Polaris 500 2X4 - Manuals

4 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. Your key can be duplicated only by mating a Polaris key blank with one of your existing keys, so if both keys are lost, the ignition...

5 SAFETY Operator Safety WARNING Failure to follow the warnings contained in this manual can result in severe injury or death.A Polaris RANGER is not a toy and can be hazardous to operate. This vehicle handles differently than other vehicles, such as motorcycles and cars. A collision or rollover can...

6 SAFETY Operator Safety The following signal words and symbols appear throughout this manual and on your RANGER . Your safety is involved when these words and symbols are used. Become familiar with their meanings before reading the manual. The safety alert symbol , on your vehicle or in this manual...

7 SAFETY Operator Safety WARNING Serious injury or death can result if you do not follow these instructions and procedures, which are outlined in further detail within your owner’s manual. S Read this manual and all labels carefully. Follow the operating pro- cedures described. S Never allow anyone ...

9 SAFETY Operator Safety S Never modify this vehicle through improper installation or use of accessories. S Never exceed the stated load capacity for this vehicle. Cargo should be properly distributed and securely attached. Reduce speed and follow the instructions in this manual for hauling cargo or...

10 SAFETY Operator Safety WARNING Make sure your RANGER is in excellent operating condition at all times. We strongly recommend that the operator check all safety components before each ride.Polaris RANGER s are designed to provide safe operation when used as directed. Failure of critical machine co...

11 SAFETY Operator Safety WARNING POTENTIAL HAZARDStalling, rolling backwards while climbing a hillWHAT CAN HAPPENVehicle overturnHOW TO AVOID THE HAZARDMaintain a steady speed when climbing a hill.If you lose all forward speed:Apply the brakes.Lock the parking brake after fully stopped.If you begin...

12 SAFETY Operator Safety WARNING POTENTIAL HAZARDOperating this vehicle on paved surfacesWHAT CAN HAPPENLoss of controlHOW TO AVOID THE HAZARDThis vehicle’s tires are designed for off-road use only, not for use on pavement. Paved surfaces may seriously affect handling and control of the vehicle, an...

14 SAFETY Operator Safety WARNING POTENTIAL HAZARDOperating this vehicle at excessive speedsWHAT CAN HAPPENLoss of control, accidentHOW TO AVOID THE HAZARDAlways travel at a speed proper for the terrain, visibility and operating conditions, and your experience. WARNING POTENTIAL HAZARDAttempting jum...

18 SAFETY Safety Decals and Locations Warning decals have been placed on the RANGER for your protection. Read and follow the instructions of the decals on the RANGER carefully. If any of the decals depicted in this manual differ from the decals on your RANGER , always read and follow the instruction...

19 SAFETY Safety Decals and Locations Fuel / Passenger Warning Decal Text Remove flammable containers from box before refueling. S Passengers can be thrown off. This can cause serious injury or death. S Never carry passengers in cargo box. Maximum 2X4 (TM) Box Load 750 lbs. (340 kg) Maximum 4X4 Box ...

20 SAFETY Safety Decals and Locations MANUFACTURED BY: POLARIS IND INC. DATE: VIN: THIS VEHICLE IS A GENERAL PURPOSE OFF-ROAD UTILITY VEHICLE AND IS NOT INTENDED FOR USE ON PUBLIC ROADS. 7078472 CE VÉHICULE USAGE GENERAL VEHICULE UTILIT- AIRE POUR SERVICE HORS ROUTE QUI NEST PAS DES- TINE A ETRE UTI...

21 SAFETY Safety Decals and Locations Discretionary Warning Decal Improper vehicle use can result in SEVERE INJURY or DEATH. NEVER: S Operate on public roads. A collision can occur with another vehicle. S Carry more than two passengers, or passengers under age five. S Use ALCOHOL or DRUGS before or ...

22 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...

23 FEATURES AND CONTROLS Some Polaris vehicles are equipped with special features such as the cab frame. Not all models come with all features. Refer to the specifications section beginning on page 102. Component Locations 1. Cab Frame (if equipped)2. Hip Bar3. Console4. Steering Wheel5. Seat6. Carg...

26 FEATURES AND CONTROLS Indicator Lights The indicator lights on the console display:1. High Gear2. Low Gear (if equipped)3. Neutral Gear4. Reverse Gear5. High Temperature6. Brakes Trailer Hitch Bracket This vehicle is equipped with a receiver hitch bracket for a trailer hitch. Trailer towing equip...

27 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. Seat Belts The RANGER ...

28 FEATURES AND CONTROLS Console 1. Cup Holder2. Indicator Lights3. Shift Lever4. Light Switch5. AWD/Differential Switch (if equipped)6. Hour Meter7. Glove Box with Lid8. 12V Accessory Plug9. Storage Tray10. Choke Knob11. Ignition Switch12. Differential Lock Lever (if equipped)13. Storage Box 11 10 ...

H L N R H N R 29 FEATURES AND CONTROLS Gear Selector (1) RANGER 2X4, 4X4 H: High Gear L: Low Gear N: Neutral R: Reverse RANGER TM H: High Gear N: Neutral R: Reverse NOTE: Low is the primary driving range for the RANGER 2X4 and 4X4. High is intended for use on hard-packed surfaces with light loads. 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. Pre-Ride Checklist Item Remarks See Page Brake system / lever travel Ensure prope...

1 2 3 4 34 OPERATION Starting the Engine WARNING Engine exhaust contains poisonous carbon monoxide and can cause loss of consciousness resulting in severe injury or death. Never run an engine in an enclosed area. CAUTION Operating the vehicle immediately after starting could cause engine damage. All...

35 OPERATION Starting the Engine Starting a Warm Engine Warm engines do not normally require the use of the choke. Overuse of the choke can cause the spark plug to become wet fouled.1. Place the transmission in neutral and move the vehicle to a level surface. 2. Lock the parking brake. 3. Sit in the...

36 OPERATION Braking 1. Release the throttle pedal completely. 2. Press on the brake pedal evenly and firmly. NOTE: Practice starting and stopping (using the brakes) until you’re familiar with the controls. NOTE: When the throttle pedal is released completely and the engine speed drops near an idle,...

37 OPERATION Driving Safely Driving Procedures 1. Sit in the driver’s seat and fasten the seat belt. 2. After starting the engine and allowing it to warm up, shift the transmission into gear. 3. Check your surroundings and determine your path of travel. 4. Release the parking brake. 5. Keeping both ...

38 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 conditions, follow these precautions:1. Slow down when entering slippery areas. 2. Maintain a high le...

39 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...

40 OPERATION Driving Safely Sidehilling WARNING Crossing hillsides or turning on hills can result in loss of control or vehicle overturn, resulting in severe injury or death. Avoid crossing the side of a hill when possible. When unavoidable, exercise extreme caution. Avoid operating on steep hills (...

1 41 OPERATION Driving Safely Driving Through Water WARNING The large tires on your RANGER may cause the vehicle to float in deep or fast-flowing water, which could result in loss of control and lead to serious injury or death. Never cross deep or fast-flowing water with your RANGER . Your Polaris R...

42 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...

43 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...

44 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. Set the parking brake. 3. Block the rear wheels on the downhill side. WARNING A rolling vehicle can cause property damage and...

45 OPERATION 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:Always load the cargo box with the load as far forward as possibl...

46 OPERATION Hauling Cargo Dumping the Cargo Box WARNING Operating the vehicle while the cargo box is raised could result in severe injury. The box could close unexpectedly and cause injury to the driver or passenger. The rear tires will also catch the rear of a raised box, damaging the vehicle and ...

47 OPERATION Hauling Cargo Towing Loads WARNING Towing improperly can alter vehicle handling and may cause loss of control or brake instability, which can result in serious injury or death. Always follow these precautions when towing:Never load more than 150 lbs. (68.1 kg) tongue weight on the towin...

48 OPERATION Driving Safely Parking the RANGER WARNING A rolling vehicle can cause property damage and serious injury. Always apply the parking brake after stopping the engine. 1. Stop the vehicle on a level surface. 2. When the engine has stopped, apply the parking brake. 3. Remove the ignition swi...

AWD 2WD AWD 2WD 49 OPERATION Differential Operation Modes The rear axle is equipped with a lockable differential. On AWD models, engaging AWD locks the front differential and the rear differential. CAUTION Damage to the differential can occur if it is engaged while the vehicle is traveling at high s...

50 OPERATION All Wheel Drive (AWD) When in AWD, the front gearcase will automatically engage anytime the rear wheels lose traction. When the rear wheels regain traction, the front gearcase will automatically disengage.There is no limit to the length of time the vehicle may remain in AWD. Engaging Fr...

51 EMISSION CONTROL SYSTEMS Crankcase Emission Control System This engine is equipped with a closed crankcase system. Blow-by gases are forced back to the combustion chamber by the intake system. All exhaust gases exit through the exhaust system. Exhaust Emission Control System The emissions from th...

52 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...

53 MAINTENANCE AND LUBRICATION 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 ...

54 MAINTENANCE AND LUBRICATION Periodic Maintenance Chart Maintenance Chart Key " Perform these procedures more frequently for vehicles subjected to severe use. E Emission-related service (Failure to conduct this maintenance will not void the emissions warranty but may affect emissions.) J Have ...

58 MAINTENANCE AND LUBRICATION Lubrication Recommendations Check and lubricate all components at the intervals outlined in the Periodic Maintenance Chart beginning on page 53. Items not listed in the chart should be lubricated at the General Lubrication interval. Lubrication Chart Key " More oft...

60 MAINTENANCE AND LUBRICATION Engine Oil Always check and change the engine oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 53. Always change the oil filter whenever changing oil. Premium 4 Synthetic Oil Polaris Premium 4 All Season Synthetic engine oil has been sp...

5 63 MAINTENANCE AND LUBRICATION Engine Oil Oil and Filter Change (2x4, 4X4) 8. Reattach the oil line. 9. Place shop towels beneath the oil filter (5). Using an oil filter wrench, turn the filter counterclockwise to remove. 10. Using a clean dry cloth, clean the filter sealing surface on the crankca...

65 MAINTENANCE AND LUBRICATION Engine Oil Oil Check (TM) 1. Position the vehicle on a level surface. 2. Start the engine and let it idle for 20-30 seconds. 3. Stop the engine and remove the seat as described on page 27. Remove the service panel (1) by pulling upward. 4. Remove the dipstick (2) and w...

66 MAINTENANCE AND LUBRICATION Engine Oil Oil and Filter Change (TM) 1. Position the vehicle on a level surface.2. Run the engine two to three minutes until warm, then stop the engine. 3. Clean the area around the drain plug (6) at the bottom of the engine. The plug is accessible through the access ...

67 MAINTENANCE AND LUBRICATION Engine Oil Oil and Filter Change (TM) 7. Place shop towels beneath the oil filter (1). Using an oil filter wrench (2), turn the filter counterclockwise to remove. 8. Using a clean dry cloth, clean the filter sealing surface on the crankcase. 9. Check to make sure the o...

68 MAINTENANCE AND LUBRICATION Gearcases Gearcase Specification Chart Gearcase Lubricant Capacity Fill Plug Torque Drain Plug Torque Main Gearcase (Transmission) (4X4) Premium AGL Synthetic Gearcase Lube 15.2 oz. (450 ml) 14 ft. lbs. (19.4 Nm) 14 ft. lbs. (19.4 Nm) Main Gearcase (Transmission) (2X4,...

69 MAINTENANCE AND LUBRICATION Gearcases Transmission (Main Gearcase) Always check and change the transmission oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 53. Maintain the oil level even with the bottom of the fill plug hole. We recommend the use of Premium AGL ...

1 2 1 2 TM 2X44X4 71 MAINTENANCE AND LUBRICATION Gearcases Rear Gearcase Always check and change the rear gearcase oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 53. Maintain the oil level even with the bottom thread of the fill plug hole. We recommend the use of P...

72 MAINTENANCE AND LUBRICATION Cooling System (2X4, 4X4) Operation 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 inc...

73 MAINTENANCE AND LUBRICATION Cooling System (2X4, 4X4) Radiator and Cooling Fan Always check and clean the screen and radiator fins at the intervals outlined in the Periodic Maintenance Chart beginning on page 53. Do not obstruct or deflect air flow through the radiator by installing unauthorized ...

1 74 MAINTENANCE AND LUBRICATION Cooling System (2X4, 4X4) Radiator Coolant Level Always check and change the coolant at the intervals outlined in the Periodic Maintenance Chart beginning on page 53. WARNING Escaping steam can cause severe burns. Never remove the pressure cap while the engine is war...

75 MAINTENANCE AND LUBRICATION Spark Plugs CAUTION Using non-recommended spark plugs can result in serious engine damage. Always use Polaris-recommended spark plugs. Refer to the specifications section beginning on page 102. Spark Plug Gap/Torque Model Electrode Gap New Plug Torque Used Plug Torque ...

76 MAINTENANCE AND LUBRICATION Polaris Variable Transmission (PVT) System WARNING Failure to comply with the instructions in this warning can result in severe injury or death.Do not modify any component of the PVT system. Doing so may reduce its strength so that a failure may occur at a high speed. ...

77 MAINTENANCE AND LUBRICATION Vehicle Immersion CAUTION If your vehicle becomes immersed, major engine damage can result if the vehicle 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, fol...

1 78 MAINTENANCE AND LUBRICATION Filter Systems (2X4, 4X4) Air Filter Always change the air filter at the intervals outlined in the Periodic Maintenance Chart beginning on page 53.1. Lift the cargo box to access the air box. 2. Remove the air box cover and inspect the gasket. It should adhere tightl...

79 MAINTENANCE AND LUBRICATION Filter Systems (2X4, 4X4) Breather Filter and Hoses 1. Lift the cargo box and locate the air box. 2. Follow the right-hand breather line (1) out the side of the air box and locate the filter (2). 3. Remove and inspect the filter for debris. Blow gently through the filt...

80 MAINTENANCE AND LUBRICATION Filter Systems (TM) Air Filter Always check and change the air filter at the intervals outlined in the Periodic Maintenance Chart beginning on page 53.1. Remove the seat to access the air cleaner. 2. Remove the breather hose (1) from the cylinder. 3. Remove the wing nu...

81 MAINTENANCE AND LUBRICATION Carburetor/Engine Idle RPM Adjustment The idle speed adjustment should be performed as outlined in the Periodic Maintenance Chart, or whenever the idle speed is changed. Recommended engine idle RPM for the RANGER 2X4 and 4X4 is 1200 +/- 200. Recommended engine idle RPM...

82 MAINTENANCE AND LUBRICATION Spark Arrestor WARNING Failure to heed the following warnings while servicing the spark arrestor could result in serious injury or death.Do not perform service on the spark arrestor while the system is hot. Exhaust system temperatures can reach 1000 ° F. Allow componen...

1 2 84 MAINTENANCE AND LUBRICATION Throttle System WARNING Failure to check or maintain proper operation of the throttle system can result in an accident and lead to serious injury or death if the throttle pedal sticks during operation.Never start or operate this vehicle if it has a sticking or impr...

85 MAINTENANCE AND LUBRICATION Throttle System Throttle Freeplay Inspection 1. Apply the parking brake (2) and shift the transmission to neutral. 2. Start the engine and warm it up thoroughly. 3. Measure the distance the throttle pedal moves before the engine begins to pick up speed. Freeplay should...

1 86 MAINTENANCE AND LUBRICATION Brakes The front and rear brakes are hydraulic disc type brakes. Press down on the brake pedal to engage the brakes. See page 31. Brake Fluid Routine inspections are recommended to keep the brake system in good operating condition. Inspect the level of the brake flui...

87 MAINTENANCE AND LUBRICATION 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. Ch...

88 MAINTENANCE AND LUBRICATION 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 53.1. Position the vehicle on level ground.2. Lightly turn the steering wheel left and right.3. ...

89 MAINTENANCE AND LUBRICATION 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 butto...

90 MAINTENANCE AND LUBRICATION Tires WARNING Operating your vehicle with worn tires will increase the possibility of skidding, loss of control and an accident, which could result in serious injury or death. Always replace tires when the tread depth measures 1/8 ″ (.3 cm) or less. Improper tire infla...

91 MAINTENANCE AND LUBRICATION Tires WARNING Improperly installed wheels can adversely affect tire wear and vehicle handling, which can result in serious injury or death. Always ensure that all nuts are torqued to specification. Do not service axle nuts that have a cotter pin installed. See your Pol...

1 92 MAINTENANCE AND LUBRICATION 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. WARNING Poor lighting while driving can result in severe injury or death. Headlight and taill...

1 93 MAINTENANCE AND LUBRICATION 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. Measure the distance from the floor to the center of the headlight and make a mark on the wall at the same height. 3. Start the en...

94 MAINTENANCE AND LUBRICATION Lights Indicator Lamp Replacement 1. Lift the hood. 2. Reach in behind the console panel and lift the release (1) to unplug the light from the harness. 3. Using a flathead screwdriver, press on the tab (2) on the top of the light to remove the indicator light assembly ...

95 MAINTENANCE AND LUBRICATION Cleaning Your RANGER Keeping your vehicle clean will not only improve its appearance but it can also extend the life of various components. With a few precautions, your vehicle can be cleaned much like an automobile.The best and safest way to clean your vehicle is with...

96 MAINTENANCE AND LUBRICATION Storage If your vehicle is to be placed in extended or off season storage, the following steps should be taken to preserve its condition.1. Perform all necessary repairs and thoroughly clean the vehicle.2. Remove the spark plug and pour approximately one ounce of Premi...

97 MAINTENANCE AND LUBRICATION Removal from Storage 1. Check the battery electrolyte level and charge the battery if necessary. Install it in the vehicle. Make sure the battery vent hose is routed properly and that it’s not pinched or restricted in any way. 2. Make sure the spark plug is tight. 3. F...

98 MAINTENANCE AND LUBRICATION Battery Keep the battery terminals and connections free of corrosion. If cleaning is necessary, remove the corrosion with a stiff wire brush. Wash with a solution of one tablespoon baking soda and one cup water. Rinse well with tap water and dry off with clean shop tow...

99 MAINTENANCE AND LUBRICATION Battery Replenishing Battery Fluid (Conventional Battery) A poorly maintained battery will deteriorate rapidly. Check the battery fluid level often. The fluid level should be kept between the upper and lower level marks (1).To refill use only distilled water. Tap water...

100 MAINTENANCE AND LUBRICATION Battery Battery Installation 1. Set the battery in its holder.2. Install the battery vent tube. It must be free from obstructions and securely installed. If not, battery gases could accumulate and cause an explosion. The tube should be routed away from the frame and b...

101 POLARIS PRODUCTS Part No. 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 Lube (q...

102 SPECIFICATIONS RANGER TM Gross Vehicle Weight 2400 lbs. (1089 kg) Fuel Capacity 8.5 gal. (32.2 l) Towing Capacity 1000 lbs. (454 kg) Max. Cargo Box Load 750 lbs. (340 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 ...

108 TROUBLESHOOTING Contact your Polaris dealer for service if you’re unable to identify solutions using the following charts. Engine Doesn’t Turn Over Possible Cause Solution Tripped circuit breaker Reset the breaker Low battery voltage Recharge battery to 12.5 VDC Loose battery connections Check a...

109 TROUBLESHOOTING Engine Backfires Possible Cause Solution Weak spark from spark plugs Inspect, clean and/or replace spark plugs Incorrect spark plug gap or heat range Set gap to specs or replace plugs Old or non-recommended fuel Replace with new fuel Incorrectly installed spark plug wires See you...

110 TROUBLESHOOTING Engine Stops or Loses Power Possible Cause Solution Out of fuel Refuel Kinked or plugged fuel vent line Inspect and replace Water present in fuel Replace with new fuel Overuse of choke Inspect, clean and/or replace spark plugs Fouled or defective spark plugs Inspect, clean and/or...

111 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. This warranty covers the parts and labor charges for repair or replacement of defective part...

112 WARRANTY LIMITATIONS OF WARRANTIES AND REMEDIES ALL IMPLIED WARRANTIES (INCLUDING BUT NOT LIMITED TO THE IM- PLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICU- LAR PURPOSE) ARE LIMITED IN DURATION TO THE ABOVE SIX MONTH WARRANTY PERIOD. POLARIS FURTHER DISCLAIMS ALL EXPRESS WAR- RANT...

113 WARRANTY Exported Vehicles EXCEPT WHERE SPECIFICALLY REQUIRED BY LAW, THERE IS NO WARRANTY OR SERVICE BULLETIN COVERAGE ON THIS VEHICLE IF IT IS SOLD OUTSIDE THE COUNTRY OF THE SELLING DEALER’S AUTHORIZED LOCATION.This policy does not apply to vehicles that have received authorization for export...

114 WARRANTY California Emission Control Warranty Statement Your Warranty Rights and Obligations The California Air Resources Board and Polaris Industries Inc., 2100 Highway 55, Medina, Minnesota 55340 (herein “POLARIS”) are pleased to explain the emission control system warranty on your 2005 and la...

115 WARRANTY California Emission Control Warranty Statement Warranty Period This warranty period begins on the date, which the LSI engine is delivered, to the origi- nal retail purchaser and ends two years after that date. During this two year period POLARIS warrants to the original retail purchaser...

116 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 engin...

118 WARRANTY California Emission Control Warranty Statement Repair and Replacement of Emission-Related Parts It is recommended that only LSI engine replacement parts, which have been authorized and approved by POLARIS, should be used in the performance of any warranty maintenance or repairs of emiss...

120 MAINTENANCE LOG Periodic Maintenance Record Use the following chart to record periodic maintenance. DATE MILES (KM) TECHNICIAN SERVICE PERFORMED / COMMENTS

122 INDEX A Age Restrictions 5 . . . . . . . . . . . . . . . . . Air Filter (2x4, 4X4) 78 . . . . . . . . . . . . . Air Filter (TM) 80 . . . . . . . . . . . . . . . . . All Wheel Drive (AWD) 49-50 . . . . . . . . Auxiliary Outlet 26 . . . . . . . . . . . . . . . . AWD Switch (4X4) 30 . . . . . . . ....

4 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. Your key can be duplicated only by mating a Polaris key blank with one of your existing keys, so if both keys are lost, the ignition...

5 SAFETY Operator Safety WARNING Failure to follow the warnings contained in this manual can result in severe injury or death.A Polaris RANGER is not a toy and can be hazardous to operate. This vehicle handles differently than other vehicles, such as motorcycles and cars. A collision or rollover can...

6 SAFETY Operator Safety The following signal words and symbols appear throughout this manual and on your RANGER . Your safety is involved when these words and symbols are used. Become familiar with their meanings before reading the manual. The safety alert symbol , on your vehicle or in this manual...

7 SAFETY Operator Safety WARNING Serious injury or death can result if you do not follow these instructions and procedures, which are outlined in further detail within your owner’s manual. S Read this manual and all labels carefully. Follow the operating pro- cedures described. S Never allow anyone ...

9 SAFETY Operator Safety S Never modify this vehicle through improper installation or use of accessories. S Never exceed the stated load capacity for this vehicle. Cargo should be properly distributed and securely attached. Reduce speed and follow the instructions in this manual for hauling cargo or...

10 SAFETY Operator Safety WARNING Make sure your RANGER is in excellent operating condition at all times. We strongly recommend that the operator check all safety components before each ride.Polaris RANGER s are designed to provide safe operation when used as directed. Failure of critical machine co...

11 SAFETY Operator Safety WARNING POTENTIAL HAZARDStalling, rolling backwards while climbing a hillWHAT CAN HAPPENVehicle overturnHOW TO AVOID THE HAZARDMaintain a steady speed when climbing a hill.If you lose all forward speed:Apply the brakes.Lock the parking brake after fully stopped.If you begin...

12 SAFETY Operator Safety WARNING POTENTIAL HAZARDOperating this vehicle on paved surfacesWHAT CAN HAPPENLoss of controlHOW TO AVOID THE HAZARDThis vehicle’s tires are designed for off-road use only, not for use on pavement. Paved surfaces may seriously affect handling and control of the vehicle, an...

14 SAFETY Operator Safety WARNING POTENTIAL HAZARDOperating this vehicle at excessive speedsWHAT CAN HAPPENLoss of control, accidentHOW TO AVOID THE HAZARDAlways travel at a speed proper for the terrain, visibility and operating conditions, and your experience. WARNING POTENTIAL HAZARDAttempting jum...

18 SAFETY Safety Decals and Locations Warning decals have been placed on the RANGER for your protection. Read and follow the instructions of the decals on the RANGER carefully. If any of the decals depicted in this manual differ from the decals on your RANGER , always read and follow the instruction...

19 SAFETY Safety Decals and Locations Fuel / Passenger Warning Decal Text Remove flammable containers from box before refueling. S Passengers can be thrown off. This can cause serious injury or death. S Never carry passengers in cargo box. Maximum 2X4 (TM) Box Load 750 lbs. (340 kg) Maximum 4X4 Box ...

20 SAFETY Safety Decals and Locations MANUFACTURED BY: POLARIS IND INC. DATE: VIN: THIS VEHICLE IS A GENERAL PURPOSE OFF-ROAD UTILITY VEHICLE AND IS NOT INTENDED FOR USE ON PUBLIC ROADS. 7078472 CE VÉHICULE USAGE GENERAL VEHICULE UTILIT- AIRE POUR SERVICE HORS ROUTE QUI NEST PAS DES- TINE A ETRE UTI...

21 SAFETY Safety Decals and Locations Discretionary Warning Decal Improper vehicle use can result in SEVERE INJURY or DEATH. NEVER: S Operate on public roads. A collision can occur with another vehicle. S Carry more than two passengers, or passengers under age five. S Use ALCOHOL or DRUGS before or ...

22 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...

23 FEATURES AND CONTROLS Some Polaris vehicles are equipped with special features such as the cab frame. Not all models come with all features. Refer to the specifications section beginning on page 102. Component Locations 1. Cab Frame (if equipped)2. Hip Bar3. Console4. Steering Wheel5. Seat6. Carg...

26 FEATURES AND CONTROLS Indicator Lights The indicator lights on the console display:1. High Gear2. Low Gear (if equipped)3. Neutral Gear4. Reverse Gear5. High Temperature6. Brakes Trailer Hitch Bracket This vehicle is equipped with a receiver hitch bracket for a trailer hitch. Trailer towing equip...

27 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. Seat Belts The RANGER ...

28 FEATURES AND CONTROLS Console 1. Cup Holder2. Indicator Lights3. Shift Lever4. Light Switch5. AWD/Differential Switch (if equipped)6. Hour Meter7. Glove Box with Lid8. 12V Accessory Plug9. Storage Tray10. Choke Knob11. Ignition Switch12. Differential Lock Lever (if equipped)13. Storage Box 11 10 ...

H L N R H N R 29 FEATURES AND CONTROLS Gear Selector (1) RANGER 2X4, 4X4 H: High Gear L: Low Gear N: Neutral R: Reverse RANGER TM H: High Gear N: Neutral R: Reverse NOTE: Low is the primary driving range for the RANGER 2X4 and 4X4. High is intended for use on hard-packed surfaces with light loads. 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. Pre-Ride Checklist Item Remarks See Page Brake system / lever travel Ensure prope...

1 2 3 4 34 OPERATION Starting the Engine WARNING Engine exhaust contains poisonous carbon monoxide and can cause loss of consciousness resulting in severe injury or death. Never run an engine in an enclosed area. CAUTION Operating the vehicle immediately after starting could cause engine damage. All...

35 OPERATION Starting the Engine Starting a Warm Engine Warm engines do not normally require the use of the choke. Overuse of the choke can cause the spark plug to become wet fouled.1. Place the transmission in neutral and move the vehicle to a level surface. 2. Lock the parking brake. 3. Sit in the...

36 OPERATION Braking 1. Release the throttle pedal completely. 2. Press on the brake pedal evenly and firmly. NOTE: Practice starting and stopping (using the brakes) until you’re familiar with the controls. NOTE: When the throttle pedal is released completely and the engine speed drops near an idle,...

37 OPERATION Driving Safely Driving Procedures 1. Sit in the driver’s seat and fasten the seat belt. 2. After starting the engine and allowing it to warm up, shift the transmission into gear. 3. Check your surroundings and determine your path of travel. 4. Release the parking brake. 5. Keeping both ...

38 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 conditions, follow these precautions:1. Slow down when entering slippery areas. 2. Maintain a high le...

39 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...

40 OPERATION Driving Safely Sidehilling WARNING Crossing hillsides or turning on hills can result in loss of control or vehicle overturn, resulting in severe injury or death. Avoid crossing the side of a hill when possible. When unavoidable, exercise extreme caution. Avoid operating on steep hills (...

1 41 OPERATION Driving Safely Driving Through Water WARNING The large tires on your RANGER may cause the vehicle to float in deep or fast-flowing water, which could result in loss of control and lead to serious injury or death. Never cross deep or fast-flowing water with your RANGER . Your Polaris R...

42 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...

43 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...

44 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. Set the parking brake. 3. Block the rear wheels on the downhill side. WARNING A rolling vehicle can cause property damage and...

45 OPERATION 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:Always load the cargo box with the load as far forward as possibl...

46 OPERATION Hauling Cargo Dumping the Cargo Box WARNING Operating the vehicle while the cargo box is raised could result in severe injury. The box could close unexpectedly and cause injury to the driver or passenger. The rear tires will also catch the rear of a raised box, damaging the vehicle and ...

47 OPERATION Hauling Cargo Towing Loads WARNING Towing improperly can alter vehicle handling and may cause loss of control or brake instability, which can result in serious injury or death. Always follow these precautions when towing:Never load more than 150 lbs. (68.1 kg) tongue weight on the towin...

48 OPERATION Driving Safely Parking the RANGER WARNING A rolling vehicle can cause property damage and serious injury. Always apply the parking brake after stopping the engine. 1. Stop the vehicle on a level surface. 2. When the engine has stopped, apply the parking brake. 3. Remove the ignition swi...

AWD 2WD AWD 2WD 49 OPERATION Differential Operation Modes The rear axle is equipped with a lockable differential. On AWD models, engaging AWD locks the front differential and the rear differential. CAUTION Damage to the differential can occur if it is engaged while the vehicle is traveling at high s...

50 OPERATION All Wheel Drive (AWD) When in AWD, the front gearcase will automatically engage anytime the rear wheels lose traction. When the rear wheels regain traction, the front gearcase will automatically disengage.There is no limit to the length of time the vehicle may remain in AWD. Engaging Fr...

51 EMISSION CONTROL SYSTEMS Crankcase Emission Control System This engine is equipped with a closed crankcase system. Blow-by gases are forced back to the combustion chamber by the intake system. All exhaust gases exit through the exhaust system. Exhaust Emission Control System The emissions from th...

52 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...

53 MAINTENANCE AND LUBRICATION 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 ...

54 MAINTENANCE AND LUBRICATION Periodic Maintenance Chart Maintenance Chart Key " Perform these procedures more frequently for vehicles subjected to severe use. E Emission-related service (Failure to conduct this maintenance will not void the emissions warranty but may affect emissions.) J Have ...

58 MAINTENANCE AND LUBRICATION Lubrication Recommendations Check and lubricate all components at the intervals outlined in the Periodic Maintenance Chart beginning on page 53. Items not listed in the chart should be lubricated at the General Lubrication interval. Lubrication Chart Key " More oft...

60 MAINTENANCE AND LUBRICATION Engine Oil Always check and change the engine oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 53. Always change the oil filter whenever changing oil. Premium 4 Synthetic Oil Polaris Premium 4 All Season Synthetic engine oil has been sp...

5 63 MAINTENANCE AND LUBRICATION Engine Oil Oil and Filter Change (2x4, 4X4) 8. Reattach the oil line. 9. Place shop towels beneath the oil filter (5). Using an oil filter wrench, turn the filter counterclockwise to remove. 10. Using a clean dry cloth, clean the filter sealing surface on the crankca...

65 MAINTENANCE AND LUBRICATION Engine Oil Oil Check (TM) 1. Position the vehicle on a level surface. 2. Start the engine and let it idle for 20-30 seconds. 3. Stop the engine and remove the seat as described on page 27. Remove the service panel (1) by pulling upward. 4. Remove the dipstick (2) and w...

66 MAINTENANCE AND LUBRICATION Engine Oil Oil and Filter Change (TM) 1. Position the vehicle on a level surface.2. Run the engine two to three minutes until warm, then stop the engine. 3. Clean the area around the drain plug (6) at the bottom of the engine. The plug is accessible through the access ...

67 MAINTENANCE AND LUBRICATION Engine Oil Oil and Filter Change (TM) 7. Place shop towels beneath the oil filter (1). Using an oil filter wrench (2), turn the filter counterclockwise to remove. 8. Using a clean dry cloth, clean the filter sealing surface on the crankcase. 9. Check to make sure the o...

68 MAINTENANCE AND LUBRICATION Gearcases Gearcase Specification Chart Gearcase Lubricant Capacity Fill Plug Torque Drain Plug Torque Main Gearcase (Transmission) (4X4) Premium AGL Synthetic Gearcase Lube 15.2 oz. (450 ml) 14 ft. lbs. (19.4 Nm) 14 ft. lbs. (19.4 Nm) Main Gearcase (Transmission) (2X4,...

69 MAINTENANCE AND LUBRICATION Gearcases Transmission (Main Gearcase) Always check and change the transmission oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 53. Maintain the oil level even with the bottom of the fill plug hole. We recommend the use of Premium AGL ...

1 2 1 2 TM 2X44X4 71 MAINTENANCE AND LUBRICATION Gearcases Rear Gearcase Always check and change the rear gearcase oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 53. Maintain the oil level even with the bottom thread of the fill plug hole. We recommend the use of P...

72 MAINTENANCE AND LUBRICATION Cooling System (2X4, 4X4) Operation 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 inc...

73 MAINTENANCE AND LUBRICATION Cooling System (2X4, 4X4) Radiator and Cooling Fan Always check and clean the screen and radiator fins at the intervals outlined in the Periodic Maintenance Chart beginning on page 53. Do not obstruct or deflect air flow through the radiator by installing unauthorized ...

1 74 MAINTENANCE AND LUBRICATION Cooling System (2X4, 4X4) Radiator Coolant Level Always check and change the coolant at the intervals outlined in the Periodic Maintenance Chart beginning on page 53. WARNING Escaping steam can cause severe burns. Never remove the pressure cap while the engine is war...

75 MAINTENANCE AND LUBRICATION Spark Plugs CAUTION Using non-recommended spark plugs can result in serious engine damage. Always use Polaris-recommended spark plugs. Refer to the specifications section beginning on page 102. Spark Plug Gap/Torque Model Electrode Gap New Plug Torque Used Plug Torque ...

76 MAINTENANCE AND LUBRICATION Polaris Variable Transmission (PVT) System WARNING Failure to comply with the instructions in this warning can result in severe injury or death.Do not modify any component of the PVT system. Doing so may reduce its strength so that a failure may occur at a high speed. ...

77 MAINTENANCE AND LUBRICATION Vehicle Immersion CAUTION If your vehicle becomes immersed, major engine damage can result if the vehicle 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, fol...

1 78 MAINTENANCE AND LUBRICATION Filter Systems (2X4, 4X4) Air Filter Always change the air filter at the intervals outlined in the Periodic Maintenance Chart beginning on page 53.1. Lift the cargo box to access the air box. 2. Remove the air box cover and inspect the gasket. It should adhere tightl...

79 MAINTENANCE AND LUBRICATION Filter Systems (2X4, 4X4) Breather Filter and Hoses 1. Lift the cargo box and locate the air box. 2. Follow the right-hand breather line (1) out the side of the air box and locate the filter (2). 3. Remove and inspect the filter for debris. Blow gently through the filt...

80 MAINTENANCE AND LUBRICATION Filter Systems (TM) Air Filter Always check and change the air filter at the intervals outlined in the Periodic Maintenance Chart beginning on page 53.1. Remove the seat to access the air cleaner. 2. Remove the breather hose (1) from the cylinder. 3. Remove the wing nu...

81 MAINTENANCE AND LUBRICATION Carburetor/Engine Idle RPM Adjustment The idle speed adjustment should be performed as outlined in the Periodic Maintenance Chart, or whenever the idle speed is changed. Recommended engine idle RPM for the RANGER 2X4 and 4X4 is 1200 +/- 200. Recommended engine idle RPM...

82 MAINTENANCE AND LUBRICATION Spark Arrestor WARNING Failure to heed the following warnings while servicing the spark arrestor could result in serious injury or death.Do not perform service on the spark arrestor while the system is hot. Exhaust system temperatures can reach 1000 ° F. Allow componen...

1 2 84 MAINTENANCE AND LUBRICATION Throttle System WARNING Failure to check or maintain proper operation of the throttle system can result in an accident and lead to serious injury or death if the throttle pedal sticks during operation.Never start or operate this vehicle if it has a sticking or impr...

85 MAINTENANCE AND LUBRICATION Throttle System Throttle Freeplay Inspection 1. Apply the parking brake (2) and shift the transmission to neutral. 2. Start the engine and warm it up thoroughly. 3. Measure the distance the throttle pedal moves before the engine begins to pick up speed. Freeplay should...

1 86 MAINTENANCE AND LUBRICATION Brakes The front and rear brakes are hydraulic disc type brakes. Press down on the brake pedal to engage the brakes. See page 31. Brake Fluid Routine inspections are recommended to keep the brake system in good operating condition. Inspect the level of the brake flui...

87 MAINTENANCE AND LUBRICATION 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. Ch...

88 MAINTENANCE AND LUBRICATION 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 53.1. Position the vehicle on level ground.2. Lightly turn the steering wheel left and right.3. ...

89 MAINTENANCE AND LUBRICATION 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 butto...

90 MAINTENANCE AND LUBRICATION Tires WARNING Operating your vehicle with worn tires will increase the possibility of skidding, loss of control and an accident, which could result in serious injury or death. Always replace tires when the tread depth measures 1/8 ″ (.3 cm) or less. Improper tire infla...

91 MAINTENANCE AND LUBRICATION Tires WARNING Improperly installed wheels can adversely affect tire wear and vehicle handling, which can result in serious injury or death. Always ensure that all nuts are torqued to specification. Do not service axle nuts that have a cotter pin installed. See your Pol...

1 92 MAINTENANCE AND LUBRICATION 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. WARNING Poor lighting while driving can result in severe injury or death. Headlight and taill...

1 93 MAINTENANCE AND LUBRICATION 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. Measure the distance from the floor to the center of the headlight and make a mark on the wall at the same height. 3. Start the en...

94 MAINTENANCE AND LUBRICATION Lights Indicator Lamp Replacement 1. Lift the hood. 2. Reach in behind the console panel and lift the release (1) to unplug the light from the harness. 3. Using a flathead screwdriver, press on the tab (2) on the top of the light to remove the indicator light assembly ...

95 MAINTENANCE AND LUBRICATION Cleaning Your RANGER Keeping your vehicle clean will not only improve its appearance but it can also extend the life of various components. With a few precautions, your vehicle can be cleaned much like an automobile.The best and safest way to clean your vehicle is with...

96 MAINTENANCE AND LUBRICATION Storage If your vehicle is to be placed in extended or off season storage, the following steps should be taken to preserve its condition.1. Perform all necessary repairs and thoroughly clean the vehicle.2. Remove the spark plug and pour approximately one ounce of Premi...

97 MAINTENANCE AND LUBRICATION Removal from Storage 1. Check the battery electrolyte level and charge the battery if necessary. Install it in the vehicle. Make sure the battery vent hose is routed properly and that it’s not pinched or restricted in any way. 2. Make sure the spark plug is tight. 3. F...

98 MAINTENANCE AND LUBRICATION Battery Keep the battery terminals and connections free of corrosion. If cleaning is necessary, remove the corrosion with a stiff wire brush. Wash with a solution of one tablespoon baking soda and one cup water. Rinse well with tap water and dry off with clean shop tow...

99 MAINTENANCE AND LUBRICATION Battery Replenishing Battery Fluid (Conventional Battery) A poorly maintained battery will deteriorate rapidly. Check the battery fluid level often. The fluid level should be kept between the upper and lower level marks (1).To refill use only distilled water. Tap water...

100 MAINTENANCE AND LUBRICATION Battery Battery Installation 1. Set the battery in its holder.2. Install the battery vent tube. It must be free from obstructions and securely installed. If not, battery gases could accumulate and cause an explosion. The tube should be routed away from the frame and b...

101 POLARIS PRODUCTS Part No. 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 Lube (q...

102 SPECIFICATIONS RANGER TM Gross Vehicle Weight 2400 lbs. (1089 kg) Fuel Capacity 8.5 gal. (32.2 l) Towing Capacity 1000 lbs. (454 kg) Max. Cargo Box Load 750 lbs. (340 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 ...

108 TROUBLESHOOTING Contact your Polaris dealer for service if you’re unable to identify solutions using the following charts. Engine Doesn’t Turn Over Possible Cause Solution Tripped circuit breaker Reset the breaker Low battery voltage Recharge battery to 12.5 VDC Loose battery connections Check a...

109 TROUBLESHOOTING Engine Backfires Possible Cause Solution Weak spark from spark plugs Inspect, clean and/or replace spark plugs Incorrect spark plug gap or heat range Set gap to specs or replace plugs Old or non-recommended fuel Replace with new fuel Incorrectly installed spark plug wires See you...

110 TROUBLESHOOTING Engine Stops or Loses Power Possible Cause Solution Out of fuel Refuel Kinked or plugged fuel vent line Inspect and replace Water present in fuel Replace with new fuel Overuse of choke Inspect, clean and/or replace spark plugs Fouled or defective spark plugs Inspect, clean and/or...

111 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. This warranty covers the parts and labor charges for repair or replacement of defective part...

112 WARRANTY LIMITATIONS OF WARRANTIES AND REMEDIES ALL IMPLIED WARRANTIES (INCLUDING BUT NOT LIMITED TO THE IM- PLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICU- LAR PURPOSE) ARE LIMITED IN DURATION TO THE ABOVE SIX MONTH WARRANTY PERIOD. POLARIS FURTHER DISCLAIMS ALL EXPRESS WAR- RANT...

113 WARRANTY Exported Vehicles EXCEPT WHERE SPECIFICALLY REQUIRED BY LAW, THERE IS NO WARRANTY OR SERVICE BULLETIN COVERAGE ON THIS VEHICLE IF IT IS SOLD OUTSIDE THE COUNTRY OF THE SELLING DEALER’S AUTHORIZED LOCATION.This policy does not apply to vehicles that have received authorization for export...

114 WARRANTY California Emission Control Warranty Statement Your Warranty Rights and Obligations The California Air Resources Board and Polaris Industries Inc., 2100 Highway 55, Medina, Minnesota 55340 (herein “POLARIS”) are pleased to explain the emission control system warranty on your 2005 and la...

115 WARRANTY California Emission Control Warranty Statement Warranty Period This warranty period begins on the date, which the LSI engine is delivered, to the origi- nal retail purchaser and ends two years after that date. During this two year period POLARIS warrants to the original retail purchaser...

116 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 engin...

118 WARRANTY California Emission Control Warranty Statement Repair and Replacement of Emission-Related Parts It is recommended that only LSI engine replacement parts, which have been authorized and approved by POLARIS, should be used in the performance of any warranty maintenance or repairs of emiss...

120 MAINTENANCE LOG Periodic Maintenance Record Use the following chart to record periodic maintenance. DATE MILES (KM) TECHNICIAN SERVICE PERFORMED / COMMENTS

122 INDEX A Age Restrictions 5 . . . . . . . . . . . . . . . . . Air Filter (2x4, 4X4) 78 . . . . . . . . . . . . . Air Filter (TM) 80 . . . . . . . . . . . . . . . . . All Wheel Drive (AWD) 49-50 . . . . . . . . Auxiliary Outlet 26 . . . . . . . . . . . . . . . . AWD Switch (4X4) 30 . . . . . . . ....