Polaris 4X4 500 EFI - Manuals

5 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 instructio...

6 SAFETY Safety Decals and Locations Clutch Cover Warning WARNINGNO STEP• Moving parts hazard under belt-clutch guard. To prevent serious injury, do not operate vehicle with guard removed. • Do not modify engine or clutch. Doing so can cause part failure, possible imbalance, and excessive engine RPM...

7 SAFETY Safety Decals and Locations Shift Caution CAUTIONTo avoid transmission damage, shift only when vehicle is stationary and at idle. Discretionary Warning WARNINGImproper vehicle use can result in SEVERE INJURY or DEATH.NEVER:• Operate on public roads. A collision can occur with a another vehi...

8 SAFETY Operator Safety 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 saf...

9 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. The safety alert symbol , on your vehicle or in this manu...

13 SAFETY Operator Safety 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 modif...

21 SAFETY Fuel Safety 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...

22 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 100. Cab Frame (if Equipped) Console Steering Wheel Hip Bar Seat Storage Box (unde...

23 FEATURES AND CONTROLS Component Locations Headlights Hood Hold-Down Strap Front Bumper/Brush Guard Radiator (if equipped)

25 FEATURES AND CONTROLS Component Locations Indicator Lights The indicator light panel is located on the console. See page 28. 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...

26 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. Fuel Cap/Fuel Gauge Th...

27 FEATURES AND CONTROLS Seat Belts 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 plat...

28 FEATURES AND CONTROLS Console Indicator Lights AWD/Differential Switch Cup Holder Cup Holder Storage Compartment (with lid) 12V Accessory Outlet Storage Tray Ignition Switch Storage Box Light Switch Gear Selector (Shifter)

29 FEATURES AND CONTROLS Gear Selector H: High GearL: Low GearN: NeutralR: Reverse NOTE: Low gear is the primary driving range for the RANGER . High gear is intended for use on hard- packed surfaces with light loads. To change gears, stop the vehicle, and with the engine idling, move the lever to th...

30 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 peda...

31 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. Light Switch The ignition switch key must be in the ON/RUN position to operate the headlights. The light switch has t...

32 OPERATION Vehicle Break-In Period The break-in period for your new Polaris RANGER is the first twenty hours of operation, or the time it takes to use the first two tanks full of gasoline. No single action on your part is as important as a proper break- in period. Careful treatment of a new engine...

33 OPERATION Pre-Ride Inspection WARNING If a proper inspection is not done before each use, severe injury or death could result. Always inspect the vehicle before each use to ensure it's in proper operating condition. Item Remarks Page Brake system/pedal travel Ensure proper operation 30 79 Brake f...

34 OPERATION Starting Engine 1. Sit in the driver's seat and fasten the seat belt.2. Engage the park brake.3. Shift the transmission to neutral.4. Apply the brakes. NOTE: Do not press the throttle pedal while starting the engine. 5. Turn the ignition key past the ON/RUN position to START. Engage the...

35 OPERATION Stopping the Engine 1. Release the throttle pedal completely and brake to a complete stop.2. Turn the engine off.3. Engage the park brake. Braking 1. Release the throttle pedal completely.2. Press on the brake pedal evenly and firmly. NOTE: Practice starting and stopping (using the brak...

36 OPERATION Driving Safely Driving Procedure 1. Sit in the driver's seat and fasten the seat belt.2. After starting the engine and allowing it to warm up, apply the ser- vice brakes, and shift the transmission into gear. 3. Check your surroundings and determine your path of travel.4. Release the pa...

37 OPERATION Driving Safely Driving On Slippery Surfaces When driving on slippery surfaces such as wet trails, loose gravel, or ice, be alert for the possibility of skidding and sliding. Under these con- ditions, follow these precautions:1. Slow down when entering slippery areas.2. Maintain a high l...

38 OPERATION Driving Safely Driving Uphill Whenever traveling uphill, follow these precautions:1. Always travel straight uphill. 2. Avoid steep hills (15 ° maximum). 3. Keep both feet on the floor. 4. Proceed at a steady rate of speed and throttle opening. WARNING Climbing hills improperly can cause...

39 OPERATION Driving Safely Driving on a Sidehill (Sidehilling) 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. WARNING Crossing hillsides or turning on hills can result in loss of control...

40 OPERATION Driving Safely Driving Through Water Your Polaris RANGER can operate through water up to a maximum recommended depth equal to the floor- boards. Follow these procedures when oper- ating through water:1. Always determine water depths and current before entering. 2. Choose a crossing wher...

41 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. WARNING Severe injury or death can result if your vehicle suddenly comes in contact with a hidden obstacle. Not a...

42 OPERATION Driving Safely Driving in Reverse Follow these guidelines when operating in reverse:1. Back slowly.2. Apply the brakes lightly for stopping.3. Avoid turning at sharp angles.4. Always avoid backing downhill.5. Never open the throttle suddenly while backing.6. Always inspect left and righ...

43 OPERATION Driving Safely Parking on an Incline Avoid parking on an incline if possible. If it's unavoidable, follow these precautions:1. Place the transmission in gear.2. Engage the park brake.3. Turn the engine off.4. Block the rear wheels on the downhill side. WARNING A rolling vehicle can caus...

44 OPERATION Driving Safely Hauling Cargo 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 BRAKI...

45 OPERATION Driving Safely Hauling Cargo The RANGER has been designed to carry or tow specific capacities. Always read and understand the load distribution warnings listed on the warning labels. Never exceed the following capacities. Model Maximum Capacities (Level Ground) Cargo Box RANGER 4X4 500 ...

46 OPERATION Driving Safely 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. Engage the park brake. 3. Dismount the vehicle.4. Ensure that the cargo is positioned evenly or toward the front of the cargo bo...

47 OPERATION Driving Safely Towing Loads Belt Life To extend belt life, use the lowest gear possible when hauling or towing heavy cargo. 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...

48 OPERATION Driving Safely Parking the Vehicle 1. Stop the vehicle on a level surface.2. Turn the engine off.3. Engage the park brake.4. Remove the ignition switch key to prevent unauthorized use. WARNING A rolling vehicle can cause property damage and serious injury. Always engage the park brake a...

49 OPERATION Differential Operation Modes The 4X4 rear axle is equipped with a lockable differential that allows the operator to choose between an open differential or a closed differen- tial. AWD Press the top of the rocker switch to engage All Wheel Drive (AWD). When in AWD, the rear wheels rotate...

50 OPERATION All Wheel Drive (AWD) The illuminated amber AWD 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 will automatically dis...

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

52 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...

53 MAINTENANCE Periodic Maintenance Chart Maintenance Chart Key X Perform these operations more often for vehicles subjected to severe use. E Emission Control System Service - 4 Cycle (California) Q Have an authorized Polaris dealer perform these services. WARNING Improperly performing the procedure...

57 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 lubrica...

58 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 formulat...

59 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 s...

60 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 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...

61 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 gas...

62 MAINTENANCE Engine Oil Oil and Filter Change Oil Pump Priming This priming procedure must be 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 t...

63 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 52. Maintain the oil level even with the bottom of the fill plug hole.Refer to the Gearcase Sp...

64 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. ...

65 MAINTENANCE Gearcases Front Gearcase 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...

66 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 102 f...

67 MAINTENANCE Spark Plugs Spark Plug Gap/Torque 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. CAUTI...

68 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 b...

69 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 (he...

70 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...

71 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 t...

72 MAINTENANCE Polaris Variable Transmission (PVT) System When To Use Low Range vs. High Range Belt slip is responsible for creating excessive heat that destroys belts, wears clutch components and causes outer clutch covers to fail. Switch to low range while operating at slower speeds to extend the ...

73 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.1. Loosen the bottom screws that secure the clutch cover. Allow the water to drain. Tighten the screws. 2. Apply the brakes. St...

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 ...

75 MAINTENANCE Filter Systems Breather Filter and Hoses 1. Lift the cargo box and locate the air box. 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...

76 MAINTENANCE Spark Arrestor Use the following procedure to periodically purge accumulated carbon from the exhaust pipe.1. Remove 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 ...

77 MAINTENANCE Throttle System Throttle Freeplay If the throttle pedal has excessive play due to cable stretch or mis- adjustment, 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...

78 MAINTENANCE Throttle System Throttle Body/Idle RPM Idle RPM is preset by the manufacturer. If the engine idle speed is not satisfactory, please see your Polaris dealer for adjustment. Throttle Freeplay Adjustment 1. Remove the seat.2. Locate the throttle cable adjuster. 3. Squeeze the end of the ...

79 MAINTENANCE Brakes 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 a...

80 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. Inspect the brake disc spline and pad wear surface for excessive wear. 5. Change pads when w...

81 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...

82 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 ...

83 MAINTENANCE Tires Tire Tread Depth Always replace tires when tread depth is worn to 1/8" (3 mm) or less. Axle and Wheel Nut Torque Specifications Inspect the following items occasionally for tightness, and if they've been loosened for maintenance service. NOTE: Do not lubricate the stud or th...

84 MAINTENANCE Tires Wheel Removal 1. Stop the engine. Place the transmission in gear. Engage the park 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 washers. Remove the wheel. Wheel Installation 1...

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. Headlight Lamp Replacement 1. Open the hood.2. Unplug the headlamp from the wiring harness. Be sure to pull on ...

86 MAINTENANCE Lights Headlight Beam Adjustment 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 ...

87 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 pedal travel. If the...

88 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 Ba...

89 MAINTENANCE Battery Battery Removal 1. Open the hood.2. On conventional batteries, remove the battery vent tube. 3. Disconnect the black (nega- tive) battery cable first. 4. Disconnect the red (positive) battery cable last. 5. Lift the battery out of the vehicle. Be careful not to tip a conventio...

90 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 92 before installing the battery.1. Ensure that the battery ...

91 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 each month during storage and recharge as needed ...

92 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 89. 2. Charge the battery with a charging output no larger than 1/10 of the battery’s amp/hr rating. Charge as neede...

93 MAINTENANCE Battery Battery Charging (Sealed Battery) NOTE: Always verify battery condition before and 1-2 hours after the end of charging. State of Charge Voltage Action Charge Time (Using constant current charger @ standard amps specified on top of battery) 100% 12.8-13.0 volts None, check at 3...

94 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. 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...

95 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: • Wheel bearings• Ra...

96 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 exposed to road salt (or salt in the air in coastal areas) are more susceptib...

97 MAINTENANCE Cleaning and Storage Storage Tips Clean the Exterior Make any necessary repairs and clean the vehicle as recommended. See page 94. Stabilize the Fuel 1. Fill the fuel tank.2. Add Polaris Carbon Clean Fuel Treatment or Polaris Fuel Stabilizer. Follow the instructions on the container f...

98 MAINTENANCE Cleaning and Storage Storage Tips Fog the Engine 1. Treat the fuel system with Polaris Carbon Clean. Follow the instruc- tions on the container. Start the engine. Allow it to idle for several minutes so the Carbon Clean reaches the injectors. Stop the engine. 2. Remove the spark plugs...

99 MAINTENANCE Removal from Storage 1. 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. 2. Make sure the spark plug is tight.3. Fill the fuel ta...

100 SPECIFICATIONS RANGER 4X4 500 EFI Gross Vehicle Weight 2700 lbs. (1226 kg) Dry Weight 1185 lbs. (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) ...

102 POLARIS PRODUCTS Part Number Description Engine Lubricant 2870791 Fogging Oil (12 oz. Aerosol) 2871281 Premium 4 Synthetic 0W-40 (4-Cycle) Engine Oil (qt.) 2871844 Premium 4 Synthetic 0W-40 (4-Cycle) Engine Oil (gal.) Gearcase / Transmission Lubricants 2873602 Premium AGL Synthetic Gearcase Lubr...

103 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 38. Driving at low RPM or ground speed (3-7 MPH) Drive at a higher speed or use...

104 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 solenoid connections Check all connections and tighten Loose ...

105 TROUBLESHOOTING Engine Pings or Knocks Engine Runs Irregularly, Stalls or Misfires Possible Cause Solution Poor quality or low octane fuel Replace with recommended fuel Incorrect ignition timing See your dealer Incorrect spark plug gap or heat range Set gap to specs or replace plugs Possible Cau...

106 TROUBLESHOOTING Engine Stops or Loses Power Possible Cause Solution Out of fuel Refuel Kinked or plugged fuel vent line Inspect and replace 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 S...

107 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 d...

108 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 ...

109 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 ex...

111 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 2...

112 WARRANTY California Emission Control Warranty Statement Owner's Warranty Responsibilities: • 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 tha...

113 WARRANTY California Emission Control Warranty Statement Emission-Related Parts Covered Under This Warranty (1) Fuel Metering System (i) Carburetor and internal parts (and/or pressure regulator or fuel injection system)(ii) Air/fuel ratio feedback and control system, if applicable(iii) Cold start...

114 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 changing, adding or removing parts.When the LSI engine is...

115 WARRANTY X Perform these procedures more often for vehicles subjected to severe use. E Emission-Related Service. Q Have an authorized Polaris dealer perform these services Repair and Replacement of Emission-Related Parts It is recommended that only LSI engine replacement parts, which have been a...

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

118 INDEX A Adding Coolant . . . . . . . . . . . . . . . . 69 Adjustment Headlight Beam . . . . . . . . . . . . 86 Park Brake . . . . . . . . . . . . . . . . 80 Rear Spring . . . . . . . . . . . . . . . 81 Rear Suspension . . . . . . . . . . . 81 Throttle Freeplay . . . . . . . . . . . 78 Age Restri...

119 INDEX E Electromagnetic Interference . . . . . . 51 Emission Control, Crankcase . . . . . . 51 Emission Control, Exhaust . . . . . . . . 51 Emission Control, Noise . . . . . . . . . . 51 Emissions Limited Warranty . . . . . 110 Engine Fogging . . . . . . . . . . . . . . . . . 98 Engine Idle Spee...

121 INDEX S Speed, Towing . . . . . . . . . . . . . . . . . 47 Spring, Rear, Adjustment . . . . . . . . . 81 Stabilizing the Fuel . . . . . . . . . . . . . . 97 Starting the Engine . . . . . . . . . . . . . . 34 Steering Wheel Inspection . . . . . . . . 81 Stopping the Engine . . . . . . . . . . . ....

5 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 instructio...

6 SAFETY Safety Decals and Locations Clutch Cover Warning WARNINGNO STEP• Moving parts hazard under belt-clutch guard. To prevent serious injury, do not operate vehicle with guard removed. • Do not modify engine or clutch. Doing so can cause part failure, possible imbalance, and excessive engine RPM...

7 SAFETY Safety Decals and Locations Shift Caution CAUTIONTo avoid transmission damage, shift only when vehicle is stationary and at idle. Discretionary Warning WARNINGImproper vehicle use can result in SEVERE INJURY or DEATH.NEVER:• Operate on public roads. A collision can occur with a another vehi...

8 SAFETY Operator Safety 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 saf...

9 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. The safety alert symbol , on your vehicle or in this manu...

13 SAFETY Operator Safety 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 modif...

21 SAFETY Fuel Safety 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...

22 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 100. Cab Frame (if Equipped) Console Steering Wheel Hip Bar Seat Storage Box (unde...

23 FEATURES AND CONTROLS Component Locations Headlights Hood Hold-Down Strap Front Bumper/Brush Guard Radiator (if equipped)

25 FEATURES AND CONTROLS Component Locations Indicator Lights The indicator light panel is located on the console. See page 28. 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...

26 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. Fuel Cap/Fuel Gauge Th...

27 FEATURES AND CONTROLS Seat Belts 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 plat...

28 FEATURES AND CONTROLS Console Indicator Lights AWD/Differential Switch Cup Holder Cup Holder Storage Compartment (with lid) 12V Accessory Outlet Storage Tray Ignition Switch Storage Box Light Switch Gear Selector (Shifter)

29 FEATURES AND CONTROLS Gear Selector H: High GearL: Low GearN: NeutralR: Reverse NOTE: Low gear is the primary driving range for the RANGER . High gear is intended for use on hard- packed surfaces with light loads. To change gears, stop the vehicle, and with the engine idling, move the lever to th...

30 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 peda...

31 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. Light Switch The ignition switch key must be in the ON/RUN position to operate the headlights. The light switch has t...

32 OPERATION Vehicle Break-In Period The break-in period for your new Polaris RANGER is the first twenty hours of operation, or the time it takes to use the first two tanks full of gasoline. No single action on your part is as important as a proper break- in period. Careful treatment of a new engine...

33 OPERATION Pre-Ride Inspection WARNING If a proper inspection is not done before each use, severe injury or death could result. Always inspect the vehicle before each use to ensure it's in proper operating condition. Item Remarks Page Brake system/pedal travel Ensure proper operation 30 79 Brake f...

34 OPERATION Starting Engine 1. Sit in the driver's seat and fasten the seat belt.2. Engage the park brake.3. Shift the transmission to neutral.4. Apply the brakes. NOTE: Do not press the throttle pedal while starting the engine. 5. Turn the ignition key past the ON/RUN position to START. Engage the...

35 OPERATION Stopping the Engine 1. Release the throttle pedal completely and brake to a complete stop.2. Turn the engine off.3. Engage the park brake. Braking 1. Release the throttle pedal completely.2. Press on the brake pedal evenly and firmly. NOTE: Practice starting and stopping (using the brak...

36 OPERATION Driving Safely Driving Procedure 1. Sit in the driver's seat and fasten the seat belt.2. After starting the engine and allowing it to warm up, apply the ser- vice brakes, and shift the transmission into gear. 3. Check your surroundings and determine your path of travel.4. Release the pa...

37 OPERATION Driving Safely Driving On Slippery Surfaces When driving on slippery surfaces such as wet trails, loose gravel, or ice, be alert for the possibility of skidding and sliding. Under these con- ditions, follow these precautions:1. Slow down when entering slippery areas.2. Maintain a high l...

38 OPERATION Driving Safely Driving Uphill Whenever traveling uphill, follow these precautions:1. Always travel straight uphill. 2. Avoid steep hills (15 ° maximum). 3. Keep both feet on the floor. 4. Proceed at a steady rate of speed and throttle opening. WARNING Climbing hills improperly can cause...

39 OPERATION Driving Safely Driving on a Sidehill (Sidehilling) 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. WARNING Crossing hillsides or turning on hills can result in loss of control...

40 OPERATION Driving Safely Driving Through Water Your Polaris RANGER can operate through water up to a maximum recommended depth equal to the floor- boards. Follow these procedures when oper- ating through water:1. Always determine water depths and current before entering. 2. Choose a crossing wher...

41 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. WARNING Severe injury or death can result if your vehicle suddenly comes in contact with a hidden obstacle. Not a...

42 OPERATION Driving Safely Driving in Reverse Follow these guidelines when operating in reverse:1. Back slowly.2. Apply the brakes lightly for stopping.3. Avoid turning at sharp angles.4. Always avoid backing downhill.5. Never open the throttle suddenly while backing.6. Always inspect left and righ...

43 OPERATION Driving Safely Parking on an Incline Avoid parking on an incline if possible. If it's unavoidable, follow these precautions:1. Place the transmission in gear.2. Engage the park brake.3. Turn the engine off.4. Block the rear wheels on the downhill side. WARNING A rolling vehicle can caus...

44 OPERATION Driving Safely Hauling Cargo 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 BRAKI...

45 OPERATION Driving Safely Hauling Cargo The RANGER has been designed to carry or tow specific capacities. Always read and understand the load distribution warnings listed on the warning labels. Never exceed the following capacities. Model Maximum Capacities (Level Ground) Cargo Box RANGER 4X4 500 ...

46 OPERATION Driving Safely 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. Engage the park brake. 3. Dismount the vehicle.4. Ensure that the cargo is positioned evenly or toward the front of the cargo bo...

47 OPERATION Driving Safely Towing Loads Belt Life To extend belt life, use the lowest gear possible when hauling or towing heavy cargo. 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...

48 OPERATION Driving Safely Parking the Vehicle 1. Stop the vehicle on a level surface.2. Turn the engine off.3. Engage the park brake.4. Remove the ignition switch key to prevent unauthorized use. WARNING A rolling vehicle can cause property damage and serious injury. Always engage the park brake a...

49 OPERATION Differential Operation Modes The 4X4 rear axle is equipped with a lockable differential that allows the operator to choose between an open differential or a closed differen- tial. AWD Press the top of the rocker switch to engage All Wheel Drive (AWD). When in AWD, the rear wheels rotate...

50 OPERATION All Wheel Drive (AWD) The illuminated amber AWD 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 will automatically dis...

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

52 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...

53 MAINTENANCE Periodic Maintenance Chart Maintenance Chart Key X Perform these operations more often for vehicles subjected to severe use. E Emission Control System Service - 4 Cycle (California) Q Have an authorized Polaris dealer perform these services. WARNING Improperly performing the procedure...

57 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 lubrica...

58 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 formulat...

59 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 s...

60 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 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...

61 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 gas...

62 MAINTENANCE Engine Oil Oil and Filter Change Oil Pump Priming This priming procedure must be 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 t...

63 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 52. Maintain the oil level even with the bottom of the fill plug hole.Refer to the Gearcase Sp...

64 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. ...

65 MAINTENANCE Gearcases Front Gearcase 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...

66 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 102 f...

67 MAINTENANCE Spark Plugs Spark Plug Gap/Torque 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. CAUTI...

68 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 b...

69 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 (he...

70 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...

71 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 t...

72 MAINTENANCE Polaris Variable Transmission (PVT) System When To Use Low Range vs. High Range Belt slip is responsible for creating excessive heat that destroys belts, wears clutch components and causes outer clutch covers to fail. Switch to low range while operating at slower speeds to extend the ...

73 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.1. Loosen the bottom screws that secure the clutch cover. Allow the water to drain. Tighten the screws. 2. Apply the brakes. St...

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 ...

75 MAINTENANCE Filter Systems Breather Filter and Hoses 1. Lift the cargo box and locate the air box. 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...

76 MAINTENANCE Spark Arrestor Use the following procedure to periodically purge accumulated carbon from the exhaust pipe.1. Remove 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 ...

77 MAINTENANCE Throttle System Throttle Freeplay If the throttle pedal has excessive play due to cable stretch or mis- adjustment, 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...

78 MAINTENANCE Throttle System Throttle Body/Idle RPM Idle RPM is preset by the manufacturer. If the engine idle speed is not satisfactory, please see your Polaris dealer for adjustment. Throttle Freeplay Adjustment 1. Remove the seat.2. Locate the throttle cable adjuster. 3. Squeeze the end of the ...

79 MAINTENANCE Brakes 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 a...

80 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. Inspect the brake disc spline and pad wear surface for excessive wear. 5. Change pads when w...

81 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...

82 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 ...

83 MAINTENANCE Tires Tire Tread Depth Always replace tires when tread depth is worn to 1/8" (3 mm) or less. Axle and Wheel Nut Torque Specifications Inspect the following items occasionally for tightness, and if they've been loosened for maintenance service. NOTE: Do not lubricate the stud or th...

84 MAINTENANCE Tires Wheel Removal 1. Stop the engine. Place the transmission in gear. Engage the park 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 washers. Remove the wheel. Wheel Installation 1...

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. Headlight Lamp Replacement 1. Open the hood.2. Unplug the headlamp from the wiring harness. Be sure to pull on ...

86 MAINTENANCE Lights Headlight Beam Adjustment 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 ...

87 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 pedal travel. If the...

88 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 Ba...

89 MAINTENANCE Battery Battery Removal 1. Open the hood.2. On conventional batteries, remove the battery vent tube. 3. Disconnect the black (nega- tive) battery cable first. 4. Disconnect the red (positive) battery cable last. 5. Lift the battery out of the vehicle. Be careful not to tip a conventio...

90 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 92 before installing the battery.1. Ensure that the battery ...

91 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 each month during storage and recharge as needed ...

92 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 89. 2. Charge the battery with a charging output no larger than 1/10 of the battery’s amp/hr rating. Charge as neede...

93 MAINTENANCE Battery Battery Charging (Sealed Battery) NOTE: Always verify battery condition before and 1-2 hours after the end of charging. State of Charge Voltage Action Charge Time (Using constant current charger @ standard amps specified on top of battery) 100% 12.8-13.0 volts None, check at 3...

94 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. 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...

95 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: • Wheel bearings• Ra...

96 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 exposed to road salt (or salt in the air in coastal areas) are more susceptib...

97 MAINTENANCE Cleaning and Storage Storage Tips Clean the Exterior Make any necessary repairs and clean the vehicle as recommended. See page 94. Stabilize the Fuel 1. Fill the fuel tank.2. Add Polaris Carbon Clean Fuel Treatment or Polaris Fuel Stabilizer. Follow the instructions on the container f...

98 MAINTENANCE Cleaning and Storage Storage Tips Fog the Engine 1. Treat the fuel system with Polaris Carbon Clean. Follow the instruc- tions on the container. Start the engine. Allow it to idle for several minutes so the Carbon Clean reaches the injectors. Stop the engine. 2. Remove the spark plugs...

99 MAINTENANCE Removal from Storage 1. 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. 2. Make sure the spark plug is tight.3. Fill the fuel ta...

100 SPECIFICATIONS RANGER 4X4 500 EFI Gross Vehicle Weight 2700 lbs. (1226 kg) Dry Weight 1185 lbs. (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) ...

102 POLARIS PRODUCTS Part Number Description Engine Lubricant 2870791 Fogging Oil (12 oz. Aerosol) 2871281 Premium 4 Synthetic 0W-40 (4-Cycle) Engine Oil (qt.) 2871844 Premium 4 Synthetic 0W-40 (4-Cycle) Engine Oil (gal.) Gearcase / Transmission Lubricants 2873602 Premium AGL Synthetic Gearcase Lubr...

103 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 38. Driving at low RPM or ground speed (3-7 MPH) Drive at a higher speed or use...

104 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 solenoid connections Check all connections and tighten Loose ...

105 TROUBLESHOOTING Engine Pings or Knocks Engine Runs Irregularly, Stalls or Misfires Possible Cause Solution Poor quality or low octane fuel Replace with recommended fuel Incorrect ignition timing See your dealer Incorrect spark plug gap or heat range Set gap to specs or replace plugs Possible Cau...

106 TROUBLESHOOTING Engine Stops or Loses Power Possible Cause Solution Out of fuel Refuel Kinked or plugged fuel vent line Inspect and replace 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 S...

107 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 d...

108 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 ...

109 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 ex...

111 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 2...

112 WARRANTY California Emission Control Warranty Statement Owner's Warranty Responsibilities: • 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 tha...

113 WARRANTY California Emission Control Warranty Statement Emission-Related Parts Covered Under This Warranty (1) Fuel Metering System (i) Carburetor and internal parts (and/or pressure regulator or fuel injection system)(ii) Air/fuel ratio feedback and control system, if applicable(iii) Cold start...

114 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 changing, adding or removing parts.When the LSI engine is...

115 WARRANTY X Perform these procedures more often for vehicles subjected to severe use. E Emission-Related Service. Q Have an authorized Polaris dealer perform these services Repair and Replacement of Emission-Related Parts It is recommended that only LSI engine replacement parts, which have been a...

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

118 INDEX A Adding Coolant . . . . . . . . . . . . . . . . 69 Adjustment Headlight Beam . . . . . . . . . . . . 86 Park Brake . . . . . . . . . . . . . . . . 80 Rear Spring . . . . . . . . . . . . . . . 81 Rear Suspension . . . . . . . . . . . 81 Throttle Freeplay . . . . . . . . . . . 78 Age Restri...

119 INDEX E Electromagnetic Interference . . . . . . 51 Emission Control, Crankcase . . . . . . 51 Emission Control, Exhaust . . . . . . . . 51 Emission Control, Noise . . . . . . . . . . 51 Emissions Limited Warranty . . . . . 110 Engine Fogging . . . . . . . . . . . . . . . . . 98 Engine Idle Spee...

121 INDEX S Speed, Towing . . . . . . . . . . . . . . . . . 47 Spring, Rear, Adjustment . . . . . . . . . 81 Stabilizing the Fuel . . . . . . . . . . . . . . 97 Starting the Engine . . . . . . . . . . . . . . 34 Steering Wheel Inspection . . . . . . . . 81 Stopping the Engine . . . . . . . . . . . ....