Polaris 2008 99 Ranger - Manuals

CONTENTS UNDERSTANDING WARNINGS 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . SAFETY WARNING AND OPERATION DECALS 2-7 . . . . . . . . . . . . LABEL LOCATIONS 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DAILY PRE-RIDE INSPECTION 9 . . . . . . . . . . . ...

1 UNDERSTANDING WARNINGS SAFETY ALERT The following precautionary signal words are used throughout this manual to con-vey the following messages: This is the safety alert symbol. When you see this symbolon your machine or in this manual, be alert to the potentialfor personal injury. Your safety is i...

2 SAFETY WARNING AND OPERATION DECALS VEHICLE ROLLOVER COULD CAUSE SEVERE INJURY OR DEATHThis cab frame is not designed or intended to provide rollover protectionin the event of vehicle overturning. See Owner’s Manual. WARNING l Riders can be thrown off. This can cause serious in-jury or death. l Ne...

3 SAFETY WARNING AND OPERATION DECALS Recoil handle must be firmly seated toprevent water entry. Drain starter motorif water enters. See owner’s manual. 7075741 WARNING/AVERTISSEMENT 7075439 This vehicle is designed for operator and “ONE” passenger only Ce Vehicule est concu pour ne transporterque l...

4 SAFETY WARNING AND OPERATION DECALS Text found below 7077683 OPERATOR/LOAD DISTRIBUTION WARNINGS VIOLATION OF ANY OF THE FOLLOWING WARNINGS COULD CAUSE LOSSOF CONTROL AND RESULT IN SEVERE INJURY OR DEATH. MAKE STARTS, STOPS, TURNS AND DIRECTIONS CHANGES IN A SMOOTHMANNER so as not to shift the loa...

8 LABEL LOCATION 2 4 6 5 1 3 1. Warning (General) 2. Warning (Vehicle roll-over) 3. Warning (Load Distribution) 4. Warning (Cargo Bed) 5. Tire Pressure 6. Towing Information

9 DAILY PRE-RIDE INSPECTION Inspect your vehicle each time before riding to ensure it is in proper workingorder. If proper inspection is not done, severe injury or death could result. If a proper inspection is not performed serious injury or death can result. Always inspect your RANGER before riding...

10 OPERATION WARNINGS WARNING WARNING POTENTIAL HAZARD Operating this vehicle without proper instruction. WHAT CAN HAPPEN The risk of an accident is greatly increased if the operator does not knowhow to operate the vehicle properly in different situations and on differ-ent types of terrain. HOW TO A...

20 VEHICLE IDENTIFICATION NUMBERS Important: Record these numbers from your vehicle in the spaces provided. 1. Frame VIN: 3. Engine Serial Number (Right front side of engine crankcase) Remove the spare key and store in a safe place. Record your ignition key num-ber here. It is a four digit number fo...

21 CONTROL PARTS AND FUNCTIONS Fuel Gauge The fuel gauge on the instrument panel shows the amount of fuel in the fuel tank. When the red indicator needle comes near the E (empty) mark, refuel at the earliestopportunity. Ignition Switch This is a three-position, key-operated switch. The key can be re...

22 CONTROL PARTS AND FUNCTIONS Parking Brake Lever The parking brake lever is located at the right side of the driver’s seat. Pull the leverup and to the rear to apply the parking brake. To release, push in and hold the knob on the end of the lever and push the leverall the way down. Spring pressure...

23 CONTROL PARTS AND FUNCTIONS Seat Belts The vehicle is equipped with lap-style seat belts for the operator and passenger. WARNING Seat belts reduce injury. Always were your seat belt. Minimum age recommen-dation for passengers if five years old. Passengers under five years of age re-quire special ...

27 CONTROL AND PARTS FUNCTIONS VEHICLE NOMENCLATURE - Left View 1. Cab Frame 2. Cab Frame Hand Hold 3. Dashboard 4. Steering Wheel 5. Gear Shift Lever 6. Seat 7. Cargo Box 8. Seat Belts 9. Parking Brake 10. Engine Compartment Access Panel 11. Hood Latches (attached to hood; left and right sides unde...

28 CONTROL AND PARTS FUNCTIONS VEHICLE NOMENCLATURE - Front View 14 16 15 13 12 12 12. Headlights 13. Air Box (under hood) 14. Battery (under hood) 15. Radiator (under hood) 16. Front Bumper/Brush Guard

29 CONTROL AND PARTS FUNCTIONS VEHICLE NOMENCLATURE - Rear View 17 18 21 20 19 17 17. Tail Gate Latches (Top and Bottom) 18. Tail Gate 19. Muffler (Spark Arrester) 20. Trailer Hitch Receiver 21. Taillight

30 CONTROL AND PARTS FUNCTIONS VEHICLE NOMENCLATURE - Instrument Panel 12 2 8 11 1 3 7 5 6 9 4 10 1. Choke Knob 2. Ignition Switch 3. Hour Meter 4. Passenger Warning Decal 5. Neutral Indicator Light 6. Reverse Indicator Light 7. Brake Light 8. Coolant Temperature Warning Light 9. Fuel Gauge 10. 12V ...

31 CONTROL AND PARTS FUNCTIONS Demand 6 Drive Exclusive Demand 6 Drive System (All Wheel Drive) This Polaris AWD is equipped with a unique, Polaris exclusive, Demand 6 Drive(AWD) system which is activated by a switch on the dash. When the switch is “off”the RANGER is in 4 wheel drive at all times. W...

32 CONTROL AND PARTS FUNCTIONS Transmission Gear Selector Operation The transmission gear selector is located tothe right of the vehicle driver’s seat. Thetransmission selector lever has four posi-tions: high forward (D2); reverse; neutral;and low forward (D1). Use of (low forward gear - D1) is reco...

33 CONTROL AND PARTS FUNCTIONS Disengaging Wheel Hubs When backing uphill while in Demand 6 Drive and then going forward downhill, oneor both hubs may remain engaged. If one or both hubs remain engaged they canbe disengaged by stopping, shifting to and moving in reverse. Then proceed inforward again...

34 CONTROL AND PARTS FUNCTIONS Engine Cooling System Coolant Level The recovery bottle (1), locatedon the left side of the machinemust be maintained between theminimum and maximum levelsindicated on the recovery bottle.The engine coolant level is con-trolled or maintained by the re-covery system. Th...

35 CONTROL AND PARTS FUNCTIONS Engine Cooling System Radiator Coolant Level Inspection NOTE: This procedure is only required if the cooling system has been drained for maintenance and/or repair. However, if the recovery bottle has run dry, the levelin the radiator should be inspected and coolant add...

37 CONTROL AND PARTS FUNCTIONS 4 Cycle Premium 4 Synthetic Lubricant Polaris Premium 4 All Season Synthetic engine oil has been specially formulatedfor use in Polaris 4 cycle engines. It is a fully synthetic, high performance, multi-vis-cosity oil designed to provide the ultimate in lubrication perf...

38 CONTROL AND PARTS FUNCTIONS Oil and Filter Change The recommended oil change interval is 100 hours, 1000 miles, or every sixmonths, whichever comes first. Suggested break in oil change is at 20 hours, 500miles, or one month, whichever comes first. Severe use operation requires morefrequent servic...

39 CONTROL AND PARTS FUNCTIONS Oil and Filter Change (Cont.) 14. Reinstall drain plug.15. Remove dipstick (2) and add 2 quarts (1.9 l) of Polaris Premium 4 synthetic oil. Reinstall dipstick. NOTE: If sump is not drained, add about 1 3/4 quarts initially. 16. Place gear selector in neutral and set pa...

40 STARTING THE ENGINE Stopping the Engine 1. Release the throttle pedal completely. 2. Put the gear shift lever into (N) Neutral. 3. Apply the parking brake to help prevent the vehicle from rolling. 4. Turn the ignition switch key to the OFF position. Procedure for Starting a Cold Engine WARNING Do...

41 STARTING THE ENGINE 7. If engine does not start, release ignition switch and wait five seconds; then turn the ignition switch to start for another five seconds. Repeat this procedure untilengine starts. NOTE: Do not press the throttle pedal while starting the engine. After the Engine Starts 1. If...

42 STARTING THE ENGINE Procedure for Starting a Warm Engine Warm engines do not normally require the use of the choke since the spark plugcan easily become wet fouled. 1. Place the transmission in neutral and move the vehicle to a level surface. 2. Lock the parking brake 3. Turn the fuel tank valve ...

44 VEHICLE BREAK-IN PERIOD The break in period for your new Polaris RANGER is defined as the first twenty hours of operation, or the time it takes to use the first two tanks full of gasoline. Nosingle action on your part is as important as a proper break in period. Careful treat-ment of a new engine...

45 CARRYING LOADS The RANGER has been designed to carry or tow a certain amount of load. Always read and understand the load distribution warnings listed on the warning labels.Never exceed the following weights. Maximum Capacities (Level Ground) Cargo Box RANGER - 1500 lbs. (681 kg) 1000 lbs. (454 k...

46 OPERATING SAFETY Load Distribution 1. Always load the cargo box placing the load as far forward as possible. 2. Always operate the vehicle with extreme care whenever hauling or towing loads. 3. Slow down and drive in D-1 only. 4. The cargo box dump latch must be securely latched before loading an...

48 OPERATING SAFETY Riding On Slippery Surfaces Whenever driving on slippery surfaces such as wet trails or loosegravel, or during cold freezing weather, special attention must bepaid to prevent vehicle turnover. Always: 1. Slow down when entering slippery areas. 2. Maintain a high level of alertnes...

49 OPERATING SAFETY Operating on Hills WARNING Improperly crossing hills or turning on hills can be dangerous! Loss of vehicle control or overturning of the vehicle could occur. Avoid crossing the side of a steep hill if possible. Use extreme care when operating your RANGER in hilly terrain. Wheneve...

52 OPERATING SAFETY Crossing Streams Your Polaris RANGER can operate through water up to depths reaching the floor- boards. Before fording streams always: 1. Determine water depths and current. 2. Choose a crossing where both banks have gradual inclines. 3. Proceed slowly, avoiding rocks and obstacl...

53 OPERATING SAFETY Trail Obstacles Keep Alert! Look ahead and learn to read the trail as you ride. Stay on the right side of the trail,if possible, and be constantly alert for hazards such as logs, rocks and low hangingbranches. WARNING Hidden or unseen hazards on the trail can be dangerous. Person...

54 OPERATING SAFETY Backing Up 1. When backing up, always avoid backing downhill. 2. Back slowly. 3. When in reverse, apply the brakes lightly for stopping. 4. Avoid turning at sharp angles in reverse. 5. Never open the throttle suddenly while backing. 6. Always inspect left and right fields of visi...

56 NOISE EMISSION CONTROL SYSTEM REGULATION TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED! U.S. Federal law prohibits the following acts or the causing thereof: (1) The removal or rendering inoperative by any person other than for purposes ofmaintenance, repair, or replacement of any device or elem...

57 BATTERY Battery CAUTION Whenever removing the battery, discon-nect the negative (black) cable first. Whenreinstalling the battery, connect the nega-tive (black) cable last. Replenishing the Battery Fluid A poorly maintained battery will deterioraterapidly. Check the battery fluid level often.The ...

58 BATTERY Battery Removal 1. Disconnect hold down straps holding the battery (1) in positionand remove battery retainer. 2. Remove the battery vent tube from the battery. 3. Disconnect the black (negative) battery cable first. 4. Disconnect the red (positive) bat- tery cable next. 5. Lift the batte...

59 MAINTENANCE Periodic Maintenance Schedule Careful periodic maintenance will help keep your vehicle in the safest, most reliablecondition. Inspection, adjustment and lubrication intervals of important compo-nents are explained in the following chart: Maintenance intervals are based upon average ri...

62 MAINTENANCE Lubrication Recommendations Item Lube Rec. Method Frequency* 1.Engine Oil Polaris Pre-mium 4 Syn-thetic 0W40 Add to proper level on dipstick.See page 37. Check level dai-ly. 2. Brake Fluid DOT 3 Only Maintain level between fill lines.See page 78. As required;change everytwo years or 2...

66 MAINTENANCE WARNING Vehicle operation with insufficient, deteriorated, or contaminated engineoil will cause accelerated wear and may result in engine seizure, acci-dent, and injury. Engine Oil In order for the engine to functionproperly, maintain the engine oil at theproper level, and change the ...

68 MAINTENANCE Front Gearcase Lubrication Fill plug/Dipstick Front Gearcase Lubrication The front gearcase fill plug is located on the right side of the front gearcase. The front gearcase lubricant level should be checked every six months or 1000miles (1600 km), whichever comes first. Front gearcase...

69 MAINTENANCE The following items should be checked occasionally for tightness; or if they havebeen loosened for maintenance service. Axle and Wheel Nut Torque Specifications Front Spindle Nut(s) Dealer Performed Service Front Wheel Nuts 15 Ft. Lbs. Center and Rear Hub Retaining Nut(s) 120 Ft. Lbs....

70 MAINTENANCE Rear Spring Adjustment The rear shock absorber springs areadjusted by rotating the adjuster inthe direction required to increase ordecrease spring tension. Air Filter Service It is recommended that the air filter bereplaced yearly. When riding in ex-tremely dusty conditions replace-me...

71 MAINTENANCE CAUTION: Operation of your vehicle without a breather filter can cause engine damage. Breather Filter and Hoses Do not perform this operation immediately after the enginehas been run. The exhaust system becomes very hot and can cause severe burns. 1. Open hood and locate the airbox (1...

72 MAINTENANCE Coolant Level Inspection NOTE: Check the coolant level when the engine is cold (room oratmospheric temperature). 1. Situate the vehicle on level ground. 2. Check the coolant level through the coolant levelgauge on the reserve tank lo-cated Behind the left hand en-gine compartment pane...

73 MAINTENANCE Spark Plugs Proper electrode gap is .028 ″ /.7mm. Spark plug torque is 17 ft. lbs. (2.3 kg/m). Use NGK BKR5ES spark plugs. Proper electrode gap is .025 ″ (.06 cm). Spark plug torque is 17 ft. lbs.(2.3 kg/m) for a used spark plug, 11 ft. lbs (1.52 kg/m) for a new spark plug. Spark plug...

74 MAINTENANCE Spark Arrestor The exhaust pipe must be period-ically purged of accumulated car-bon as follows: 1. Remove the clean out plugs located on the bottom of themuffler as shown above. 2. Place the transmission in neutral and start the engine.Purge accumulated carbonfrom the system by momen-...

75 MAINTENANCE Tool Kit To help you perform routine maintenance, a tool kit is provided in the storagecompartment under the seat. Items included in the kit are: screwdriver open end wrench (8-10 mm) open end wrench (12-14 mm) tire pressure gauge spark plug wrench and handle NOTE: Other tools are als...

76 MAINTENANCE Throttle Pedal If the throttle pedal (1) has exces-sive play due to cable stretch orcable misadjustment, it will cause adelay in throttle response, especial-ly at low engine speed. Also, thethrottle may not open fully. If thethrottle pedal has no play, thethrottle may be hard to contr...

77 MAINTENANCE Carburetor The idle speed adjustment should be performed in accordance with the PeriodicMaintenance Chart or whenever the idle speed is changed. The following proce-dure covers the idle speed adjustment: Carburetor/Engine Idle RPM Adjustment Recommended engine idle RPM is 1200 +/- 200...

78 MAINTENANCE Front and Rear Brakes The front and brakes are hydraulicdisc type brakes activated by thebrake pedal. The following checks are recom-mended to keep the brake system ingood operating condition. How oftenthey need checking depends uponthe type of driving that has been done. Inspect the ...

79 MAINTENANCE Rear Brake The rear brake is a hydraulic disctype brake which is activated by thesame pedal which activates the frontbrake system. The rear brake sys-tem is self adjusting and requires nomaintenance other than periodicchecks of the pads for wear. Wear Line Pads should be changed when ...

81 MAINTENANCE Wheel Removal Procedure 1. Stop the engine, place the transmission in gear and lock the parking brake. 2. Loosen the wheel nuts slightly. 3. Elevate the side of the vehicle by placing a suitable stand under the frame. 4. Remove the wheel nuts and remove the wheel. Wheel Installation 1...

82 MAINTENANCE Tire Inspection CAUTION: Maintain proper tire pressure according to charts below. Improper tire inflation may affect vehicle maneuverability. When replacing a tire always use original equipment size and type. CAUTION: The use of non-standard size or type tires may affect vehicle handl...

84 MAINTENANCE Headlight Beam The headlight beam can be adjusted up and down. 1. Place the vehicle on a level surface with the headlight approximately 25’ (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. Sta...

86 MAINTENANCE Cleaning Your RANGER Keeping your vehicle clean will not only improve its appearance but it can also ex-tend the life of various components. With a few precautions, your vehicle can becleaned much like an automobile. Washing If a high pressure type car wash system is used, extreme car...

87 MAINTENANCE Storage If your vehicle is to be placed in extendedor off season storage, the following stepsshould be taken to preserve its condition. 1. Perform all necessary repairs and thor- oughly clean the vehicle. 2. Turn the fuel valve to “off” and drain the carburetor. 3. Remove the spark pl...

88 MAINTENANCE WARNING Do not run the engine in a closed area. Exhaust gases contain carbonmonoxide; a colorless, odorless, poisonous gas. Breathing exhaustgas leads to carbon monoxide poisoning, asphyxiation and death. Bolt and Nut Tightening Tightness of the bolts, nuts and other fasteners should ...

89 TROUBLESHOOTING Procedures The following information is provided to help you identify probable causes for ques-tions you may have about the operation of your vehicle. See your Polaris dealerwith any additional questions you may have. ENGINE CRANKS BUT FAILS TO START No Fuel Water in Fuel Spark Pl...

90 SPECIFICATIONS Gross Vehicle Weight 3020 lbs. Fuel Capacity 9.5 Gallons C Towing Capacity 1500 lbs. CA Maximum Cargo Box Load 1000 lbs. A P A Overall Length 113 in. AC Overall Width 58 in. (Tires) 60 ″ (Cargo Box) C I T Overall Height 75 in. T I Wheelbase 81 in. I ES Ground Clearance 8.5 in. S Dr...

93 WARRANTY LIMITED WARRANTY Polaris Industries Inc., 1225 Highway 169 North, Minneapolis, Minnesota55441-5078, gives a SIX MONTH LIMITED WARRANTY on all components of thePolaris RANGER against defects in material or workmanship. This warranty cov- ers the parts and labor charges for repair or repla...

94 WARRANTY WARRANTY OR ANY OTHER CONTRACT, NEGLIGENCE, OR OTHER TORTOR OTHERWISE. Some states do not permit the exclusion or limitation of inciden-tal or consequential damages or implied warranties, so the above limitations or ex-clusions may not apply to you if inconsistent with controlling state ...

INDEX 95 Air Cleaner 70 . . . . . . . . . . . . . . . . . . . . . . All Wheel Drive 31 . . . . . . . . . . . . . . . . . . . Backing Up 54 . . . . . . . . . . . . . . . . . . . . . . Battery Installation 58 . . . . . . . . . . . . . . . . Battery Maintenance 57 . . . . . . . . . . . . . . Battery Re...