Polaris 2010 Ranger XP- User Manual

5 INTRODUCTION 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 occur quickly, ev...

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

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

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

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

15 SAFETY Operator Safety Equipment Modifications 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 modifications to the vehicle for these pur- poses. Any modifications to the original equipmen...

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

17 SAFETY Operator Safety Seat Belts Riding in this vehicle without wearing the seat belt increases the risk of serious injury in the event of an accident or sudden stop. Riders must wear seat belts at all times. Seat belts reduce the severity of injury in the event of a sudden stop or accident. Alw...

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

19 SAFETY Operator Safety Operating on Public Roads Operating this vehicle on public streets, roads or highways could result in a collision with another vehicle.Never operate this vehicle on any public street, road or highway, including dirt and gravel roads. In some areas it's unlawful to operate t...

20 SAFETY Operator Safety Operating on Slippery Terrain Failure to use extra caution when operating on excessively rough, slippery or loose terrain could cause loss of traction, loss of control, accident or overturn.Do not operate on excessively slippery surfaces.Always reduce speed and use addition...

21 SAFETY Operator Safety Improper Tire Maintenance Operating this vehicle with improper tires or with improper or uneven tire pressure could cause loss of control or accident.Always use the size and type of tires specified for your vehicle.Always maintain proper tire pressure as described in the ow...

22 FEATURES AND CONTROLS Component Locations Not all models come with all features. Refer to the specifications section beginning on page 110. Headlights Front Bumper/Brush Guard Radiator ROPS Cab Frame Console Hip Bar Cargo Box Fuel Tank Cap

24 FEATURES AND CONTROLS Console Auxiliary Outlets The 12-volt receptacles have spade connections on the back that may be used to power an auxiliary light or other optional accessories or lights. The con- nections are behind the console, under the dash.On Crew models, an additional receptacle is loc...

25 FEATURES AND CONTROLS Console Mode Button The yellow button located directly under the speedometer is used to tog- gle through mode options available such as odometer, trip meter, hour meter and tachometer. See page 35 for operation of the modes. Gear Selector H: High GearL: Low GearN: NeutralR: ...

26 FEATURES AND CONTROLS Switches Ignition Switch The ignition switch is a three-position, key-operated switch. The key can be removed from the switch when it is in the OFF position. Light Switch The ignition switch key must be in the ON/RUN position to operate the headlights. Use the light switch t...

27 FEATURES AND CONTROLS Switches AWD/Differential Lock Switch The AWD/Differential Switch has three positions:• All Wheel Drive (AWD)• Differential Lock (2WD)• Differential UnlockPress the top of the rocker switch to engage All Wheel Drive (AWD). See page 59 for operating instructions.Move the rock...

28 FEATURES AND CONTROLS Trailer Hitch Bracket This vehicle is equipped with a receiver hitch bracket for a trailer hitch. To avoid injury and property damage, always heed the warnings and towing capacities outlined on pages 54-56. Brake Pedal Depress the brake pedal to slow or stop the vehicle. App...

29 FEATURES AND CONTROLS Park Brake Lever To help prevent the vehicle from rolling, engage the park brake when parking the vehicle. When the park brake is fully engaged and the park brake indicator is illuminated, engine speed is limited to 1300 RPM in all gears, except neutral. If throttle is appli...

31 FEATURES AND CONTROLS Seat Belts Seat Belt Inspection Inspect all 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 ...

32 FEATURES AND CONTROLS Rollover Protective Structure (ROPS) The Rollover Protective Structure (ROPS) on this vehicle meets OSHA 1928.53 rollover performance requirements. Always have your autho- rized Polaris dealer thoroughly inspect the ROPS if it ever becomes damaged in any way. No device can a...

33 FEATURES AND CONTROLS Instrument Cluster The instrument cluster measures distance traveled by the vehicle, as well as time, hours of operation and engine RPM. Tip: In addition to showing vehicle speed, the speedometer needle flashes when a low fuel condition exists. Rider Information Center Speed...

34 FEATURES AND CONTROLS Instrument Cluster Rider Information Center The rider information center is located in the instrument cluster. All seg- ments will light up for 2.5 seconds at start-up. Tip: If the instrument cluster fails to illuminate, a battery over-voltage may have occurred and the instr...

35 FEATURES AND CONTROLS Instrument Cluster Rider Information Center Standard Modes Use the yellow mode button located under the speedometer to toggle through the mode options. See page 24. Odometer Mode The odometer records the miles traveled by the vehicle. Trip Meter Mode The trip meter records t...

36 FEATURES AND CONTROLS Instrument Cluster Rider Information Center Diagnostic Mode The wrench icon will display when the gauge is in the diagnostic mode. To exit the diagnostic mode, turn the key switch off and on. Any move- ment of the tires will also cause the gauge to exit the diagnostic mode.T...

37 FEATURES AND CONTROLS Instrument Cluster Rider Information Center Diagnostic Mode Battery Voltage Screen View this screen to check battery voltage level. Tachometer Screen View the tachometer to check engine speed. AWD Diagnostic Screen The gauge indicates whether or not current is flowing throug...

38 FEATURES AND CONTROLS Instrument Cluster Rider Information Center Diagnostic Mode Programmable service interval To enable or disable the service interval: 1. Enter the diagnostic mode. 2. Toggle to the service interval screen. 3. Press and hold the mode button for about seven (7) seconds, until e...

39 FEATURES AND CONTROLS Instrument Cluster Rider Information Center Accessing Blink Codes The EFI diagnostic mode is for informational purposes only. Please see your Polaris dealer for all major repairs. See page 40 for Blink Codes and Failure Descriptions. Use the follow- ing procedure to access b...

40 FEATURES AND CONTROLS Instrument Cluster Rider Information Center Blink Code Descriptions Blink Code Failure Description -- No RPM Signal 21 Loss of Synchronization 45 Barometric Pressure Sensor: Circuit Low Input 46 Barometric Pressure Sensor: Circuit High Input 22 TPS: Open or Short Circuit to ...

41 OPERATION Failure to operate the vehicle properly can result in a collision, loss of control, accident or overturn, which may result in serious injury or death. Read and understand all safety warnings outlined in the safety section of this owner’s manual. Break-In Period The break-in period for y...

42 OPERATION Break-In Period Engine and Drivetrain Break-in 1. Fill the fuel tank with gasoline. Review the gasoline warnings on page 17. 2. Check the oil level. Add the recommended oil as needed to maintain the oil level in the normal (safe) operating range. 3. Drive slowly at first. Select an open...

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

44 OPERATION Starting the Engine 1. Always start the engine outdoors or in a well-ventilated area.2. Sit in the driver's seat and fasten the seat belt.3. Apply the brakes. Engage the park brake. 4. Shift the transmission to neutral.5. Do not press the throttle pedal while starting the engine. Turn t...

45 OPERATION Stopping the Engine 1. Release the throttle pedal completely and brake to a complete stop.2. Turn the engine off.3. Engage the park brake. WARNING! A rolling vehicle can cause serious injury. Always engage the park brake after stopping the engine. Braking 1. Release the throttle pedal c...

46 OPERATION Driving Procedure 1. Wear a helmet and eye protection.2. Perform the pre-ride inspection. See page 43.3. Sit in the driver's seat and fasten the seat belt.4. Start the engine and allow it to warm up. 5. Apply the service brakes and shift the transmission into gear.6. Check your surround...

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

48 OPERATION Driving Uphill Whenever traveling uphill, follow these pre- cautions:1. Always travel straight uphill. 2. Avoid steep hills (15 ° maximum). 3. Keep both feet on the floor. 4. Always check the terrain carefully before ascending any hill. 5. Never climb hills with excessively slippery or ...

49 OPERATION Driving on a Sidehill (Sidehilling) Driving on a sidehill is not recommended. Improper procedure could cause loss of control or overturn. Avoid crossing the side of any hill unless absolutely necessary.If crossing a sidehill is unavoidable , follow these precautions: 1. Slow down.2. Exe...

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

51 OPERATION Driving Over Obstacles Follow these precautions when operating over obstacles:1. Always check for obstacles before operating in a new area.2. Look ahead and learn to read the terrain. Be constantly alert for haz- ards such as logs, rocks and low hanging branches. 3. Travel slowly and us...

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

53 OPERATION Parking on an Incline Avoid parking on an incline if possible. If it's unavoidable, follow these precautions:1. Apply the brakes. 2. Place the transmission in gear.3. Engage the park brake.4. Turn the engine off.5. Block the rear wheels on the downhill side. 15 ° maximum

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

56 OPERATION Towing Loads Towing improperly can alter vehicle handling and may cause loss of control or brake instability. Always follow these precautions when tow- ing:1. Never load more than 150 lbs. (68.1 kg) tongue weight on the tow- ing bracket. 2. Do not operate the vehicle faster than 10 mph ...

57 OPERATION Dumping the Cargo Box 1. Select a level site to dump the cargo box. Do not attempt to dump or unload the vehicle while parked on an incline. 2. Apply the brakes. 3. Place the transmission in gear.4. Engage the park brake.5. Dismount the vehicle.6. Ensure that the cargo is posi- tioned e...

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

59 OPERATION All Wheel Drive (AWD) Engaging AWD Press the top of the rocker switch to engage All Wheel Drive (AWD). The illuminated amber AWD switch indicates that the vehicle is in AWD.When the AWD switch is on, the front wheels will automatically engage any time the rear wheels lose traction. When...

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

61 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. Polaris warrants tha...

62 MAINTENANCE Periodic Maintenance Chart Careful periodic maintenance will help keep your vehicle in the safest, most reliable condition. Inspection, adjustment and lubrication of important components are explained in the periodic maintenance chart.Inspect, clean, lubricate, adjust and replace part...

63 MAINTENANCE Periodic Maintenance Chart Maintenance Chart Key X Perform these operations more often 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.) Q Have an authorized Polaris dea...

67 MAINTENANCE Lubrication Recommendations Check and lubricate all components at the intervals outlined in the Peri- odic Maintenance Chart beginning on page 62, or more often under severe use, such as wet or dusty conditions. Items not listed in the chart should be lubricated at the general lubrica...

68 MAINTENANCE Engine Intake Restrictor Plate Some RANGER 800 models are equipped with an intake restrictor plate in order to meet vehicle class regulations. This plate MUST NOT be removed for any reason. Removal of the intake restrictor plate will void the warranty on the vehicle. Engine Oil Always...

69 MAINTENANCE Engine Oil Always check and change the oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 62. Always use the recommended engine oil. Oil Check The oil dipstick and fill tube is located on the engine.1. Position the vehicle on a level surface. 2. Lift the...

70 MAINTENANCE Engine Oil Oil and Filter Change Always change the oil and filter at the intervals outlined in the Periodic Maintenance Chart beginning on page 62. Always change the oil filter whenever changing oil.1. Position the vehicle on a level surface.2. Run the engine for two to three minutes ...

71 MAINTENANCE Engine Oil Oil and Filter Change 13. Remove the dipstick and fill the sump with two quarts (1.9 l) of rec- ommended oil. 14. Shift the transmission to neutral. 15. Apply the brakes. Engage the park brake.16. Start the engine. Allow it to idle for one to two minutes. 17. Stop the engin...

72 MAINTENANCE Gearcases Gearcase Specification Chart RANGER 4X4 Gearcase Specifications Gearcase Lubricant Capacity Fill Plug Torque Drain Plug Torque Main Gearcase (Transmission) Premium AGL Synthetic Gearcase Lube 34 oz. (1000 ml) 12 ft. lbs. (16.3 Nm) 12 ft. lbs. (16.3 Nm) Front Gearcase Premium...

73 MAINTENANCE Gearcases Transmission (Main Gearcase) (4X4/Crew) Always check and change the transmission oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 62. Maintain the oil level even with the bottom of the fill plug hole threads.Refer to the Gearcase Specificatio...

74 MAINTENANCE Gearcases Transmission (Main Gearcase) (6X6) Always check and change the transmission oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 62. Maintain the oil level even with the bottom of the fill plug hole.Refer to the Gearcase Specifications Chart on p...

75 MAINTENANCE Gearcases Front Gearcase Always check and change the front gearcase oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 62. Maintain the oil level even with the bottom thread of the fill plug hole. Refer to the Gearcase Specifications Chart on page 72 for...

76 MAINTENANCE Gearcases Middle Gearcase (6X6) Always check and change the middle gearcase oil at the intervals out- lined in the Periodic Maintenance Chart beginning on page 62. Maintain the oil level even with the bottom thread of the fill plug hole.Refer to the Gearcase Specifications Chart on pa...

77 MAINTENANCE Gearcases Rear Gearcase (6X6) Always check and change the rear gearcase oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 62.Refer to the Gearcase Specifications Chart on page 72 for recommended lubricants, capacities and torque specifications. See page...

78 MAINTENANCE Spark Plugs Spark Plug Recommendations Refer to the specifications section beginning on page 110 for the recom- mended spark plug type for your vehicle. Always torque spark plugs to specification. NOTICE: Using non-recommended spark plugs can result in serious engine damage. Always us...

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

80 MAINTENANCE Cooling System Radiator and Cooling Fan Always check and clean the screen and radiator fins at the intervals out- lined in the Periodic Maintenance Chart beginning on page 62. Do not obstruct or deflect air flow through the radiator by installing unautho- rized accessories in front of...

81 MAINTENANCE Cooling System Radiator Coolant Level 1. Lift the hood. CAUTION! Escaping steam can cause burns. Never remove the pressure cap while the engine is warm or hot. Always allow the engine to cool before removing the pressure cap. 2. Slowly remove the radiator cap. 3. View the coolant leve...

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

83 MAINTENANCE 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 operat- ing.1. Position the vehicle on a level surface.2. Remove the drain plug. Allow the water to drain completely. Rein- stal...

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

85 MAINTENANCE Filter Systems Air Filter Always change the air filter at the intervals outlined in the Periodic Maintenance Chart beginning on page 62. Service the air filter more fre- quently if the vehicle is operated in wet conditions or at high throttle openings for extended periods.1. Lift the ...

86 MAINTENANCE Spark Arrestor 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 components to cool sufficiently ...

88 MAINTENANCE Throttle System Failure to check or maintain proper operation of the throttle system can result in an accident and lead to serious injury or death if the throttle pedal sticks during operation.Always check the pedal for free movement and return before starting the engine and occasiona...

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

90 MAINTENANCE Brakes The front and rear brakes are hydraulic disc type brakes activated by the brake pedal. See page 28. Brake Fluid Inspect the brake system routinely. Inspect the level of the brake fluid before each operation. WARNING! After opening a bottle of brake fluid, always discard any unu...

91 MAINTENANCE Brakes Brake Inspection 1. Check the brake system for fluid leaks. 2. Check the brake pedal for excessive travel or a spongy feel. 3. Check the friction pads for wear, damage and looseness. 4. Inspect the brake disc spline and pad wear surface for excessive wear. 5. Change pads when w...

92 MAINTENANCE Brakes Park Brake Adjustment Inspect and adjust park brake cable tension after the first 25 hours of operation and every 100 hours thereafter to ensure proper cable tension. Loss of tension in the park brake cable may cause illumination of the park brake light and activation of the li...

93 MAINTENANCE Suspension Adjustments The front and rear suspensions can be adjusted to provide a stiffer sus- pension, if necessary.1. Remove the top shock mounting bolts from the inside mounting holes. 2. Reposition the shocks to the outside mounting holes.3. Reinstall the shock mounting bolts. To...

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

95 MAINTENANCE Tires Wheel Removal 1. Apply the brakes. Engage the park brake. 2. Stop the engine. Place the transmission in gear.3. Loosen the wheel nuts slightly.4. Elevate the side of the vehicle by placing a suitable stand under the frame. 5. Remove the wheel nuts and washers. Remove the wheel. ...

96 MAINTENANCE Lights Poor lighting can result in reduced visibility when driving. Headlight and taillight lenses become dirty during normal operation. Clean lights frequently and replace burned out lamps promptly. Always make sure lights are adjusted properly for best visibility.When servicing a ha...

97 MAINTENANCE Lights Headlight Beam Adjustment 1. Place the vehicle on a level surface with the headlight approxi- mately 25 ft. (7.6 m) from a wall. 2. Place the transmission in gear. Engage the park brake.3. Measure the distance from the floor to the center of the headlight and make a mark on the...

98 MAINTENANCE Fuses If the engine stops or will not start, or if you experience other electrical failures, a fuse may need replacement. Locate and correct any short circuits that may have caused the blown fuse, then replace the fuse. Spare fuses are pro- vided in the fuse box. If you suspect that a...

99 MAINTENANCE Battery Battery electrolyte is poisonous. It contains sulfuric acid. Serious burns can result from contact with skin, eyes or clothing.Antidote: External : Flush with water. Internal : Drink large quantities of water or milk. Follow with milk of magnesia, beaten egg, or vegetable oil....

100 MAINTENANCE Battery Battery Removal Improperly connecting or disconnecting battery cables can result in an explosion and cause serious injury or death. When removing the battery, always disconnect the negative (black) cable first. When reinstalling the battery, always connect the negative (black...

101 MAINTENANCE Battery Battery Installation Using a new battery that has not been fully charged can damage the bat- tery and result in a shorter life. It can also hinder vehicle performance. Follow the battery charging instructions on page 102 before installing the battery.1. Ensure that the batter...

102 MAINTENANCE Battery Battery Charging (Conventional Battery) 1. Remove the battery from the vehicle to prevent damage from leak- ing or spilled electrolyte during charging. See page 100. 2. Charge the battery with a charging output no larger than 1/10 of the battery’s amp/hr rating. Charge as nee...

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

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

105 MAINTENANCE Cleaning and Storage Washing the Vehicle If a high pressure water system is used for cleaning (not recommended), exercise extreme caution. The water may damage components and could remove paint and labels. Avoid directing the water stream at the follow- ing items: • Wheel bearings• R...

106 MAINTENANCE Cleaning and Storage Chrome Wheel Care (if equipped) Proper maintenance will protect chrome wheels from corrosion, pre- serve wheel life and ensure a “like new” appearance for many years. Chrome wheels exposed to road salt (or salt in the air in coastal areas) are more susceptible to...

107 MAINTENANCE Cleaning and Storage Storage Tips NOTICE: Starting the engine during the storage period will disturb the protective film created by fogging and damage could occur. Never start the engine during the storage period. Clean the Exterior Make any necessary repairs and clean the vehicle as...

108 MAINTENANCE Cleaning and Storage Storage Tips Fluid Levels Inspect the fluid levels. Add or change fluids as recommended in the Periodic Maintenance Chart beginning on page 62.• Front gearcase fluid• Rear and Middle gearcase fluids (6X6)• Transmission fluid• Brake fluid (change every two years a...

109 MAINTENANCE Removal from Storage 1. Check the battery electrolyte level and charge the battery if neces- sary. Install it in the vehicle. Make sure the battery vent hose is routed properly and that it's not pinched or restricted in any way. 2. Make sure the spark plug is tight.3. Fill the fuel t...

110 SPECIFICATIONS RANGER 4X4 Maximum Weight Capacity 1500 lbs. (681 kg) (includes weight of operator, passenger, cargo, accessories) Dry Weight 1237 lbs. (561 kg) Fuel Capacity 8.8 gal. (33.3 l) Engine Oil Capacity 1.9 qts. (1.8 l) Coolant Capacity 3.25 qts. (3 l) Towing Capacity 2000 lbs. (907 kg)...

111 SPECIFICATIONS Clutching See your Polaris dealer for clutching specifications. RANGER 4X4 Lubrication System Pressurized Wet Sump Engine Oil Polaris 2W-50 Driving System Type PVT, 4-wheel independent shaft, lockable differ- ential Shift Type Single Lever (H/L/N/R) Gear Reduction - Low 7.70:1 Gea...

114 SPECIFICATIONS RANGER CREW Maximum Weight Capacity 1750 lbs. (795 kg) (includes weight of operator, passengers, cargo, accessories) Dry Weight 1510 lbs. (685 kg) Fuel Capacity 8.8 gal. (33.3 l) Engine Oil Capacity 2 qts. (1.9 l) Coolant Capacity 1.6 gal. (6 l) Towing Capacity 2000 lbs. (907 kg) ...

116 POLARIS PRODUCTS Part Number Description Engine Lubricant 2870791 Fogging Oil (12 oz. Aerosol) 2876244 PS-4 PLUS Performance Synthetic 2W-50 4-Cycle Oil (qt.) 2876245 PS-4 PLUS Performance Synthetic 2W-50 4-Cycle Oil (gal.) Gearcase / Transmission Lubricants 2873602 Premium AGL Synthetic Gearcas...

117 TROUBLESHOOTING Drive Belt Wear/Burn Possible Cause Solution Driving onto a pickup or tall trailer in high range Use low range during loading. Starting out going up a steep incline Use low range. See warnings on page 48. Driving at low RPM or ground speed (3-7 MPH) Drive at a higher speed or use...

118 TROUBLESHOOTING Park Brake Engine Limiting Feature Fails to Disengage Engine Doesn't Turn Over Engine Turns Over, Fails to Start Engine Backfires Possible Cause Solution Park brake is not completely disengaged Ensure lever is in forward-most position Park brake connector malfunction or switch mo...

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

120 TROUBLESHOOTING Engine Stops or Loses Power Possible Cause Solution Out of fuel Refuel Kinked or plugged fuel vent line Inspect and replace Water is present in fuel Replace with new fuel Fouled or defective spark plugs Inspect, clean and/or replace spark plug Worn or defective spark plug wires S...

121 DECLARATION OF CONFORMITY Polaris Industries Inc., 2100 Hwy 55, Medina, MN 55340 U.S.A.Telephone 763-542-0500 We, Polaris Industries Inc., declare that the vehicles listed below conform to the essential health and safety requirements applicable to off-road all-terrain vehicles. PRODUCT IDENTIFIC...

122 WARRANTY LIMITED WARRANTY Polaris Sales Inc., 2100 Highway 55, Medina, MN 55340, gives a SIX MONTH LIM- ITED WARRANTY on all components of the Polaris RANGER against defects in mate- rial or workmanship. Polaris also gives a one year limited warranty on the final drive chain (if equipped) for fa...

123 WARRANTY LIMITATIONS OF WARRANTIES AND REMEDIES Warranty applies to the product only and does not allow for coverage of personal loss. Some items are considered "consumable," meaning they are considered part of normal maintenance or part of completing an effective repair. The following i...

124 WARRANTY LIMITATIONS OF WARRANTIES AND REMEDIES ALL IMPLIED WARRANTIES (INCLUDING BUT NOT LIMITED TO THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PAR- TICULAR PURPOSE) ARE LIMITED IN DURATION TO THE ABOVE SIX MONTH WARRANTY PERIOD. POLARIS FURTHER DISCLAIMS ALL EXPRESS WARRANTIES ...

125 WARRANTY Exported Vehicles EXCEPT WHERE SPECIFICALLY REQUIRED BY LAW, THERE IS NO WAR- RANTY OR SERVICE BULLETIN COVERAGE ON THIS VEHICLE IF IT IS SOLD OUTSIDE THE COUNTRY OF THE SELLING DEALER'S AUTHORIZED LOCA- TION.This policy does not apply to vehicles that have received authorization for ex...

128 WARRANTY California Emission Control Warranty Statement(4X4 Model Only) Your Warranty Rights and Obligations The California Air Resources Board is pleased to explain the emission control system warranty on your 2005 and later Large Spark Ignition Engine (herein “LSI engine”). In California, new ...

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

132 INDEX A Accessory Outlets . . . . . . . . . . . . . . 24 Air Filter . . . . . . . . . . . . . . . . . . . . . 85 Air Filter Cleaning . . . . . . . . . . . . . . 85 All Wheel Drive . . . . . . . . . . . . . 59-60 Disengaging AWD. . . . . . . . . . 59 Engaging AWD . . . . . . . . . . . . 59 Lockin...