Polaris Series 11 Ranger- Manuals

4 VEHICLE IDENTIFICATION NUMBERS The vehicle frame vehicle identification number (VIN)(1), engine serial number and vehicle model number (2) are important for model identification when registering your vehicle, when obtaining insurance, and when ordering replacement parts. In the event your vehicle ...

5 TABLE OF CONTENTS WELCOME 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . VEHICLE IDENTIFICATION NUMBERS 4 . . . . . . . . TABLE OF CONTENTS 5 . . . . . . . . . . . . . . . . . . . . . . SAFETY 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FEATURES 25 ...

7 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...

8 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 RANGER or in this manual, ...

11 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 o...

12 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...

20 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 SEAT BELT for maximum protection. WARNING IMPROPER TIRE PRESSURE OR OVERLOADING can cause loss of control resultin...

21 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...

22 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 Box Load 850 lbs. Maximum 4x4 Box Load 1000 lbs....

23 SAFETY Safety Decals and Locations Warning Decal Text 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 while ope...

24 SAFETY Fuel Safety 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 near th...

25 FEATURES Component Locations 1. Cab Frame2. Cab Frame Hand Hold3. Console4. Steering Wheel5. Seat6. Cargo Box7. Seat Belts8. Fuel Tank Cap / Fuel Gauge9. Battery (under driver’s seat) 1 4 7 5 6 2 3 8 9

28 FEATURES Auxiliary Outlet The 12-volt receptacle (1) has spade connections on the back that may be used to power an auxiliary light or other optional accessories or lights. The connections are behind the console, under the hood. Indicator Lights The indicator lights on the console display:1. High...

29 FEATURES 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 is equipped w...

30 FEATURES AND CONTROLS Console 1. Storage Box2. Cup Holder3. Indicator Lights4. Light Switch5. AWD Switch (if equipped)6. Hour Meter7. Glove Box with Lid8. 12V Accessory Plug9. Storage Tray10. Choke Knob11. Ignition Switch12. Shift Lever13. Differential Lock Lever (2x4 and 4x4) 11 10 6 3 8 13 12 7...

31 CONTROLS Gear Selector The transmission gear selector (1) is located on the console to the right of the steering wheel. It has four positions (2): high, low, neutral and reverse. NOTE: Low is the primary driving range for this vehicle. High is intended for use on hard-packed surfaces with light l...

32 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 Turn the headlights and taillights on by flipping the light switch up (the ignition switch key must be in the ON posi...

33 CONTROLS Brake Pedal The brake pedal (1) is the left pedal on the foot board. Depress the brake pedal to slow or stop the vehicle. Throttle Pedal The throttle pedal (2) is the right pedal on the floor board. Push the pedal down to increase engine speed. Spring pressure returns the pedal to the re...

34 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 ...

35 OPERATION Pre-Ride Inspection Inspect your vehicle before each operation to ensure it’s in proper working order.Before operating your vehicle, inspect all operating controls and parts. Item/Inspection Procedure 1. Tires - check condition and pressures 2. Fuel and oil tanks - fill both tanks to th...

36 OPERATION Starting the Engine Starting a Cold Engine 1. Place the transmission in neutral. 2. Lock the parking brake. 3. Sit in the driver’s seat and fasten your seat belt. 4. Pull the choke knob (1) all the way out. 5. Turn the ignition key to START. 6. If the engine does not start within five s...

37 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...

38 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,...

39 OPERATION Driving Safely Driving Procedures 1. Sit in the driver’s seat with the seat belt 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 bo...

40 SAFETY 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 level...

41 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. 15 _ Maximum WARNING Climbing hills imprope...

42 OPERATION Driving Safely 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. Crossing hillsides or turning on hills can result in loss of control or vehicle overturn, resultin...

43 OPERATION Driving Safely Driving Through Water Your Polaris RANGER can operate through water up to a maximum recommended depth equal to the floorboards (1). Follow these procedures when operating through water:1. Always determine water depths and current before entering. 2. Choose a crossing wher...

44 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. Severe injury or death can result if your vehicle suddenly comes in contact with a hidden obstacle. Not all obsta...

45 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...

46 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...

47 OPERATION 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. Maximum Capacities (Level Ground) Cargo Box RANGER 2X4 1350 lbs. (614 kg) 850 lb...

48 OPERATION Hauling Cargo 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. Ensure that the cargo is positioned evenly or toward the front of the cargo bo...

49 OPERATION Hauling Cargo Towing Loads Maximum 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 1...

50 OPERATION Driving Safely Parking the RANGER 1. Stop the vehicle on a level surface. 2. When the engine has stopped, apply the parking brake. 3. Remove the ignition switch key to prevent unauthorized use. WARNING A rolling vehicle can cause property damage and serious injury. Always apply the park...

51 OPERATION All Wheel Drive (AWD) Your Polaris RANGER (4X4 and 6X6) is equipped with an exclusive Polaris All Wheel Drive (AWD) system that can be activated by a switch on the console. When the switch is off, the RANGER is in two-wheel drive at all times. When the switch is on, the RANGER is in AWD...

53 NOISE EMISSION CONTROL SYSTEM TAMPERING WITH NOISE CONTROL SYSTEM IS 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 element of des...

54 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 schedule.Maintenance intervals are bas...

58 MAINTENANCE AND LUBRICATION Lubrication Recommendations NOTE: Hours are based on 10 mph average. If service is due at 20 hours, the equivalent odometer reading would be 200 miles. Perform all services at whichever reading is reached first. Lubrication Chart Key " More often under severe use, ...

60 MAINTENANCE AND LUBRICATION Engine Oil Premium 4 Synthetic Lubricant Polaris Premium 4 All Season Synthetic engine oil has been specially formulated for use in Polaris 4-cycle engines. It’s a fully synthetic, high performance, multi-viscosity oil designed to provide the ultimate in lubrication pe...

61 MAINTENANCE AND LUBRICATION Engine Oil Maintain the engine oil at the proper level to ensure a properly functioning engine, and change the oil and oil filter every 100 hours or every six months, whichever comes first. Dirt and metal particles collect in the oil, and oil loses its lubricative qual...

62 MAINTENANCE AND LUBRICATION Engine Oil Oil and Filter Change 1. Run the engine two to three minutes until warm. Stop the engine. 2. Clean the area around the drain plug (B) at the bottom of the oil tank. 3. Place a drain pan beneath the oil tank and remove the drain plug. Allow the oil to drain c...

63 MAINTENANCE AND LUBRICATION Engine Oil Oil and Filter Change 14. Install the new filter and turn by hand until the filter gasket contacts the sealing surface, then turn and additional 1/2 turn. 15. Approximately one cup of engine oil will remain in the crankcase. To drain, remove the drain plug o...

64 MAINTENANCE AND LUBRICATION Gearcases Transmission (Main Gearcase) The transmission lubricant level should be checked at 25 hours or monthly, whichever comes first. Transmission oil should be changed annually. NOTE : Refer to the Gearcase Specifications Chart on page 67. Always use Polaris Premiu...

65 MAINTENANCE AND LUBRICATION Gearcases Front Gearcase The front gearcase lubricant level should be checked every six months or 100 hours, whichever comes first. The oil should be changed annually. If the vehicle is used in wet conditions, the oil should be checked more frequently. If the oil has a...

66 MAINTENANCE AND LUBRICATION Gearcases Middle Gearcase The middle gearcase lubricant level should be checked at 25 hours or monthly, whichever comes first. Middle gearcase oil should be changed annually. NOTE : Refer to the Gearcase Specifications Chart on page 67. Always use Polaris Premium Gearc...

67 MAINTENANCE AND LUBRICATION Gearcases Rear Gearcase The rear gearcase lubricant level should be checked at 25 hours or monthly, whichever comes first. Oil should be changed annually. NOTE : Refer to the Gearcase Specifications Chart on page 67. Always use Polaris Premium Gearcase Lube. See page 9...

68 MAINTENANCE AND LUBRICATION Cooling System Operation The overflow bottle (1) is located in front of the right front tire of the vehicle. The coolant level must be maintained between the minimum and maximum marks on the overflow bottle.The engine coolant level is controlled or maintained by the re...

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

70 MAINTENANCE AND LUBRICATION Cooling System Radiator and Cooling Fan Check and clean the screen and radiator fins for obstructions caused by insects or mud. Refer to the Periodic Maintenance Schedule beginning on page 54. Do not obstruct or deflect air flow through the radiator by installing unaut...

71 MAINTENANCE AND LUBRICATION Polaris Variable Transmission (PVT) System PVT Drying There may be some instances when water is accidently ingested into the PVT system. Use the following instructions to dry it out before operating.1. Shift the transmission into neutral and apply full throttle for no ...

72 MAINTENANCE AND LUBRICATION Vehicle Immersion If it’s impossible to take your RANGER to a dealer before starting it, follow the steps outlined below.1. Move the vehicle to dry land, or at the very least, to a water level below the floor. 2. Disconnect the fuel pump wires. 3. Remove the spark plug...

73 MAINTENANCE AND LUBRICATION Filter Systems Air Filter Service We recommended that the air filter be replaced annually. When operating in extremely dusty conditions, it should be replaced more often.1. Lift the cargo box to access the airbox. 2. Remove the airbox cover and inspect the gasket. It s...

74 MAINTENANCE AND LUBRICATION Filter Systems Breather Filter and Hoses 1. Lift the cargo box and locate the airbox (1). 2. Follow the right-hand breather line out the side of the airbox and locate the filter (2). 3. Remove and inspect the filter for debris. Blow gently through the filter in the dir...

75 MAINTENANCE AND LUBRICATION Spark Plugs S Use NGK BKR5ES spark plugs. S Proper electrode gap is .025 ″ (.06 cm). S Spark plug torque is 14 ft. lbs.(19 Nm). Spark plug condition is indicative of engine operation. The spark plug firing end condition should be read after the engine is warmed up and ...

76 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...

78 MAINTENANCE AND LUBRICATION Throttle System 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. The throttle may also not open fully. If the throttle pedal has no fr...

79 MAINTENANCE AND LUBRICATION Throttle System Throttle Freeplay Adjustment 1. Slide the boots (1) off the inline cable adjuster sleeve (2). Loosen the adjuster locknut (3). 2. Turn the adjuster until 1/16 to 1/8 inch freeplay is achieved. NOTE: While adjusting freeplay, you must flip the throttle l...

80 MAINTENANCE AND LUBRICATION Carburetor/Engine Idle RPM Adjustment The idle speed adjustment should be performed as outlined in the Periodic Maintenance Schedule, or whenever the idle speed is changed.Recommended engine idle RPM is 1200 +/- 200. If the engine idle speed is not satisfactory, and al...

81 MAINTENANCE AND LUBRICATION Brakes Brake Inspection The front and rear brakes are hydraulic disc type brakes and are activated by the brake pedal. See page 33.Routine inspections are recommended to keep the brake system in good operating condition. Inspect the level of the brake fluid before each...

83 MAINTENANCE AND LUBRICATION Steering Wheel Inspection Check the steering wheel for specified freeplay and smooth operation as outlined in the Periodic Maintenance Schedule.1. Park the vehicle on level ground.2. Lightly turn the steering wheel left and right.3. There should be 0.8 - 1.0 in (20 - 2...

84 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...

85 MAINTENANCE AND LUBRICATION Tires Tire Tread Depth Always replace tires when tread depth is worn to 1/8 ″ (.3 cm) or less. Axle and Wheel Nut Torque Specifications Inspect the following items occasionally for tightness, and if they’ve been loosened for maintenance service. Front Spindle Nut(s) De...

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

87 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. Headlight Beam Adjustment 1. Place the vehicle on a level surface with the headlight approximat...

88 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 ...

89 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...

90 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...

91 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...

92 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...

93 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 bo...

94 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. (3...

96 POLARIS RECOMMENDED PRODUCTS Part No. Description Engine Lubricant 2870791 Fogging Oil (12 oz. Aerosol) 2871098 Premium 2 Cycle Engine Oil (Quart) 2871281 Engine Oil (Quart) Premium 4 Synthetic 0W-40 (4-Cycle) 2871844 Engine Oil (Gallon) Premium 4 Synthetic 0W-40 (4-Cycle) 2871567 Engine Oil (16 ...

97 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 al...

98 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 your...

99 TROUBLESHOOTING Engine Stops or Loses Power Possible Cause Solution Out of fuel Turn fuel valve to reserve, 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 ...

100 WARRANTY LIMITED WARRANTY Polaris Industries Inc., 2100 Highway 55, Medina, MN 55340, 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 defective par...

101 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...

102 INDEX A Adding or Changing Coolant 68 . . . . . . . . . . Age Restrictions 7 . . . . . . . . . . . . . . . . . . . . . Air Filter 73 . . . . . . . . . . . . . . . . . . . . . . . . . . All Wheel Drive (AWD) 51 . . . . . . . . . . . . . . Auxiliary Outlet 28 . . . . . . . . . . . . . . . . . . . ...