Polaris 2015 Ranger Diesel / Crew Diesel- Manuals

4 INTRODUCTION The RANGER is an off-road vehicle. Familiarize yourself with all laws and regulations concerning the operation of this vehicle in your area. The following signal words and symbols appear throughout this manual and on your vehicle. Your safety is involved when these words and symbols a...

6 INTRODUCTION Vehicle Identification Numbers Record your vehicle's identification numbers and key number in the spaces provided. Remove the spare key and store it in a safe place. An ignition key can be duplicated only by ordering a POLARIS key blank (using your key number) and mating it with one o...

7 INTRODUCTION European Vibration and Noise The driver-perceived noise and hand/arm and whole body vibration levels of this machinery is measured per prEN 15997.The operating conditions of the machinery during testing:The vehicles were in like-new condition. The environment was controlled as indicat...

8 SAFETY Safe Riding Gear The driver and all passengers must wear helmet, eye protection, gloves, long-sleeve shirt, long pants, over-the-ankle boots and seat belt at all times. Protective gear reduces the chance of injury. Helmet Wearing a helmet can prevent a severe head injury. Whenever riding th...

9 SAFETY Safe Riding Gear Eye Protection Do not depend on eyeglasses or sunglasses for eye protection. Whenever riding this POLARIS vehicle, always wear shatterproof goggles or use a shatterproof helmet face shield. POLARIS recommends wearing approved Personal Protective Equipment (PPE) bearing mark...

10 SAFETY Safety Labels and Locations Warning labels have been placed on the vehicle for your protection. Read and follow the instructions of the labels on the vehicle carefully. If any of the labels depicted in this manual differ from the labels on your vehicle, always read and follow the instructi...

11 SAFETY Safety Labels and Locations Payload Warning/Shift Caution WARNING CAUTION To avoid transmission damage, shift only when vehicle is stationary and at idle. When vehicle is stopped, place shift in parked position. Seat Belt/Drive Responsibly Warning WARNING Improper vehicle use can result in...

12 SAFETY Safety Labels and Locations Load/Passenger/Tire Pressure Warning WARNING • Never carry passengers in cargo box.• Passengers can be thrown off. This can cause serious injury or death. • If total payload is greater than 500 lbs., the vehicle must be operated in LOW range. IMPROPER TIRE PRESS...

13 SAFETY Operator Safety Serious injury or death can result if you do not follow these instructions and procedures, which are outlined in further detail within your owner's manual. • Read this entire manual and all labels carefully. Follow the operating procedures described. • Never allow anyone un...

14 SAFETY Operator Safety • Always travel slowly and use extra caution when operating on unfamiliar terrain. Be alert to changing terrain. • Never operate on excessively rough, slippery or loose terrain.• Always follow proper procedures for turning. Practice turning at slow speeds before attempting ...

15 SAFETY Operator Safety • Always use the proper size and type of tires specified in this manual. Always maintain proper tire pressure as specified on safety labels. • Never modify this vehicle through improper installation or use of non-POLARIS approved accessories. • Never exceed the stated load ...

16 SAFETY Operator Safety Failure to operate the RANGER properly can result in a collision, loss of control, accident or rollover, which may result in serious injury or death. Heed all safety warnings outlined in this section of the owner’s manual. See the OPERATION section of the owner’s manual for...

17 SAFETY Operator Safety Cab Nets Riding in this vehicle without using the cab nets (or doors, if equipped) increases the risk of serious injury or death in the event of an accident or rollover. Always use the cab nets (or doors) while riding in this vehicle. Always keep hands and feet inside the v...

18 SAFETY Operator Safety Exposure to Exhaust Engine exhaust fumes are poisonous and can cause loss of consciousness or death in a short time. Never start the engine or let it run in an enclosed area. The engine exhaust from this product contains chemicals known to cause cancer, birth defects or oth...

19 SAFETY Operator Safety Turning Improperly Turning improperly could cause loss of traction, loss of control, accident or rollover. Always follow proper procedures for turning as described in this owner’s manual. Never turn abruptly or at sharp angles. Never turn at high speeds. Practice turning at...

21 FEATURES AND CONTROLS Component Locations Your vehicle is equipped with cab nets on both sides of the vehicle. Cab nets (or doors, if equipped) must be used by both operator and passengers at all times. Any illustrations without cab nets are only to allow component identification. Always use the ...

22 FEATURES AND CONTROLS Console Auxiliary Outlets The 12-volt receptacles have 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 con- sole, under the dash. Gear Selector H: High GearL: Low GearN: Neutra...

23 FEATURES AND CONTROLS Switches 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. Mode Button The MODE button is located on the instrument cluster. Use the MODE button to toggle through mode options ...

24 FEATURES AND CONTROLS Brake Pedal Depress the brake pedal to slow or stop the vehicle. Apply the brakes while starting the engine. Throttle Pedal Push the throttle pedal down to increase engine speed. Spring pressure returns the pedal to the rest position when released. Always check that the thro...

25 FEATURES AND CONTROLS Seat and Storage Compartments The electrical compartment is located under the center rear-most seat. Never use this area for storage. Storage compartments are located under all other seats. Remove the storage bin under the right rear-most passenger seat to access the battery...

26 FEATURES AND CONTROLS Fuel Cap The fuel tank filler cap is located on the left side of the vehicle near the driver’s seat. Use only the recommended diesel fuel. See page 37. Hood Latches Remove the hood to access the coolant overflow bottle, the radiator cap and the headlight adjustment screws.To...

27 FEATURES AND CONTROLS Rollover Protective Structure (ROPS) The Rollover Protective Structure (ROPS) on this vehicle meets OSHA 1928.53 rollover performance requirements. Always have your authorized POLARIS dealer thoroughly inspect the ROPS if it ever becomes damaged in any way. No device can ass...

28 FEATURES AND CONTROLS Cab Nets Riding in this vehicle without using the cab nets (or doors, if equipped) increases the risk of serious injury or death in the event of an accident or rollover. Cab nets (or doors) must be used by both operator and passengers at all times. Make sure all latches are ...

29 FEATURES AND CONTROLS Seat Belts This POLARIS vehicle is equipped with three-point lap and diagonal seat belts on all seats. Always make sure the seat belts are secured for all riders before operating. The driver's seat belt is equipped with a seat belt interlock. Vehicle speed will be limited to...

30 FEATURES AND CONTROLS Instrument Cluster Your vehicle is equipped with an instrument cluster that senses vehicle speed from the transmission. In addition to showing vehicle speed, the speedometer needle flashes when a warning condition exists. NOTICE: High water pressure may damage components. Wa...

31 FEATURES AND CONTROLS Instrument Cluster Rider Information Center 3. MPH / KM/H Display - MPH is displayed when the instrument cluster is in the Standard mode. KM/H is displayed when the instrument cluster is in the Metric mode. 4. High Beam Indicator - LED icon illuminates whenever the Headlamp ...

32 FEATURES AND CONTROLS Instrument Cluster Information Display Area The LCD portion of the instrument cluster is the information display area which displays the following information: odometer, trip meter, RPM, battery voltage, engine temperature, air temperature, engine hours, trouble codes, servi...

33 FEATURES AND CONTROLS Instrument Cluster Information Display Area Tachometer (RPM) Engine RPM can be displayed digitally. Engine Temperature Engine temperature can be displayed in °F or °C. Refer to “Units of Measurement” to change the format. Clock The clock displays the time in a 12-hour or 24-...

34 FEATURES AND CONTROLS Instrument Cluster Information Display Area Programmable Service Interval The initial factory service interval setting is 50 hours. Each time the engine is started, the engine hours are subtracted from the service interval hours. When the service interval reaches 0, the LCD ...

35 OPERATION Failure to operate the vehicle properly can result in a collision, loss of control, accident or rollover, which may result in serious injury or death. Read and understand all warnings outlined in the safety section of this manual. Break-In Period The break-in period for your new RANGER ...

36 OPERATION Pre-Ride Inspection Failure to inspect and verify that the vehicle is in safe operating condition before operating increases the risk of an accident. Always inspect the vehicle before each use to make sure it's in safe operating condition. Item Remarks Page Brake system/pedal travel Ens...

37 OPERATION Fuel Recommendations NOTICE: For the best engine performance, to prevent engine damage and to comply with EPA/CARB warranty requirements, use ONLY the recommended diesel fuels. Use only CLEAN diesel fuel. POLARIS recommends the following diesel fuels for use in this vehicle:• Ultra Low ...

38 OPERATION Fuel Recommendations Bio-Diesel Fuels In Europe and in the United States, as well as some other countries, non-mineral oil based fuel resources such as RME (Rapeseed Methyl Ester) and SOME (Soybean Methyl Ester), collectively known as FAME (Fatty Acid Methyl Esters), are being used as e...

39 OPERATION Fuel Recommendations Bio-Diesel Fuels B21 To B100 Bio-diesel Fuel Blend Usage B21 to B100 bio-diesel is not approved for this POLARIS application. Approved Engines Only the KOHLER KDW engine series listed below may operate with bio-diesel fuel concentrations up to B20 for POLARIS applic...

40 OPERATION Fuel Recommendations Refueling The fuel tank filler cap is located on the right side of the vehicle near the passenger seat. Remove the cap and add the recommended fuel to the bottom of the filler neck. Do not overfill. Cold Weather Operation Cold weather operation can result in fuel ge...

41 OPERATION Cold Weather Operation Bio-Diesel Blended Fuel NOTICE: Never use bio-diesel blended fuel containing more than 20% bio-diesel in this vehicle. See page 38. Bio-diesel blended fuel has unique qualities that should be considered before using it in this vehicle: • Cold weather conditions ca...

42 OPERATION Operating Conditions NOTICE: Observe the following environmental operating conditions to maintain engine performance and avoid premature engine wear. • Avoid operating in the presence of chemical gases or fumes.• Avoid operating in a corrosive atmosphere such as salt water spray.• NEVER...

43 OPERATION Starting the Engine NOTICE: NEVER use an engine starting aid such as ether. Engine damage will result. Before operating this vehicle in cold weather, review the cold weather operation information beginning on page 40. Always wait for the glow plug indicator light to turn off before cran...

44 OPERATION Driving Procedure 1. Wear a helmet, eye protection, gloves, long-sleeve shirt, long pants and over-the-ankle boots. 2. Perform the pre-ride inspection. See page 36.3. Sit in the driver's seat and fasten the seat belt.4. Always use the cab nets (or doors) while riding in this vehicle.5. ...

45 OPERATION Driving with a Passenger 1. Perform the pre-ride inspection. See page 36.2. Make sure all passengers are at least 12 years of age and tall enough to comfortably and safely sit in a passenger seat with the seat belt secured, put both feet on the floor and grasp the hand hold. 3. Make sur...

46 OPERATION Driving on Slippery Surfaces Skidding or sliding can cause loss of control or rollover (if tires regain traction unexpectedly). When operating on slippery surfaces such as ice or loose gravel, reduce speed and use extra caution to reduce the chance of skidding or sliding out of control....

47 OPERATION Driving Uphill Whenever traveling uphill, follow these precautions:1. Always travel straight uphill.2. Avoid excessively steep hills.3. Keep both feet on the floor.4. Always check the terrain carefully before ascending any hill. Never climb hills with excessively slippery or loose surfa...

48 OPERATION Driving Through Water Your POLARIS RANGER can operate through water up to a maximum recommended depth equal to the floorboards. NOTICE: Immersion can result in major damage if the vehicle isn't serviced correctly and promptly. After immersion, always take the vehicle to your dealer serv...

49 OPERATION Driving in Reverse Follow these precautions when operating in reverse:1. Always check for obstacles or people behind the vehicle. Always inspect left and right fields of vision before backing. 2. Always avoid backing downhill.3. Back slowly.4. Apply the brakes lightly for stopping. 5. A...

50 OPERATION Parking the Vehicle 1. Apply the brakes. Stop the vehicle on a level surface.2. When parking inside a garage or other structure, be sure that the structure is well ventilated and that the vehicle is not close to any source of flame or sparks, including any appliance with pilot lights. 3...

51 OPERATION Hauling Cargo Hauling cargo improperly can alter vehicle handling and may cause loss of control or brake instability, which can result in serious injury or death. Always follow these precautions when hauling cargo: Never exceed the maximum weight capacity of the vehicle. When determinin...

52 OPERATION Towing Loads Towing improperly can alter vehicle handling and may cause loss of control or brake instability. Always follow these precautions when towing:1. Never load more than 150 lbs. (68.1 kg) tongue weight on the towing bracket.2. Always shift to low gear for towing.3. When towing ...

53 OPERATION Dumping the Cargo Box 1. Select a level site to dump the cargo box. Do not attempt to dump or unload the vehicle while parked on an incline. 2. Apply the brakes. Place the transmission in PARK. 3. Ensure that the cargo is positioned evenly or toward the front of the cargo box. 4. Releas...

54 OPERATION All Wheel Drive (AWD) Engaging AWD Press the top of the switch to engage All Wheel Drive (AWD). The 4X4 indicator illuminates in the rider information center to indicate that the vehicle is in AWD. See page 31.When the AWD switch is on, the front wheels will automatically engage any tim...

55 OPERATION All Wheel Drive (AWD) Locking the Differential NOTICE: Damage to the differential can occur if it is engaged while the vehicle is traveling at high speeds or while the rear wheels are spinning. Slow the vehicle to nearly stopped before engaging the differential. Locking the differential...

56 WINCH GUIDE These safety warnings and instructions apply if your vehicle came equipped with a winch or if you choose to add an accessory winch to your vehicle. Improper winch use can result in SEVERE INJURY or DEATH. Always follow all winch instructions and warnings in this manual. Your winch may...

58 WINCH GUIDE Winch Operation Read the Winch Safety Precautions in the preceding pages before using your winch. Tip: Consider practicing the operation and use of your winch before you actually need to use it in the field. Improper winch use can result in SEVERE INJURY or DEATH. Always follow all wi...

59 WINCH GUIDE Winch Operation 4. Always use the hook strap when handling the hook. WARNING! Never put your fingers into the hook. This could lead to SEVERE INJURY. A. Attach the hook itself onto the load or use a tow strap or chain to secure the load to the winch cable. Tip: A “tow strap” is NOT in...

60 WINCH GUIDE Winch Operation 8. Read and adhere to the following information for winch damping to ensure safe winch use. A. In order to absorb energy that could be released by a winch cable failure, always place a “damper” on the winch cable. A damper can be a heavy jacket, tarp, or other soft, de...

61 WINCH GUIDE Winch Operation 14. The winch motor may become hot during winch use. If you winch for more than 45 seconds, or if the winch stalls during operation, stop winching and permit the winch to cool down for 10 minutes before using it again. 15. After winching is complete, especially if winc...

62 WINCH GUIDE Shock Loading WARNING! Your winch cable is very strong but it is NOT designed for dynamic, or “shock” loading. Shock loading may tension a winch cable beyond its strength and cause the cable to break. The end of a broken winch cable under such high loading can cause SEVERE INJURY or D...

63 WINCH GUIDE Winch Maintenance and Service Safety WARNING! Improper or lack of winch maintenance and service could lead to SEVERE INJURY or DEATH. Always follow all winch instructions and warnings in this manual. 1. Always inspect your winch before each use. Inspect for worn or kinked winch cable....

64 EMISSION CONTROL SYSTEMS Noise Emission Control System Do not modify the engine, intake or exhaust components, as doing so may affect compliance with U.S.A. EPA noise control requirements (40 CFR 205) and local noise level requirements. Operation on Public Lands in the U.S.A. Your POLARIS vehicle...

65 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 part...

68 MAINTENANCE Lubrication Recommendations Check and lubricate all components at the intervals outlined in the Periodic Maintenance Chart beginning on page 65, or more often under severe use, such as wet or dusty conditions. Items not listed in the chart should be lubricated at the general lubricati...

69 MAINTENANCE Engine Oil Oil Check Always check the oil when the engine is cold. If the engine is hot when the oil is checked, the level will appear to be overfull. CAUTION! Always remove all cargo from the cargo box before lifting the box to access engine components. Access the oil fill cap, dipst...

70 MAINTENANCE Engine Oil Oil and Filter Change Always change the oil and filter at the intervals outlined in the Periodic Maintenance Chart beginning on page 65. Always change the oil filter whenever changing oil.The crankcase drain plug is located on the bottom of the crankcase. Access the drain p...

72 MAINTENANCE Gearcases Gearcase Specification Chart Transmission (Main Gearcase) Always check and change the transmission oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 65. Refer to the Gearcase Specifications Chart for recommended lubricants, capacities and torq...

73 MAINTENANCE Gearcases Front Gearcase Always check and change the front gearcase oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 65. Maintain the oil level even with the bottom thread of the fill plug hole. Refer to the Gearcase Specifications Chart on page 72 for...

74 MAINTENANCE Cooling System The engine coolant level is controlled or maintained by the recovery system. The recovery system components are the overflow bottle, radiator filler neck, radiator pressure cap and connecting hose.As coolant operating temperature increases, the expanding (heated) excess...

75 MAINTENANCE Cooling System Overflow Bottle Coolant Level Always check and change the coolant at the intervals outlined in the Periodic Maintenance Chart beginning on page 65. Maintain the coolant level between the minimum and maximum marks on the bottle (when the fluid is cool). 1. Position the v...

76 MAINTENANCE POLARIS Variable Transmission (PVT) System 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...

77 MAINTENANCE POLARIS Variable Transmission (PVT) System Belt Replacement/Debris Removal If a belt fails, always clean any debris from the duct and from the clutch and engine compartments when replacing the belt. WARNING! Failure to remove ALL debris when replacing the belt could result in vehicle ...

80 MAINTENANCE Vehicle Immersion NOTICE: If your vehicle becomes immersed, major engine damage can result if the machine is not thoroughly inspected. Take the vehicle to your dealer before starting the engine. If it's impossible to take your RANGER to a dealer before starting it, follow the steps ou...

81 MAINTENANCE Filter Systems Air Filter Always change the air filter at the intervals outlined in the Periodic Maintenance Chart beginning on page 65. Service the air filter more frequently if the vehicle is operated in wet or dusty conditions or at high throttle for extended periods.1. Lift the ca...

82 MAINTENANCE Spark Arrester Failure to heed the following warnings while servicing the spark arrester could result in serious injury or death. • Do not perform service on the spark arrester while the system is hot. Exhaust system temperatures can reach 1000 ° F. Allow components to cool sufficient...

83 MAINTENANCE Alternator Belt Belt Adjustment Check the alternator belt at the correct service interval as outlined in the Periodic Maintenance Chart beginning on page 65. Stop the machine on a flat level surface. Put the gear selector in Park, stop the engine and exit the vehicle. See page 43.1. R...

84 MAINTENANCE Fuel Filter/Water Separator The fuel filter/water separator is located under the seat on the right side of the vehicle, between the engine and fuel tank.Inspect the separator daily for leaks. Drain water and replace the separator at the intervals outlined in the Periodic Maintenance C...

85 MAINTENANCE Throttle System 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 occasion...

86 MAINTENANCE Brakes The front and rear brakes are hydraulic disc type brakes activated by the brake pedal. See page 24. Brake Fluid Inspect the brake system routinely. Inspect the level of the brake fluid before each operation. WARNING! After opening a bottle of brake fluid, always discard any unu...

87 MAINTENANCE Brakes Brake Inspection 1. Check the brake system for fluid leaks.2. Check the brake pedal for excessive travel or a spongy feel. 3. Check the friction pads for wear, damage and looseness.4. Check brake discs for signs of cracks, excessive corro- sion, warping or other damage. Clean a...

88 MAINTENANCE Suspension Adjustments The front and rear suspensions can be adjusted to provide a stiffer suspension, if necessary.1. Remove the top shock mounting bolts from the inside mounting positions.2. Reposition the shocks to the outside mounting holes.3. Reinstall the shock mounting bolts. T...

89 MAINTENANCE Tires Operating your vehicle with worn tires, improperly inflated tires, non-standard tires or improperly installed tires will affect vehicle handling and could cause an accident resulting in serious injury or death. Always follow all tire maintenance procedures as outlined in this ma...

90 MAINTENANCE Tires Wheel Removal 1. Position the vehicle on a level surface.2. Place the transmission in PARK. Stop the engine.3. Loosen the wheel nuts slightly.4. Elevate the side of the vehicle by placing a suitable stand under the frame.5. Remove the wheel nuts and washers. Remove the wheel. Wh...

91 MAINTENANCE Lights Poor lighting can result in reduced visibility when driving. Headlight and taillight lenses become dirty during normal operation. Clean lights frequently and replace burned out lamps promptly. Do not operate this vehicle at night or in low light conditions until the headlight i...

92 MAINTENANCE Lights Headlight Beam Adjustment 1. Place the vehicle on a level surface with the headlight approximately 25 ft. (7.6 m) from a wall. 2. Place the transmission in PARK.3. Measure the distance from the floor to the center of the headlight and make a mark on the wall at the same height....

93 MAINTENANCE Fuses If the engine stops or will not start, or if you experience other electrical failures, a fuse may need replacement. Locate and correct any short circuits that may have caused the blown fuse, then replace the fuse. Raise the passenger seat to access the fuses. Spare fuses are pro...

94 MAINTENANCE Battery Your vehicle has a sealed battery, which requires little maintenance. 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. ...

95 MAINTENANCE Battery Battery Charging The following battery charging instructions apply only to the installation of a sealed battery. Read all instructions before proceeding with the installation of this battery.The sealed battery is already filled with electrolyte and has been sealed and fully ch...

96 MAINTENANCE Cleaning and Storage Washing the Vehicle Keeping your POLARIS vehicle clean will not only improve its appearance but it can also extend the life of various components. NOTICE: High water pressure may damage components. POLARIS recommends washing the vehicle by hand or with a garden ho...

97 MAINTENANCE Cleaning and Storage Polishing the Vehicle POLARIS recommends the use of common household aerosol furniture polish for polishing the finish on your POLARIS vehicle. Follow the instructions on the container.• Avoid the use of automotive products, some of which can scratch the finish of...

98 MAINTENANCE Cleaning and Storage Storage Tips Inspect and Lubricate Inspect all cables and lubricate all areas of the vehicle as recommended in the Periodic Maintenance Chart beginning on page 65. Battery Maintenance See page 94 for storage and charging procedures. Fluid Levels Inspect the fluid ...

99 MAINTENANCE Removal from Storage 1. Charge the battery if necessary. Install it in the vehicle. 2. Fill the fuel tank with fuel.3. Check all the points listed in the Daily Pre-Ride Inspection section on page 36. Tightness of the bolts, nuts and other fasteners should be checked by an authorized P...

100 SPECIFICATIONS RANGER Diesel Maximum Weight Capacity 1500 lbs. (681 kg) (including operator, passenger, cargo, accessories) Dry Weight 1430 lbs. (649 kg) Test GVW - Rollover Protection System (ROPS) 3400 lbs. (1542 kg) per OSHA 29 CFR 1928.53 Fuel Capacity 10 gal. (37.8 l) Engine Oil Capacity 2....

101 SPECIFICATIONS Clutching See your POLARIS dealer for clutching specifications. RANGER Diesel Driving System Type PVT, 4-wheel independent shaft, lockable differential Shift Type Single Lever (H/L/N/R/P) Transmission Gear Ratio - High Front 3.10:1 / Rear 9.26:1 Transmission Gear Ratio - Low Front...

102 SPECIFICATIONS RANGER CREW Diesel Maximum Weight Capacity 1750 lbs. (795 kg) (including operator, passengers, cargo, accessories) Dry Weight 1690 lbs. (767 kg) Test GVW - Rollover Protection System (ROPS) 3700 lbs. (1678 kg) per OSHA 29 CFR 1928.53 Fuel Capacity 10 gal. (37.8 l) Engine Oil Capac...

104 POLARIS PRODUCTS Part Number Description Engine Lubricant 2878473 15W-40 Diesel Oil (2 qt./1.9 l) 2879832 5W-40 Synthetic Diesel Oil (2 qt./1.9 l) Gearcase / Transmission Lubricants 2878068 AGL Full Synthetic Gearcase Lubricant & Transmission Fluid (qt./.95 l) 2878069 AGL Full Synthetic Gear...

105 TROUBLESHOOTING Drive Belt Wear/Burn Possible Cause Solution Driving onto a pickup or tall trailer in high range Use low range during loading. Starting out going up a steep incline Use low range. See warnings on page 47. Driving at low RPM or ground speed (3-7 MPH) Drive at a higher speed or use...

106 TROUBLESHOOTING Engine Doesn't Turn Over Engine Turns Over, Fails to Start Engine Backfires Possible Cause Solution Low battery voltage Recharge the battery to 12.8 VDC Loose battery connections Check all connections and tighten Loose starter connections Check all connections and tighten Loose e...

107 TROUBLESHOOTING Engine Runs Irregularly, Stalls or Misfires Engine Stops or Loses Power Possible Cause Solution Poor fuel quality or incorrect fuel Replace with recommended fuel Low fuel level Refuel Clogged fuel filter Replace Clogged air filter Replace Loose ignition connections Check all conn...

108 WARRANTY Limited Warranty POLARIS Industries Inc., 2100 Highway 55, Medina, MN 55340, gives a SIX MONTH LIMITED WARRANTY on all components of the POLARIS vehicle against defects in material or workmanship. POLARIS further warrants that the spark arrestor in this product will meet the efficiency ...

110 WARRANTY How To Obtain Warranty Service If your vehicle requires warranty service, you must take it to a POLARIS Servicing Dealer. When requesting warranty service you must present your copy of the Warranty Registration Form to the dealer. (THE COST OF TRANSPORTATION TO AND FROM THE DEALER IS YO...

113 MAINTENANCE LOG Use the following chart to record periodic maintenance. DATE MILES (KM) OR HOURS TECHNICIAN SERVICE PERFORMED / COMMENTS

115 INDEX A Accessory Outlets . . . . . . . . . . . . . . . . . . . . . . . . . 22 Air Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81 Air Filter Cleaning . . . . . . . . . . . . . . . . . . . . . . . . 81 All Wheel Drive . . . . . . . . . . . . . . . . . . . . . . . 54-55 ...