 6M Inspect adjust lubricate E replace if necessary E Choke cable 50H 6M Inspect adjust lubricate E replace if necessary E Carburetor air 50H 6M Inspect ducts for proper seal intake ducts flange ing air leaks Drive belt 50H 6M Inspect adjust replace as needed Cooling system 50H 6M Inspect coolant strength if applicable seasonally pressure test system yearly gt Engine oil change 100 H 6M Perform a break in oil change E at one month gt Oil filter change 100 H 6M Replace with oil change E gt Oil tank vent hose 100 H 12M Inspect routing condition E p Valve clearance 100 H 12 M Inspect adjust gt Perform these procedures more often for vehicles subjected to severe use E Emission Related Service m Have an authorized Polaris dealer perform these services 55 MAINTENANCE Periodic Maintenance Chart Item Maintenance Interval Remarks whichever comes first Hours Calendar Miles Km E Fuel system 100 H 12M Check for leaks at tank cap E lines fuel valve filter pump carburetor replace lines every two years E Fuel filter 100 H 12M Replace yearly gt Radiator
101. t of that part This warranty shall apply only towards the repair replacement and or adjustment of the component parts listed below 116 WARRANTY California Emission Control Warranty Statement Emission Related Parts Covered Under This Warranty 1 2 3 4 5 Fuel Metering System 1 Carburetor and internal parts and or pressure regulator or fuel injection system ii Air fuel ratio feedback and control system if applicable iii Cold start enrichment system if applicable iv Regulator assy gaseous fuel if applicable Air Induction System i Intake manifold if applicable ii Air filter Ignition System 1 Spark plugs ii Magneto or electronic ignition system iii Spark advance retard system if applicable Exhaust manifold if applicable Miscellaneous Items Used in Above Systems 1 Electronic controls if applicable ii Hoses belts connectors and assemblies iii Filter lock assy gaseous fuel if applicable If an authorized dealer determines that other LSI engine components have been dam aged due to the failure of a warranted emission related part during the warranty period POLARIS will repair and or replace the necessary components 117 WARRANTY California Emission Control Warranty Statement What is Not Covered Under This Warranty This warranty does not cover any emission related part which malfunctions fails or is damaged due to alterations and or modifications such as
102. ted metallic filings 5 After the oil has drained completely install a new sealing washer Drain Plug NOTE Refer to the Gearcase Specifications Chart on page 63 for recom mended lubricants capacities and torque specifications Reinstall the drain plug Torque to specification Add the recommended oil as needed Do not overfill Reinstall the fill plug Torque to specification Check for leaks 10 Dispose of used oil properly Co ND 64 MAINTENANCE Gearcases Front Gearcase 4X4 Always check and change the front gearcase oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 52 Maintain the oil level even with the bottom thread of the fill plug hole Refer to the Gearcase Specifications Chart on page 63 for recommended lubricants capacities and torque specifications See page 106 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 spec ification Oil Change 1 Support the vehicle securely with a jackstand 2 Remove the front tire on the driver s Drain Plug 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 Drain the oil 6 Clean
103. these procedures when transporting the vehicle SNe ae Ue Ne Stop the engine Remove the key to prevent loss during transporting Place the transmission in gear Engage the park brake Secure the fuel cap oil cap and seat 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 101 SPECIFICATIONS RANGER 2X4 Gross Vehicle Weight 2500 Ibs 1135 kg Dry Weight 1105 Ibs 501 kg Overall Length 113 in 282 cm Overall Width box 60 in 152 4 cm Overall Width tires 58 in 147 3 cm Overall Height 75 in 190 5 cm Wheelbase 76 in 193 cm Cargo Box L x W x H 58 x 42 x 10 in 147 x 106 7 x 25 4 cm Ground Clearance 11 5 in 29 cm Min Turning Radius 132 in 335 3 cm Fuel Capacity 9 gal 34 1 Engine Oil Capacity 2 qts 2 1 1 Coolant Capacity 2 25 qts 2 4 1 Towing Capacity 1500 Ibs 681 kg Max Cargo Box Load 850 Ibs 386 kg Engine 4 valve 4 stroke single cylinder with counter balance Displacement 499 cc Bore x Stroke 92 x 75 Pilot Jet 42 5 Main Jet 135 Needle Jet P 6 829 Jet Needle 4MB32 3 Air Screw 2 5 Alternator Output 250 W Compression Ratio 10 2 1 Starting System Electric Carburetor 34 mm CV Mikuni Ignition System CDI Ignition Timing 30 5000 RPM Spark Plug NGK BKR5E Fro
104. tor replace lines every two years E Valve clearance 100 H 12M Inspect adjust E Idle speed As required Adjust 119 WARRANTY California Emission Control Warranty Statement Repair and Replacement of Emission Related Parts It is recommended that only LSI engine replacement parts which have been authorized and approved by POLARIS should be used in the performance of any warranty mainte nance or repairs of emission related parts These replacement parts will be provided at no charge if the part is still under warranty How to File a Warranty Claim Where to Get Warranty Service All repairs qualifying under this Limited Warranty must be performed by a dealer who sold you the LSI engine or a dealer authorized by POLARIS In the event that any emis sion related part is found to be defective during the warranty period you must notify the Polaris Warranty Department at 1 763 417 8650 and you will be advised of the appro priate dealer where the warranty repair is to be performed The Air Index of this Engine is 3 0 2 4 6 8 10 Most Clean Least Clean Note The lower the Air Index the less pollution This engine is certified to be emission compliant for 1000 hours of use 120 MAINTENANCE LOG Use the following chart to record periodic maintenance DATE MILES KM OR HOURS TECHNICIAN SERVICE PERFORMED COMMENTS
105. uired mos from date of manufacture 75 100 12 5 12 8 volts May need slight 3 6 hours charge if no charge given check in 3 months Needs charge 5 11 hours 50 75 12 0 12 5 volts At least 13 hours 25 50 11 5 12 0 volts Needs charge verify state of charge 0 25 11 5 volts or less Needs charge with desulfating charger At least 20 hours 95 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 CAUTION High water pressure may damage components Polaris recommends washing the vehicle by hand or with a garden hose using mild soap 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 e Avoid the use of harsh cleaners which can scratch the finish e Do not use a power washer to clean the vehicle e Do not use medium to heavy duty compounds on the finish e Always use clean cloths and pads for cleaning and polishing Old or reuse
106. water to prevent damage to the vehicle 91 MAINTENANCE Battery Battery Installation Using a new battery that has not been fully charged can damage the bat tery and result in a shorter life It can also hinder vehicle performance Follow the battery charging instructions on page 94 before installing the battery 1 Ensure that the battery is fully charged 2 Place the battery in the battery holder 3 With conventional batteries install the battery vent tube sealed bat teries do not have a vent tube NOTE The vent tube must be free of obstructions and securely installed Route the tube away from the frame and vehicle body to prevent con tact with electrolyte A WARNING Battery gases could accumulate in an improperly installed vent tube and cause an explosion resulting in serious injury or death Always ensure that the vent tube is free of obstructions and is securely installed as recommended 4 On conventional batteries coat the terminals with dielectric grease or petroleum jelly 5 Connect and tighten the red positive cable first 6 Connect and tighten the black negative cable last 7 Verify that cables are properly routed 92 MAINTENANCE Battery Battery Storage Whenever the vehicle is not used for a period of three months or more remove the battery from the vehicle ensure that it s fully charged and store it out of the sun in a cool dry place Check battery voltage
107. xposed to road salt or salt in the air in coastal areas are more susceptible to corrosion if not properly cleaned Clean chrome wheels more often if they re exposed to salt or other corrosive elements 1 Wash chrome wheels frequently Use a mild detergent Never use abrasive cleaners on plated or painted surfaces 2 Rinse well with clear water Soap detergents salt dirt mud and other elements can cause corrosion 3 Polish the clean chrome wheels periodically Use an automotive grade chrome polish 4 Routinely and liberally apply a weather resistant wax to each pol ished chrome wheel Choose a product suitable for chrome finishes Read and follow the product labels and instructions Removing Corrosion If light rust is found on the chrome finish use steel wool 0000 OTT grade to remove it Gently rub the affected areas with the steel wool until the corrosion has been removed Clean and polish the wheel as out lined above 98 MAINTENANCE Cleaning and Storage Storage Tips CAUTION Starting the engine during the storage period will disturb the protective film created by fogging and damage could occur Never start the engine during the storage period Clean the Exterior Make any necessary repairs and clean the vehicle as recommended See page 96 Stabilize the Fuel 1 Fill the fuel tank Add Polaris Carbon Clean Fuel Treatment or Polaris Fuel Stabilizer Follow the instructions on the containe

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