Page 4 - WELCOME; RANGER
1 WELCOME Thank you for purchasing a Polaris vehicle, and welcome to our world- wide family of Polaris owners. We proudly produce an exciting line of utility and recreational products. • Snowmobiles• All-terrain vehicles (ATVs)• RANGER utility vehicles • Victory motorcyclesWe believe Polaris sets a ...
Page 6 - TABLE OF CONTENTS
3 TABLE OF CONTENTS Vehicle Identification Numbers . . . . . . . . . . . . . 4Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5Features and Controls . . . . . . . . . . . . . . . . . . . 22Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38Emission Control...
Page 7 - VEHICLE IDENTIFICATION NUMBERS; spaces provided. Remove the spare key and store it in a safe place. An; Engine Serial Number
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. An ignition key can be duplicated only by ordering a Polaris key blank (using your key number) and mating it with one of your existi...
Page 8 - SAFETY; Safety Decals and Locations; Read and follow the instructions of the decals on the vehicle; Container/Passenger/Tire Pressure Warning; MAXIMUM WEIGHT CAPACITY
5 SAFETY Safety Decals and Locations Warning decals have been placed on the vehicle for your protection. Read and follow the instructions of the decals on the vehicle carefully. If any of the decals depicted in this manual differ from the decals on your vehicle, always read and follow the instructio...
Page 9 - Clutch Cover Warning; Cab Frame/Seat Belt Warning; Warning
6 SAFETY Safety Decals and Locations Clutch Cover Warning WARNINGNO STEP• Moving parts hazard under belt-clutch guard. To prevent serious injury, do not operate vehicle with guard removed. • Do not modify engine or clutch. Doing so can cause part failure, possible imbalance, and excessive engine RPM...
Page 10 - Shift Caution; Shift
7 SAFETY Safety Decals and Locations Shift Caution CAUTIONTo avoid transmission damage, shift only when vehicle is stationary and at idle. Discretionary Warning WARNINGImproper vehicle use can result in SEVERE INJURY or DEATH.NEVER:• Operate on public roads. A collision can occur with a another vehi...
Page 11 - Operator Safety; Age Restrictions; This vehicle is an ADULT VEHICLE ONLY. Operation is prohibited; Know Your Vehicle; WARNING
8 SAFETY Operator Safety Age Restrictions This vehicle is an ADULT VEHICLE ONLY. Operation is prohibited for anyone under 16 years of age. No person under the age of 5 may ride as a passenger in this vehicle. Know Your Vehicle As the operator of the vehicle, you are responsible for your personal saf...
Page 12 - CAUTION; NOTE
9 SAFETY Operator Safety The following signal words and symbols appear throughout this manual and on your vehicle. Your safety is involved when these words and sym- bols are used. Become familiar with their meanings before reading the manual. The safety alert symbol , on your vehicle or in this manu...
Page 16 - Equipment Modifications; on a Polaris
13 SAFETY Operator Safety Equipment Modifications We are concerned for the safety of our customers and for the general public. Therefore, we strongly recommend that consumers do not install on a Polaris RANGER any equipment that may increase the speed or power of the vehicle, or make any other modif...
Page 24 - Fuel Safety
21 SAFETY Fuel Safety WARNING Gasoline is highly flammable and is explosive under certain conditions. Always exercise extreme caution whenever handling gasoline.Always stop the engine when refueling.Always refuel outdoors or in a well ventilated area.Do not smoke or allow open flames or sparks in or...
Page 25 - FEATURES AND CONTROLS; Component Locations; section beginning on page 108.
22 FEATURES AND CONTROLS Component Locations Some Polaris vehicles are equipped with special features such as the cab frame. Not all models come with all features. Refer to the specifications section beginning on page 108. Cab Frame (if Equipped) Console Steering Wheel Hip Bar Fuel Tank Cap Seat Bel...
Page 26 - Headlights
23 FEATURES AND CONTROLS Component Locations Headlights Hood Hold-Down Strap Front Bumper/Brush Guard Radiator (if equipped)
Page 27 - Trailer Hitch Bracket; towing capacities outlined on pages 50-53.
24 FEATURES AND CONTROLS Component Locations Trailer Hitch Bracket This vehicle is equipped with a receiver hitch bracket for a trailer hitch. Trailer towing equipment is not supplied with this vehicle.To avoid injury and property damage, always heed the warnings and towing capacities outlined on pa...
Page 28 - Instrument Cluster; Your; Refer to page 34 for the location of the instrument cluster.
25 FEATURES AND CONTROLS Component Locations Instrument Cluster Your RANGER is equipped with an instrument cluster that senses vehi- cle speed from the right front wheel. The instrument cluster measures distance in miles as well as time, hours of operation and engine RPM. Refer to page 34 for the lo...
Page 29 - Rider Information Center
26 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. NOTE: If the instrument cluster fails to illuminate, a battery over-voltage may have occurred and the inst...
Page 30 - Standard Modes; The odometer records the miles traveled by the vehicle.; Trip Meter Mode; Hour Meter Mode; This mode logs the total hours the engine has been in operation.; Tachometer Mode; The engine RPM is displayed digitally.; Clock Mode
27 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 34. Odometer Mode The odometer records the miles traveled by the vehicle. Trip Meter Mode The trip meter records t...
Page 31 - Diagnostic Mode; hold
28 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...
Page 33 - Miles/Kilometers toggle
30 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...
Page 34 - Downloading Codes; ing procedure to download blink codes (failure codes) from the EFI
31 FEATURES AND CONTROLS Instrument Cluster Rider Information Center Downloading Codes The EFI diagnostic mode is for informational purposes only. Please see your Polaris dealer for all major repairs. See page 32 for Blink Codes and Failure Descriptions. Use the follow- ing procedure to download bli...
Page 35 - Blink
32 FEATURES AND CONTROLS Instrument Cluster Rider Information Center Downloading Codes 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 Ground...
Page 36 - Seat Removal; Seat Belt
33 FEATURES AND CONTROLS Seat Removal Pull up on the front of the seat and slide it toward the front of the vehicle.Install the seat by sliding the tabs into the rear of the seat base. Push down firmly on the front of the seat until the pins are fully seated into the grommets. Fuel Cap The fuel tank...
Page 37 - Console; Auxiliary Outlet; The 12-volt accessory plug receptacle; Mode Button; meter, tachometer and clock. See page 27 for operation of the modes.
34 FEATURES AND CONTROLS Console Auxiliary Outlet The 12-volt accessory plug receptacle 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. Mode Button The yellow button locate...
Page 38 - Gear Selector; and with the engine idling, move; Gear
35 FEATURES AND CONTROLS Gear Selector H: High GearL: Low GearN: NeutralR: Reverse NOTE: Low gear is the primary driving range for the RANGER . High gear is intended for use on hard- packed surfaces with light loads. To change gears, stop the vehicle, and with the engine idling, move the lever to th...
Page 39 - Brake Pedal
36 FEATURES AND CONTROLS Brake Pedal Depress the brake pedal to slow or stop the vehicle. Apply the brakes while starting the engine. Throttle Pedal Push the pedal down to increase engine speed. Spring pressure returns the pedal to the rest position when released. Always check that the throttle peda...
Page 40 - Ignition Switch
37 FEATURES AND CONTROLS Switches Ignition Switch The ignition switch is a three-position, key-operated switch. The key can be removed from the switch when it is in the OFF position. Light Switch The ignition switch key must be in the ON/RUN position to operate the headlights. The light switch has t...
Page 41 - OPERATION; Vehicle Break-In Period; The break-in period for your new Polaris
38 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...
Page 42 - Item
39 OPERATION Pre-Ride Inspection WARNING If a proper inspection is not done before each use, severe injury or death could result. Always inspect the vehicle before each use to ensure it's in proper operating condition. Item Remarks Page Brake system/pedal travel Ensure proper operation 36 87 Brake f...
Page 43 - Starting the Engine; Turn the ignition key past the ON/RUN position to START. Engage
40 OPERATION Starting the Engine 1. Sit in the driver's seat and fasten the seat belt.2. Engage the park brake.3. Shift the transmission to neutral.4. Apply the brakes. NOTE: Do not press the throttle pedal while starting the engine. 5. Turn the ignition key past the ON/RUN position to START. Engage...
Page 44 - Stopping the Engine
41 OPERATION Stopping the Engine 1. Release the throttle pedal completely and brake to a complete stop.2. Turn the engine off.3. Engage the park brake. Braking 1. Release the throttle pedal completely.2. Press on the brake pedal evenly and firmly. NOTE: Practice starting and stopping (using the brak...
Page 45 - Driving Safely; Driving Procedure; vice brakes, and shift the transmission into gear.
42 OPERATION Driving Safely Driving Procedure 1. Sit in the driver's seat and fasten the seat belt.2. After starting the engine and allowing it to warm up, apply the ser- vice brakes, and shift the transmission into gear. 3. Check your surroundings and determine your path of travel.4. Release the pa...
Page 46 - Driving on Slippery Surfaces; Drive with AWD engaged (if equipped) to assist in controlling the
43 OPERATION Driving Safely Driving on Slippery Surfaces When driving on slippery surfaces such as wet trails, loose gravel, or ice, be alert for the possibility of skidding and sliding. Under these con- ditions, follow these precautions:1. Slow down when entering slippery areas.2. Maintain a high l...
Page 47 - Driving Uphill; maximum
44 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...
Page 48 - Driving Downhill; slightly
45 OPERATION Driving Safely Driving on a Sidehill (Sidehilling) Driving Downhill Whenever descending a hill, follow these precautions:1. Proceed directly downhill.2. Slow down.3. Apply the brakes slightly to aid in slowing. WARNING Crossing hillsides or turning on hills can result in loss of control...
Page 49 - Driving Through Water; Floorboard
46 OPERATION Driving Safely Driving Through Water Your Polaris RANGER can operate through water up to a maximum recommended depth equal to the floor- boards. Follow these procedures when oper- ating through water:1. Always determine water depths and current before entering. 2. Choose a crossing wher...
Page 50 - Driving Over Obstacles; Watch for hazards such as logs, rocks and low hanging branches.
47 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...
Page 51 - Driving in Reverse
48 OPERATION Driving Safely Driving in Reverse Follow these guidelines when operating in reverse:1. Back slowly.2. Apply the brakes lightly for stopping.3. Avoid turning at sharp angles.4. Always avoid backing downhill.5. Never open the throttle suddenly while backing.6. Always inspect left and righ...
Page 52 - Parking on an Incline
49 OPERATION Driving Safely Parking on an Incline Avoid parking on an incline if possible. If it's unavoidable, follow these precautions:1. Place the transmission in gear.2. Engage the park brake.3. Turn the engine off.4. Block the rear wheels on the downhill side. WARNING A rolling vehicle can caus...
Page 53 - Hauling Cargo
50 OPERATION Driving Safely Hauling Cargo WARNING Hauling cargo improperly can alter vehicle handling and may cause loss of control or brake instability, which can result in serious injury or death. Always follow these precautions when hauling cargo:REDUCE SPEED AND ALLOW GREATER DISTANCES FOR BRAKI...
Page 54 - The; Model
51 OPERATION Driving Safely Hauling Cargo The RANGER has been designed to carry or tow specific capacities. Always read and understand the load distribution warnings listed on the warning labels. Never exceed the following capacities. Model Maximum Capacities (Level Ground) Cargo Box RANGER 4X4 EFI ...
Page 55 - Dumping the Cargo Box; Release Lever
52 OPERATION Driving Safely Dumping the Cargo Box 1. Select a level site to dump the cargo box. Do not attempt to dump or unload the vehicle while parked on an incline. 2. Engage the park brake. 3. Dismount the vehicle.4. Ensure that the cargo is positioned evenly or toward the front of the cargo bo...
Page 56 - Towing Loads
53 OPERATION Driving Safely Towing Loads Belt Life To extend belt life, use the lowest gear possible when hauling or towing heavy cargo. WARNING Towing improperly can alter vehicle handling and may cause loss of control or brake instability, which can result in serious injury or death. Always follow...
Page 57 - Parking the Vehicle
54 OPERATION Driving Safely Parking the Vehicle 1. Stop the vehicle on a level surface.2. Turn the engine off.3. Engage the park brake.4. Remove the ignition switch key to prevent unauthorized use. WARNING A rolling vehicle can cause property damage and serious injury. Always engage the park brake a...
Page 58 - Locking the Differential
55 OPERATION Differential Lock (4X4 Models) Locking the Differential The 4X4 rear axle is equipped with a lockable differential that allows the operator to choose between an open differential or a closed differential. Locking the differential in slippery or low traction conditions helps improve trac...
Page 59 - Disengaging AWD; AWD Switch
56 OPERATION 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 the rear wheels regain traction, the front wheels will automatically disengage. ...
Page 60 - EMISSION CONTROL SYSTEMS; Noise Emission Control System
57 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...
Page 61 - MAINTENANCE; Periodic Maintenance Chart; and serviced more frequently.; Severe Use Definition; cause or see your dealer.
58 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...
Page 62 - Maintenance Chart Key; Perform these operations more often for vehicles subjected to
59 MAINTENANCE Periodic Maintenance Chart Maintenance Chart Key X Perform these operations more often for vehicles subjected to severe use. E Emission Control System Service - 4 Cycle (California) Q Have an authorized Polaris dealer perform these services. WARNING Improperly performing the procedure...
Page 66 - Lubrication Recommendations; odic Maintenance Chart beginning on page 58, or more often under
63 MAINTENANCE Lubrication Recommendations Check and lubricate all components at the intervals outlined in the Peri- odic Maintenance Chart beginning on page 58, 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...
Page 67 - Swing Arm
64 MAINTENANCE Lubrication Recommendations 4X4 6X6 Swing Arm Bushings 6X6 Prop Shaft U-Joints 4X4 6X6 6X6 Ball Joint 6X6
Page 68 - Engine Oil; oil filter whenever changing oil.; Premium 4 Synthetic Oil; ent temperatures from -40
65 MAINTENANCE Engine Oil Always check and change the engine oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 58. Always change the oil filter whenever changing oil. Premium 4 Synthetic Oil Polaris Premium 4 All Season Synthetic engine oil has been specially formulat...
Page 69 - Oil Check
66 MAINTENANCE Engine Oil Always check and change the oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 58. 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. Apply th...
Page 70 - Oil and Filter Change; turn the filter counter-clockwise to remove it.
67 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 58. 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 ...
Page 71 - bring the level to the upper mark on the dipstick.; Gearcases; Gearcase Specification Chart
68 MAINTENANCE Engine Oil Oil and Filter Change 1. Remove the dipstick and fill the sump with two quarts (1.9 l) of rec- ommended oil. 2. Shift the transmission to neutral. 3. Engage the park brake.4. Apply the brakes. Start the engine. Allow it to idle for one to two minutes. 5. Stop the engine. In...
Page 72 - Position the vehicle on a level; Fill Plug
69 MAINTENANCE Gearcases Transmission (Main Gearcase) Always check and change the transmission oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 58. Maintain the oil level even with the bottom of the fill plug hole.Refer to the Gearcase Specifications Chart on page 68...
Page 73 - Oil Change; Drain Plug
70 MAINTENANCE Gearcases Transmission (Main Gearcase) Oil Change The drain plug is located on the bottom of the transmission. Access the drain plug through the drain hole in the skid plate.1. Remove the fill plug.2. Place a drain pan under the drain plug. Remove the drain plug. Drain the oil. Dispos...
Page 74 - Front Gearcases; Support the vehicle securely with a
71 MAINTENANCE Gearcases Front Gearcases Always check and change the front gearcase oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 58. Maintain the oil level even with the bottom thread of the fill plug hole. Refer to the Gearcase Specifications Chart on page 68 fo...
Page 75 - Add the recommended oil as; bottom of the gearcase. Drain the
72 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 58. Maintain the oil level even with the bottom thread of the fill plug hole.Refer to the Gearcase Specifications Chart on pa...
Page 76 - Rear Gearcase
73 MAINTENANCE Gearcases Rear Gearcase Always check and change the rear gearcase oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 58.Refer to the Gearcase Specifications Chart on page 68 for recommended lubricants, capacities and torque specifications. See page 112 f...
Page 78 - Spark Plugs; Spark Plug Gap/Torque
75 MAINTENANCE Spark Plugs Spark Plug Gap/Torque Spark plug condition is indicative of engine operation. The spark plug firing end condition should be read after the engine is warmed up and the vehicle is driven at higher speeds. Immediately check the spark plug for correct color. See page 76. CAUTI...
Page 79 - Spark Plug Condition; Normal Plug; cates the proper type and heat range for the engine and the service.; Wet Fouled Plug; end. There may be a carbon layer over the entire nose. Generally, the; Spark Plug Removal and Replacement; in the tool kit, remove the plug by rotating it counterclockwise.
76 MAINTENANCE Spark Plugs Spark Plug Condition Normal Plug The normal insulator tip is gray, tan or light brown. There will be few combustion deposits. The electrodes are not burned or eroded. This indi- cates the proper type and heat range for the engine and the service. NOTE: The tip should not b...
Page 80 - Cooling System; Operation; contracting (cooled) coolant is drawn back up from the tank, past the; Adding or Changing Coolant; water. Polaris Premium 60/40 is already premixed and ready to use. Do; radiator should be inspected. Add coolant as needed.
77 MAINTENANCE Cooling System Operation The engine coolant level is controlled or maintained by the recovery system. The recovery system components are the overflow bottle, radia- tor filler neck, radiator pressure cap and connecting hose.As coolant operating temperature increases, the expanding (he...
Page 81 - Radiator and Cooling Fan; Overflow
78 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 58. Do not obstruct or deflect air flow through the radiator by installing unautho- rized accessories in front of...
Page 82 - Radiator Coolant Level; ference with the radiator air flow can lead to overheating and; Radiator
79 MAINTENANCE Cooling System Radiator Coolant Level Always check and clean the screen and radiator fins at the intervals out- lined in the Periodic Maintenance Chart beginning on page 58. Do not obstruct or deflect air flow through the radiator by installing unautho- rized accessories in front of t...
Page 83 - Polaris Variable Transmission (PVT) System; When To Use Low Range and High Range; Condition
80 MAINTENANCE Polaris Variable Transmission (PVT) System Belt slip is responsible for creating excessive heat that destroys belts, wears clutch components and causes outer clutch covers to fail. Switch to low range while operating at slower speeds to extend the life of the PVT components (belt, cov...
Page 84 - PVT System
81 MAINTENANCE 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. The PVT system has been precision balanced. Any ...
Page 85 - PVT Drying; air-dry the belt and clutches. Do not hold the throttle wide open for
82 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. Loosen the bottom screws that secure the clutch cover.2. Allow the water to drain.3. Tighten the screws.4. Apply ...
Page 86 - Filter Systems; Fuel Filter; Air Filter
83 MAINTENANCE Filter Systems Air Filter Always change the air filter at the intervals outlined in the Periodic Maintenance Chart beginning on page 58. 1. Lift the cargo box to access the air box. 2. Remove the air box cover and inspect the gasket. It should adhere tightly to the cover and seal all ...
Page 87 - Spark Arrestor; Plugs
84 MAINTENANCE Spark Arrestor Use the following procedure to periodically purge accumulated carbon from the exhaust pipe.1. Remove the arrestor clean-out plugs located on the bottom of the muffler. 2. Shift the transmission to neutral. Apply the brakes. Start the engine. 3. Purge accumulated carbon ...
Page 88 - Throttle System; Throttle Freeplay; Throttle
85 MAINTENANCE Throttle System Throttle Freeplay If the throttle pedal has excessive play due to cable stretch or mis- adjustment, it will cause a delay in throttle response, especially at low engine speed. The throttle may also not open fully. If the throttle pedal has no freeplay, the throttle may...
Page 89 - Throttle Body/Idle RPM; Boot
86 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 ...
Page 90 - Brakes; Brake Fluid
87 MAINTENANCE Brakes The front and rear brakes are hydraulic disc type brakes activated by the brake pedal. See page 36. Brake Fluid Inspect the brake system rou- tinely. Inspect the level of the brake fluid before each opera- tion.Change the brake fluid every two years and any time the fluid becom...
Page 91 - Brake Inspection; Park Brake
88 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...
Page 92 - Steering Wheel Inspection; rized Polaris dealer.; Rear Spring Adjustment; Outside Mounting Holes
89 MAINTENANCE Steering Wheel Inspection Check the steering wheel for specified freeplay and smooth operation at the intervals outlined in the Periodic Maintenance Chart beginning on page 58. 1. Position the vehicle on level ground.2. Lightly turn the steering wheel left and right.3. There should be...
Page 93 - Seat Belts; Bolts
90 MAINTENANCE Seat Belts Inspect all three seat belts for proper operation before each use of the vehicle.1. Push the latch plate into the buckle until it clicks. The latch plate must slide smoothly into the buckle. A click indicates that it's securely latched. 2. Push the red button in the middle ...
Page 94 - Tires; Tire Tread Depth; Always replace tires; Axle and Wheel Nut Torque Specifications; been loosened for maintenance service.; Nut Type
91 MAINTENANCE Tires Tire Tread Depth Always replace tires when tread depth is worn to 1/8" (3 mm) or less. Axle and Wheel Nut Torque Specifications Inspect the following items occasionally for tightness, and if they've been loosened for maintenance service. NOTE: Do not lubricate the stud or th...
Page 95 - Wheel Removal
92 MAINTENANCE Tires Wheel Removal 1. Stop the engine. Place the transmission in gear. Engage the park brake. 2. Loosen the wheel nuts slightly.3. Elevate the side of the vehicle by placing a suitable stand under the frame. 4. Remove the wheel nuts and washers. Remove the wheel. Wheel Installation 1...
Page 96 - Lights; Headlight Lamp Replacement; Wiring
93 MAINTENANCE Lights When servicing a halogen lamp, don't touch the lamp with bare fingers. Oil from your skin leaves a residue, causing a hot spot that will shorten the life of the lamp. Headlight Lamp Replacement 1. Open the hood.2. Unplug the headlamp from the wiring harness. Be sure to pull on ...
Page 97 - Headlight Beam Adjustment; Brake Lights; Adjustment
94 MAINTENANCE Lights Headlight Beam Adjustment 1. Place the vehicle on a level surface with the headlight approxi- mately 25 ft. (7.6 m) from a wall. 2. Measure the distance from the floor to the center of the headlight and make a mark on the wall at the same height. 3. Apply the brakes. Start the ...
Page 98 - Vehicle Immersion; If it's impossible to take your
95 MAINTENANCE Vehicle Immersion If it's impossible to take your RANGER to a dealer before starting it, fol- low the steps outlined below.1. Move the vehicle to dry land or at the very least, to water below the footrests. 2. Dry any water present in the air box.3. Filter replacement is required if w...
Page 99 - Battery; has six filler caps on the top of the battery.; Conventional Battery; allow cleaning solution or tap water into the battery.; External
96 MAINTENANCE Battery Your vehicle may have either a sealed battery, which requires little maintenance, or a conventional battery. A sealed battery can be identi- fied by its flat covers on the top of the battery. A conventional battery has six filler caps on the top of the battery. Conventional Ba...
Page 100 - Battery Removal; remove the battery vent
97 MAINTENANCE Battery Battery Removal 1. Open the hood.2. On conventional batteries, remove the battery vent tube. 3. Disconnect the black (nega- tive) battery cable first. 4. Disconnect the red (positive) battery cable last. 5. Lift the battery out of the vehicle. Be careful not to tip a conventio...
Page 101 - Battery Installation
98 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 100 before installing the battery.1. Ensure that the battery...
Page 102 - Battery Storage; A poorly maintained battery will; Lower
99 MAINTENANCE Battery Battery Storage Whenever the vehicle is not used for a period of three months or more, remove the battery from the vehicle, ensure that it's fully charged, and store it out of the sun in a cool, dry place. Check battery voltage each month during storage and recharge as needed ...
Page 103 - fully charged
100 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 97. 2. Charge the battery with a charging output no larger than 1/10 of the battery’s amp/hr rating. Charge as need...
Page 104 - State of
101 MAINTENANCE Battery Battery Charging (Sealed Battery) NOTE: Always verify battery condition before and 1-2 hours after the end of charging. State of Charge Voltage Action Charge Time (Using constant current charger @ standard amps specified on top of battery) 100% 12.8-13.0 volts None, check at ...
Page 105 - Cleaning and Storage; Washing the Vehicle; but it can also extend the life of various components.; Washing Tips
102 MAINTENANCE Cleaning and Storage Washing the Vehicle Keeping your Polaris vehicle clean will not only improve its appearance but it can also extend the life of various components. The best and safest way to clean your Polaris vehicle is with a garden hose and a pail of mild soap and water. 1. Us...
Page 106 - Polishing the Vehicle; instructions on the container.; Polishing Tips; • Avoid the use of automotive products, some of which can scratch the
103 MAINTENANCE Cleaning and Storage Washing the Vehicle If a high pressure water system is used for cleaning (not recommended), exercise extreme caution. The water may damage components and could remove paint and decals. Avoid directing the water stream at the follow- ing items: • Wheel bearings• R...
Page 107 - Removing Corrosion
104 MAINTENANCE Cleaning and Storage Chrome Wheel Care (if equipped) Proper maintenance will protect chrome wheels from corrosion, pre- serve wheel life and ensure a “like new” appearance for many years. NOTE: Chrome wheels exposed to road salt (or salt in the air in coastal areas) are more suscepti...
Page 108 - Storage Tips; Clean the Exterior; Follow the instructions on the container for the recommended; disperse through the entire fuel delivery system.; Oil and Filter; Clean the air box. Drain the sediment tube.; Fluid Levels; in the Periodic Maintenance Chart beginning on page 58.
105 MAINTENANCE Cleaning and Storage Storage Tips Clean the Exterior Make any necessary repairs and clean the vehicle as recommended. See page 102. Stabilize the Fuel 1. Fill the fuel tank.2. Add Polaris Carbon Clean Fuel Treatment or Polaris Fuel Stabilizer. Follow the instructions on the container...
Page 109 - Fog the Engine
106 MAINTENANCE Cleaning and Storage Storage Tips Fog the Engine 1. Treat the fuel system with Polaris Carbon Clean. Follow the instruc- tions on the container. Start the engine. Allow it to idle for several minutes so the Carbon Clean reaches the injectors. Stop the engine. 2. Remove the spark plug...
Page 110 - Removal from Storage; sary. Install it in the vehicle. Make sure the battery vent hose is; Chart beginning on page 58.; Transporting the
107 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...
Page 111 - SPECIFICATIONS
108 SPECIFICATIONS RANGER 4X4 EFI Gross Vehicle Weight 2750 lbs. (1247 kg) Fuel Capacity 9 gal. (34 l) Engine Oil Capacity 2 qts. (2.1 l) Coolant Capacity 3.25 qts. (3 l) Towing Capacity 1500 lbs. (681 kg Hitch Tongue Capacity 150 lbs. (68 kg) Max. Cargo Box Load 1000 lbs. (454 kg) Overall Length 11...
Page 115 - POLARIS PRODUCTS; Part Number; Engine Lubricant; Additives / Miscellaneous
112 POLARIS PRODUCTS Part Number Description Engine Lubricant 2870791 Fogging Oil (12 oz. Aerosol) 2871281 Premium 4 Synthetic 0W-40 (4-Cycle) Engine Oil (qt.) 2871844 Premium 4 Synthetic 0W-40 (4-Cycle) Engine Oil (gal.) Gearcase / Transmission Lubricants 2873602 Premium AGL Synthetic Gearcase Lubr...
Page 116 - TROUBLESHOOTING; Possible Cause
113 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 44. Driving at low RPM or ground speed (3-7 MPH) Drive at a higher speed or use...
Page 117 - Engine Doesn't Turn Over
114 TROUBLESHOOTING Engine Doesn't Turn Over Engine Turns Over, Fails to Start Engine Backfires Possible Cause Solution Low battery voltage Recharge the battery to 12.8 VDC Loose battery connections Check all connections and tighten Loose solenoid connections Check all connections and tighten Loose ...
Page 118 - Engine Pings or Knocks
115 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...
Page 119 - Engine Stops or Loses Power
116 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...
Page 120 - WARRANTY; LIMITED WARRANTY; REGISTRATION
117 WARRANTY LIMITED WARRANTY Polaris Sales Inc., 2100 Highway 55, Medina, MN 55340, gives a SIX MONTH LIM- ITED WARRANTY on all components of the Polaris RANGER against defects in mate- rial or workmanship. Polaris also gives a one year limited warranty on the final drive chain for failure due to d...
Page 121 - LIMITATIONS OF WARRANTIES AND REMEDIES; Lubricants; SPARK ARRESTOR
118 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 ...
Page 122 - Exported Vehicles; Notice
119 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...
Page 124 - California Emission Control Warranty Statement; Your Warranty Rights and Obligations; The Air Index of this Engine is 3; The lower the Air Index, the less pollution.
121 WARRANTY California Emission Control Warranty Statement Your Warranty Rights and Obligations The California Air Resources Board and Polaris Industries Inc., 2100 Highway 55, Medina, Minnesota 55340 (herein "POLARIS") are pleased to explain the emission con- trol system warranty on your 2...
Page 125 - Limited Warranty California Only; What is Covered Under This Warranty
122 WARRANTY California Emission Control Warranty Statement Owner's Warranty Responsibilities: • As the LSI engine owner, you are responsible for the performance of the required maintenance listed in your Owner's Safety and Maintenance Manual (herein "Owner's Manual"). POLARIS recommends tha...
Page 126 - Emission-Related Parts Covered Under This Warranty
123 WARRANTY California Emission Control Warranty Statement Emission-Related Parts Covered Under This Warranty (1) Fuel Metering System (i) Carburetor and internal parts (and/or pressure regulator or fuel injection system)(ii) Air/fuel ratio feedback and control system, if applicable(iii) Cold start...
Page 127 - What is Not Covered Under This Warranty
124 WARRANTY California Emission Control Warranty Statement What is Not Covered Under This Warranty This warranty does not cover any emission-related part which malfunctions, fails or is damaged due to alterations and/or modifications such as changing, adding or removing parts.When the LSI engine is...
Page 128 - Repair and Replacement of Emission-Related Parts; been authorized and approved by POLARIS, should be used in the per-; How to File a Warranty Claim/Where to Get Warranty Service; by a dealer who sold you the LSI engine or a dealer authorized by
125 WARRANTY X Perform these procedures more often for vehicles subjected to severe use. E Emission-Related Service. Q Have an authorized Polaris dealer perform these services Repair and Replacement of Emission-Related Parts It is recommended that only LSI engine replacement parts, which have been a...
Page 129 - MAINTENANCE LOG; Use the following chart to record periodic maintenance.
126 MAINTENANCE LOG Use the following chart to record periodic maintenance. DATE MILES (KM) OR HOURS TECHNICIAN SERVICE PERFORMED / COMMENTS
Page 131 - INDEX; Changing Oil; Diagnostics
128 INDEX A Accessory Outlet . . . . . . . . . . . . . . . 34 Adding Coolant . . . . . . . . . . . . . . . . 77 Adjustment, Headlight Beam. . . . . . 94 Adjustment, Park Brake . . . . . . . . . . 88 Adjustment, Rear Spring . . . . . . . . . 89 Adjustment, Rear Suspension . . . . . 89 Adjustment, Thr...
Page 132 - Emission Control
129 INDEX D Driving on Slippery Surfaces . . . . . . 43 Driving Over Obstacles . . . . . . . . . . 47 Driving Procedure . . . . . . . . . . . . . . . 42 Driving Safely . . . . . . . . . . . . . . . 42-54 Driving Through Water . . . . . . . . . . 46 Driving Uphill . . . . . . . . . . . . . . . . . . ...
Page 134 - Spark Plug
131 INDEX R Receiver Hitch . . . . . . . . . . . . . . . . . 24 Release, Park Brake . . . . . . . . . . . . . 36 Removal, Battery . . . . . . . . . . . . . . . 97 Removal, Seat . . . . . . . . . . . . . . . . . . 33 Removal, Wheels . . . . . . . . . . . . . . . 92 Removing the Vehicle from Storage 1...