Polaris Series 10 Ranger 425 2x4- Manuals

Page 2 - WARNING; The engine exhaust from this

WARNING The engine exhaust from this product contains chemicals known to cause cancer, birth defects or other reproductive harm.

Page 3 - We’ve created a web site just for YOU!; Technical tips

1 We’ve created a web site just for YOU! S Technical tips S New product introductions S Event schedules S Parts and Service Manual information S Exciting details about The Way Out Check it out... www.polarisindustries.com/owner

Page 5 - WELCOME; RANGER

3 WELCOME Thank you for purchasing a Polaris vehicle, and welcome to our world-wide family of Polaris enthusiasts. Polaris proudly produces an exciting line of recreational products, including snowmobiles, all-terrain vehicles, personal watercraft, utility vehicles, and Victory motorcycles.We believ...

Page 6 - SEVERE INJURY OR DEATH can result if you do not follow

4 THIS VEHICLE IS NOT A TOY AND CAN BE HAZARDOUS TO OPERATE. This vehicle handles differently from other vehicles including motorcycles and cars. A collision or rollover can occur quickly, even during routine maneuvers such as turning and driving on hills or over obstacles, if you fail to take prope...

Page 8 - FOR MORE INFORMATION ABOUT SAFETY, call Polaris at

6 n Never operate vehicle in fast flowing water or in water deeper than that specified in this manual. Remember that wet brakes may have reduced stopping ability. Test your brakes after leaving water. If necessary, apply them lightly several times to let friction dry out the pads. n Always be sure t...

Page 10 - TABLE OF CONTENTS; Vehicle Identification Numbers

8 TABLE OF CONTENTS Vehicle Identification Numbers 10 . . . . . . . . . . . . . Safety 11 - 45 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Operator Safety 11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Decals and Locations 40 . . . . . . . . . . . . . . . . . ...

Page 11 - Maintenance and Lubrication

9 TABLE OF CONTENTS Maintenance and Lubrication 67 - 110 . . . . . . . . . . Periodic Maintenance Schedule 67 . . . . . . . . . . . . . . . . . . Lubrication Recommendations 70 . . . . . . . . . . . . . . . . . . . Oil Recommendations 74 . . . . . . . . . . . . . . . . . . . . . . . . . . Cooling Sy...

Page 12 - VEHICLE IDENTIFICATION NUMBERS; Record these numbers from your vehicle in the spaces; were stolen these numbers are essential to the recovery and

10 VEHICLE IDENTIFICATION NUMBERS Important: Record these numbers from your vehicle in the spaces provided. 1. Frame VIN: 3. Engine Serial Number (Right front side of engine crankcase) Remove the spare key and store in a safe place. The vehicle frame and engine serial numbers are important for model...

Page 13 - SAFETY; Operator Safety; are used. Become familiar with their meanings before reading the; CAUTION

11 SAFETY Operator Safety The following two pages identify signal words and symbols that appear in this manual. 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 RANGER or in this manual, ale...

Page 14 - The warranty on your entire machine is terminated

12 SAFETY Operator Safety Driving a RANGER requires your full attention. DO NOT drink alcohol or use drugs or medications before or while driving. They will reduce your alertness and slow your reaction time. In most states and provinces, it’s prohibited by law to drive while intoxicated or under the...

Page 29 - Driving On Slippery Surfaces; Whenever driving on slippery surfaces such as wet trails or loose; quick, sharp turns which can cause skids.

27 SAFETY Operator Safety Driving On Slippery Surfaces Whenever driving on slippery surfaces such as wet trails or loose gravel, or during cold freezing weather, special attention must be paid to prevent vehicle turnover. Always: 1. Slow down when entering slippery areas.2. Maintain a high level of ...

Page 30 - Operating on Hills; Whenever descending a hill always:; Whenever traveling uphill always travel straight uphill and:

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

Page 33 - Crossing Streams; Do not start the engine!

31 SAFETY Operator Safety Crossing Streams Your Polaris RANGER can operate through water up to depths reaching the floorboards. Before fording streams always:1. Determine water depths and current.2. Choose a crossing where both banks have gradual inclines. 3. Proceed slowly, avoiding rocks and obsta...

Page 34 - After running the vehicle in water, it is; critical; your machine

32 SAFETY Operator Safety Crossing Streams Never try to cross any deep or fast flowing streams.The large tires can cause the vehicle to float resulting in loss of control. D Determine stream depth and speed before crossing. WARNING NOTE: After running the vehicle in water, it is critical your machin...

Page 35 - Look ahead and learn to read the trail as you drive. Stay on the right

33 SAFETY Operator Safety Trail ObstaclesKeep Alert! Look ahead and learn to read the trail as you drive. Stay on the right side of the trail, if possible, and be constantly alert for hazards such as logs, rocks and low hanging branches. Hidden or unseen hazards on the trail can be dangerous.Persona...

Page 36 - Backing Up

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

Page 37 - Parking On An Incline; Avoid parking on an incline. If it is necessary to park on an

35 SAFETY Operator Safety Parking On An Incline Whenever the Vehicle is Parked 1. Place the transmission in gear.2. Set the parking brake. 3. Avoid parking on an incline. If it is necessary to park on an incline, always block the rear wheels on the down hill side. Always check to be sure that the pa...

Page 38 - Carrying Loads; Load Distribution; drive in low gear

36 SAFETY Operator Safety Carrying Loads The RANGER has been designed to carry or tow a certain amount of load. Always read and understand the load distribution warnings listed on the warning labels. Never exceed the following weights. Maximum Capacities (Level Ground) Cargo Box RANGER 2X4 1350 lbs....

Page 39 - Dumping the Cargo Box

37 SAFETY Operator Safety 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. Set the parking brake. 3. Dismount the vehicle.4. Release the tailgate by pulling up on the latch. 5. Stand clear and pull up on t...

Page 40 - do not tow any trailer on a

38 SAFETY Operator Safety Towing LoadsMaximum Towing Capacities (Level Ground) Total Towed Load Weight (level ground) Total Towed Load Weight (15 ° grade) Total Hitch Vertical Weight Towing Speed RANGER 2X4 1400 lbs. (636 kg) 800 lbs. (364 kg) 150 lbs (68.1 kg) 10 mph (16 kph) or less RANGER 4X4 150...

Page 41 - Parking the; When the engine has stopped, apply the parking brake to help; Remove the ignition switch key to prevent unauthorized use.

39 SAFETY Operator Safety Parking the RANGER 1. Stop the vehicle on a level surface. 2. When the engine has stopped, apply the parking brake to help prevent the vehicle from rolling. Be sure to apply the parking brake before leaving the vehicle. If the vehicle should move, it might be damaged or cau...

Page 42 - Safety Decals and Locations

40 SAFETY Safety Decals and Locations S VEHICLE ROLLOVER could cause severe injury or death This cab frame is not designed or intended to provide rollover protection. S ALWAYS WEAR YOUR SEATBELT for maximum protection. WARNING IMPROPER TIRE PRESSURE OR OVER- LOADING can cause loss of control resulti...

Page 43 - ATTENTION

41 SAFETY Safety Decals and Locations 1 2 3 ATTENTION D Operation of this vehicle without the filter element will severely damage the engine. D Clean air filter often, more frequent cleaning required in dusty conditions D Operation of this vehicle without engine breather filter(s) can cause engine d...

Page 44 - Fuel / Passenger Warning Decal Text; Remove flammable containers from box before refueling.

42 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. PRINTED IN U.S.A. 7078472 CE VÉHICULE USAGE GENERAL VEHICULE UTILIT- AIRE POUR SERVICE HORS ROUTE QUI NEST PAS DE...

Page 48 - FEATURES AND CONTROLS; Features

46 FEATURES AND CONTROLS Features 1. Cab Frame2. Cab Frame Hand Hold3. Dashboard4. Steering Wheel5. Seat6. Cargo Box7. Seat Belts8. Gas Tank Cap / Gas Gauge9. Battery (under seat) 1 4 7 5, 9 6 2 3 8

Page 51 - Auxiliary Lighting/Electrical Accessory Terminals

49 FEATURES AND CONTROLS Features Auxiliary Lighting/Electrical Accessory Terminals The 12-volt receptacle has spade connections on the back that may be used for accessory power such as an auxiliary light or other optional light or accessory. To locate these connections, lift the hood and look behin...

Page 52 - Seat Removal

50 FEATURES AND CONTROLS Features Seat Removal To remove the seat, 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 and then push down firmly on the front of the seat until the pins are fully seated into...

Page 53 - Controls

51 FEATURES AND CONTROLS Controls 30 25 24 26 27 28 32 31 29 24. Choke Knob25. Ignition Switch26. Hour Meter27. Indicator Lights28. 12V Accessory Plug29. Fog/High Beam Light Switch30. AWD (All Wheel Drive) Switch (if equipped)31. Shift Lever32. Differential Lock Lever

Page 54 - Transmission Gear Selector Operation

52 FEATURES AND CONTROLS Controls Transmission Gear Selector Operation The transmission gear selector (1) is located on the console to the right of the steering wheel and has four positions (2): high, low, neutral and reverse NOTE: Low is the primary driving range for this vehicle. High is intended ...

Page 55 - Brake Pedal

53 FEATURES AND CONTROLS Controls Brake Pedal The brake pedal (5) is the left pedal on the foot board. Depress the brake pedal to slow or stop the vehicle. Throttle Pedal The throttle pedal (6) is the right pedal on the floor board. Push the pedal down to increase engine speed. Spring pressure retur...

Page 56 - Ignition Switch; from the switch when it is in the OFF position.; Light Switch Lever; the lever is pushed down.; AWD Rocker Switch; Vehicles equipped with AWD can be operated in either 2WD or AWD.

54 FEATURES AND CONTROLS Controls Ignition Switch This is a three-position, key-operated switch. The key can be removed from the switch when it is in the OFF position. Light Switch Lever Turn on headlights and taillights by flipping the light switch lever up, with the ignition switch key in the ON p...

Page 57 - All Wheel Drive

55 FEATURES AND CONTROLS Controls All Wheel Drive (AWD) 1 All Wheel Drive The Polaris RANGER 4X4 and 6X6 are equipped with a unique, Polaris exclusive, All Wheel Drive (AWD) system, which is activated by a switch on the dash (1). When the switch is off the RANGER is in two-wheel drive at all times. ...

Page 58 - Parking Brake Lever

56 FEATURES AND CONTROLS Controls Parking Brake Lever The parking brake (1) is located below the dash in the center of the vehicle. It will help hold the vehicle from rolling while parked.To apply the parking brake, push down on the pedal with your foot.To release, Pull the release handle (2) locate...

Page 59 - OPERATION; Before You Ride; Daily Pre-operation Inspection

57 OPERATION Before You Ride Daily Pre-operation Inspection Inspect your vehicle each time before operating to ensure it is in proper working order. If proper inspection is not done, serious injury or death could result. If a proper inspection is not performed serious injury or death can result.Alwa...

Page 60 - Vehicle Break-In Period

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

Page 61 - Starting the Engine; Procedure for Starting a Cold Engine

59 OPERATION Starting the Engine Procedure for Starting a Cold Engine Do not start or operate this vehicle with sticking or improperly operating throttle pedal. A stuck or improperly operating throttle could cause an accident resulting in severe injury or death.Always contact your dealer for service...

Page 62 - After the Engine Starts; If the engine slows or stops, push the choke knob in half way.

60 OPERATION Starting the Engine After the Engine Starts 1. If the engine slows or stops, push the choke knob in half way. 2. Vary the engine RPM slightly with the throttle to aid in warm up until the engine idles smoothly. Then push the choke all the way in. CAUTION Proper engine warm up is essenti...

Page 63 - Starting a Warm Engine; If the engine has cooled to a point where it does not readily start,

61 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 brake3. Sit in the v...

Page 64 - Driving the; Braking

62 OPERATION Driving the RANGER 1. Sit in the driver’s seat with the seatbelt fastened.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 hands on the st...

Page 65 - Stopping the Engine; Apply the parking brake to help prevent the vehicle from rolling.

63 OPERATION Stopping the Engine 1. Release the throttle pedal completely.2. Put the gear shift lever into (N) Neutral. 3. Apply the parking brake to help prevent the vehicle from rolling. Be sure to apply the parking brake before leaving the vehicle. If the vehicle moves, it might be damaged or cau...

Page 66 - Fuel; Gasoline and Alcohol Blends

64 OPERATION Fuel n Never use gasohol with an octane rating lower than the minimum octane rating specified for this product. n Never use gasohol containing more than 10% ethanol (grain alcohol). n Never use gasohol containing more than 5% methanol (wood alcohol). Gasoline containing methanol must al...

Page 67 - USFS Approved Spark Arrestor

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

Page 69 - MAINTENANCE AND LUBRICATION; Periodic Maintenance Schedule; NOTE

67 MAINTENANCE AND LUBRICATION Periodic Maintenance Schedule Careful periodic maintenance will help keep your vehicle in the safest, most reliable condition. Inspection, adjustment and lubrication intervals of important components are explained in the following chart:Maintenance intervals are based ...

Page 71 - More often under severe use, such as dirty or wet conditions

69 MAINTENANCE AND LUBRICATION Periodic Maintenance Schedule Item Hours Remarks " Front Suspension 50 hrs Inspect-- lubricate, tighten fasteners " Rear Suspension 50 hrs Inspect, tighten fasteners Coolant strength/ pressure test system 100 hrs Inspect strength seasonally; pressure test syste...

Page 72 - Lubrication Recommendations

70 MAINTENANCE AND LUBRICATION Lubrication Recommendations Item Lube Rec. Method Frequency* 1. Engine Oil Polaris Premium 4 Synthetic 0W40 Add to proper level on dipstick. See page 77. Check level daily. 2. Brake Fluid DOT 3 Only Maintain level be- tween fill lines. See page 95. As required; change ...

Page 76 - Engine Oil; Check the Oil

74 MAINTENANCE AND LUBRICATION Engine Oil Check the Oil The oil tank is located under the seat. To check the oil:1. Set machine 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 50 to access the dipstick (1). 4. Re...

Page 77 - Oil and Filter Change

75 MAINTENANCE AND LUBRICATION Engine Oil Oil and Filter Change In order for the engine to function properly, maintain the engine oil at the proper level, and change the oil and oil filter in accordance with the Periodic Maintenance Schedule. Not only do dirt and metal particles collect in the oil, ...

Page 80 - Transmission Oil

78 MAINTENANCE AND LUBRICATION Transmission Oil The transmission lubricant level should be checked at 25 hours or monthly, whichever comes first. Transmission oil should be changed annually.To check the transmission lubricant level you must first position the vehicle on a level surface. Remove fill ...

Page 81 - Front Gearcase; Gearcase Lubrication; Front Gearcase Oil Changing Procedure

79 MAINTENANCE AND LUBRICATION Front Gearcase Gearcase Lubrication The front gearcase fill plug (1) is located on the right side of the front gearcase. The drain plug (2) is located on the bottom side of the gearcase.The front gearcase lubricant level should be checked every six months or 100 hours,...

Page 82 - Gearcases; Middle Gearcase Lubrication; Middle Gearcase Oil Changing Procedure

80 MAINTENANCE AND LUBRICATION Gearcases Middle Gearcase Lubrication The middle gearcase fill plug (1) is located on the right side of the middle gearcase. The drain plug (2) is located on the bottom side of the gearcase.The middle gearcase lubricant level should be checked every six months or 100 h...

Page 83 - Engine Cooling System; How it Works

81 MAINTENANCE AND LUBRICATION Engine Cooling System How it Works The overflow bottle is located in front of the right front tire of the machine. It must be maintained between the minimum and maximum levels indicated on the overflow bottle.The engine coolant level is controlled or maintained by the ...

Page 84 - Coolant Level Inspection

82 MAINTENANCE AND LUBRICATION Engine Cooling System Coolant Level Inspection NOTE: Check the coolant level when the engine is cold (room or atmospheric temperature).1. Situate the vehicle on level ground. 2. Check the coolant level by looking at the overflow bottle located in front of the right fro...

Page 85 - Radiator Coolant Level Inspection

83 MAINTENANCE AND LUBRICATION Engine Cooling System Radiator Coolant Level Inspection Lift the hood and locate the radiator cap(1) and visually inspect the level of coolant in the radiator.. NOTE: This procedure is only required if the cooling system has been drained for maintenance and/or repair. ...

Page 86 - Radiator and Cooling Fan; or mud in accordance with the Periodic Maintenance Chart.

84 MAINTENANCE AND LUBRICATION Engine Cooling System Radiator and Cooling Fan Check and clean the screen and radiator fins for obstruction by insects or mud in accordance with the Periodic Maintenance Chart. Do not obstruct or deflect airflow through the radiator by installing unauthorized accessori...

Page 87 - PVT System; PVT Drying; the PVT system. Use the following instructions to dry it out before

85 MAINTENANCE AND LUBRICATION PVT System The PVT system rotates at high speeds, creating large amounts of force on clutch components. Extensive engineering and testing has been conducted to insure the safety of this product. However, as the owner you have the following responsibilities to make sure...

Page 88 - Vehicle Immersion

86 MAINTENANCE AND LUBRICATION Vehicle Immersion If it is impossible to take it to a dealer before starting, follow the steps outlined below. S Move the vehicle to dry land or at the very least, to water below the floor. S Disconnect the fuel pump wires. S Remove the spark plug. S Loosen the carbure...

Page 89 - Air Filter Service

87 MAINTENANCE AND LUBRICATION Air Filter Service It is recommended that the air filter be replaced yearly. When operating in extremely dusty conditions replacement will be required more often.1. Lift the box.2. Remove the cover. Inspect the gasket. It should adhere tightly to the cover and seal all...

Page 90 - Breather Filter and Hoses

88 MAINTENANCE AND LUBRICATION Breather Filter and Hoses 1. Lift box and locate the airbox (1). 2. Follow right hand breather line out of the side of the airbox and locate filter (2). 3. Inspect filter for debris. Blow through gently in direction of arrow on filter to check for clogging. Replace as ...

Page 91 - Spark Plugs

89 MAINTENANCE AND LUBRICATION Spark Plugs S Proper electrode gap is .036 ″ /.90mm. S Spark plug torque is 14 ft. lbs./19 Nm. S Use NGK BKR5ES spark plugs. 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...

Page 92 - Spark Plug Removal and Replacement; tool pouch. Remove the seat to access the engine compartment.; Cylinder Head/Cylinder Base Fastener Torque; Have your dealer check the

90 MAINTENANCE AND LUBRICATION Spark Plug Removal and Replacement The spark plug is removed by using the special wrench provided in the tool pouch. Remove the seat to access the engine compartment. Remove the spark plug cap and then the spark plug by rotating counterclockwise.Reverse the procedure f...

Page 93 - Spark Arrestor

91 MAINTENANCE AND LUBRICATION Spark Arrestor The exhaust pipe must be periodically purged of accumulated carbon as follows:1. Remove the clean out plugs located on the bottom of the muffler as shown above. 2. Place the transmission in neutral and start the engine. Purge accumulated carbon from the ...

Page 95 - Throttle Pedal; Throttle Freeplay; Boot

93 MAINTENANCE AND LUBRICATION Throttle Pedal Throttle Freeplay If the throttle pedal (1) has excessive play due to cable stretch or cable misadjustment, it will cause a delay in throttle response, especially at low engine speed. Also, the throttle may not open fully. If the throttle pedal has no pl...

Page 96 - Carburetor; Carburetor/Engine Idle RPM Adjustment

94 MAINTENANCE AND LUBRICATION Carburetor The idle speed adjustment should be performed in accordance with the Periodic Maintenance Chart or whenever the idle speed is changed. The following procedure covers the idle speed adjustment: Carburetor/Engine Idle RPM Adjustment Recommended engine idle RPM...

Page 97 - Brakes; Front and Rear Brakes

95 MAINTENANCE AND LUBRICATION Brakes Front and Rear Brakes The front and rear brakes are hydraulic disc type brakes activated by the brake pedal. See page 53.The following checks are recommended to keep the brake system in good operating condition. How often they need checking depends upon the type...

Page 98 - Check brake system for fluid leaks.

96 MAINTENANCE AND LUBRICATION Brakes Front and Rear Brakes S Check brake system for fluid leaks. S Check brake for excessive travel or spongy feel. S Check friction pads for wear, damage and looseness. S Check security and surface condition of the disc. S Pads should be changed when worn to 3/64 ″ ...

Page 99 - Rear Brake

97 MAINTENANCE AND LUBRICATION Brakes Rear Brake The rear brake is a hydraulic disc type brake which is activated by the same pedal which activates the front brake system. The rear brake system requires periodic checks of the pads for wear. Wear Line S Pads should be changed when worn to 3/64 ″ (.1 ...

Page 100 - Parking Brake Inspection:

98 MAINTENANCE AND LUBRICATION Brakes Parking Brake Inspection: S Push the parking brake down with your foot. S After 8 to 12 clicks of le- ver travel, the vehicle should not roll while parked. S If the vehicle moves, ad- justment is necessary Adjustment: S Place the vehicle in neutral on a flat lev...

Page 101 - Steering Wheel

99 MAINTENANCE AND LUBRICATION Steering Wheel Check the steering wheel for specified free play and smooth operation in accordance with the periodic maintenance Chart. Inspection: S Park the vehicle on level ground. S Lightly turn the steering wheel left and right. S There should be 0.8 - 1.0 in (20 ...

Page 102 - Seat Belts; Make certain the seatbelt is adjusted to be as low on the

100 MAINTENANCE AND LUBRICATION Seat Belts Make certain all three seat belts function properly before each operation. Push the latch plate into the buckle until it clicks. The latch plate must slide smoothly into the buckle. The click sound shows it is securely latched. Push the red button in the mi...

Page 103 - Tire Inspection; Tire Tread Depth; Always replace tires when tread; Axle and Wheel Nut Torque Specifications; they have been loosened for maintenance service.

101 MAINTENANCE AND LUBRICATION Tire Inspection Tire Tread Depth Always replace tires when tread depth is worn to 1/8 ″ (.3 cm) or less. Please refer to pages 111 and 113 for your vehicle’s specifications. Axle and Wheel Nut Torque Specifications The following items should be checked occasionally fo...

Page 104 - Removing and Installing Wheels; Wheel Removal Procedure

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

Page 105 - Lights; Headlight Beam

103 MAINTENANCE AND LUBRICATION Lights Headlight Beam 1. Place the vehicle on a level surface with the headlight approximately 25’ (7.6 m) from a wall. 2. Measure the distance from the floor to the center of the headlight and make a mark on the wall at the same height. 3. Start the engine and turn o...

Page 106 - Indicator Lamp Replacement; Tool Kit

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

Page 107 - Cleaning Your; Washing

105 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. Washing If a high pressure type car wash system is ...

Page 108 - Storage

106 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 Pre...

Page 109 - Removal from Storage:; and install it in the vehicle. Make certain the battery vent hose is; Bolt and Nut Tightening

107 MAINTENANCE AND LUBRICATION Removal from Storage: 1. Check the battery electrolyte level, charge the battery if necessary, and install it in the vehicle. Make certain the battery vent hose is routed properly and that it is not pinched or restricted in any way. 2. Make sure the spark plug is tigh...

Page 110 - Battery; Replenishing Battery Fluid

108 MAINTENANCE AND LUBRICATION Battery Replenishing Battery Fluid 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. Battery Connections Battery terminals and connections should be kept f...

Page 111 - Battery Removal

109 MAINTENANCE AND LUBRICATION Battery Battery Removal 1. Remove the seat to access the battery. 2. Remove the battery vent tube from the battery. 3. Disconnect the black (negative) battery cable first. 4. Disconnect the red (positive) battery cable next. 5. Lift the battery out of the vehicle, bei...

Page 112 - Battery Installation

110 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...

Page 113 - SPECIFICATIONS

111 SPECIFICATIONS RANGER 2x4 RANGER 4x4 RANGER 6x6 Gross Vehicle Weight 2500 lbs. (1135 kg) 2700 lbs. (1226 kg) 2900 lbs. (1317 kg) Fuel Capacity 8.0 gal. (30 l) 8.0 gal. (30 l) 8.0 gal. (30 l) Towing Capacity 1400 lbs. (636 kg) 1500 lbs. (681 kgs) 1500 lbs. (681 kgs) Max. Cargo Box Load 850 lbs. (...

Page 115 - TROUBLESHOOTING

113 TROUBLESHOOTING ENGINE CRANKS BUT FAILS TO START No Fuel Water in Fuel Spark Plug Drain System No Spark to Spark Plug Contact Your Dealer ENGINE STOPS OR LOSES POWER No Fuel Contact Your Dealer Contact Your Dealer Overuse of Choke Spark Plug Fouled Engine Overheated Clean Engine Exterior Water i...

Page 116 - Procedures; Under certain conditions, it may be possible for the AWD system to

114 TROUBLESHOOTING Procedures The following information is provided to help you identify probable causes for questions you may have about the operation of your vehicle. See your Polaris dealer with any additional questions you may have. Disengaging AWD System Under certain conditions, it may be pos...

Page 117 - WARRANTY; LIMITED WARRANTY; REGISTRATION

115 WARRANTY LIMITED WARRANTY Polaris Sales Inc., P.O. Box 47700, Hamel, Minnesota 55340-9960, gives a SIX MONTH LIMITED WARRANTY on all components of the Polaris RANGER against defects in material or workmanship. This warranty covers the parts and labor charges for repair or replacement of defectiv...

Page 118 - HOW TO OBTAIN WARRANTY SERVICE

116 WARRANTY This warranty does not cover the use of unauthorized lubricants, chemicals, or fuels that are not compatible with the vehicle. The exclusive remedy for breach of this warranty shall be, at Polaris’ exclusive option, repair or replacement of any defective materials, or components or prod...

Page 119 - INDEX

117 INDEX Accessory Plug 51 . . . . . . . . . . . . . . . . . Air Cleaner 87 . . . . . . . . . . . . . . . . . . . . Airbox 48 . . . . . . . . . . . . . . . . . . . . . . . All Wheel Drive (AWD) 55 . . . . . . . . . . AWD Switch 51, 54 . . . . . . . . . . . . . . . . Backing Up 34 . . . . . . . . . ...