WARNING The engine exhaust from this product contains chemicals known to cause cancer, birth defects or other reproductive harm.
FOREWORD Congratulations and thank you from Polaris Industries Inc. for purchasing one of our products. Built with American engineering and manufacturing know-how, it is designed to provide superior comfort, utility, enjoyment and safety. This manual is furnished to ensure that the operator is aware of safe operating procedures. It also includes information about the general care and maintenance of your vehicle. Carefully read the following pages.
THIS VEHICLE IS NOT A TOY AND CAN BE HAZARDOUS TO OPERATE. This vehicle handles differently from other vehicles including motorcycles and cars. A collision or rollover can occur quickly, even during routine maneuvers such as turning and driving on hills or over obstacles, if you fail to take proper precautions. SEVERE INJURY OR DEATH can result if you do not follow these instructions: Read this manual and all labels carefully and follow the operating procedures described.
Always follow proper procedures for going down hills and for braking on hills as described in this manual. Check the terrain carefully before you start down any hill. Never go down a hill at high speed. Avoid going down a hill at an angle which would cause the vehicle to lean sharply to one side. Go straight down the hill where possible. Always follow proper procedures for crossing the side of a hill as described in this manual. Avoid hills with excessively slippery or loose surfaces.
WARNING indicates a potential hazard which could result in serious injury or death. Additional Important Information... Due to our concern for the safety of our customers and the general public, Polaris hereby strongly recommends and requests that consumers not have installed on a Polaris RANGER any equipment which is intended to increase the speed or power of the vehicle; or make any other modifications to the vehicle for these purposes.
The Polaris Preferred Registered Owners (PRO) Family Your Owners Program As the owner of a new Polaris vehicle, you are entitled to a FREE two- year membership in the Polaris PRO Family-–the Preferred Registered Owners Family. It’s an owners program for Polaris owners like you, people who have chosen the finest recreational vehicle available, people who share an interest in Polaris and its products.
CONTENTS UNDERSTANDING WARNINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 SAFETY WARNING AND OPERATION DECALS . . . . . . . . . . . . 2-7 LABEL LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 DAILY PRE-RIDE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 OPERATION WARNINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-19 VEHICLE IDENTIFICATION NUMBERS . . . . . . . . . . . . . . . . . . . . .
UNDERSTANDING WARNINGS SAFETY ALERT The following precautionary signal words are used throughout this manual to convey the following messages: This is the safety alert symbol. When you see this symbol on your machine or in this manual, be alert to the potential for personal injury. Your safety is involved! WARNING CAUTION NOTE Indicates a potential hazard which could result in serious injury or death. Indicates a potential hazard which may result in minor personal injury or damage to the vehicle.
SAFETY WARNING AND OPERATION DECALS WARNING VEHICLE ROLLOVER COULD CAUSE SEVERE INJURY OR DEATH This cab frame is not designed or intended to provide rollover protection in the event of vehicle overturning. See Owner’s Manual. 7077478 l Riders can be thrown off. This can cause serious injury or death. l Never carry riders in cargo box. 7077681 TRAILER MAX. WEIGHT 1500 LBS. HITCH MAX. VERTICAL WEIGHT 150 LBS. 7077682 IMPROPER TIRE PRESSURE OR OVERLOADING CAN CAUSE LOSS OF CONTROL.
SAFETY WARNING AND OPERATION DECALS HEADLAMPS ARE NOT SEALED. DO NOT SUBMERGE OR APPLY WATER PRESSURE DIRECTLY ONTO SERVICE OPENING. Recoil handle must be firmly seated to prevent water entry. Drain starter motor if water enters. See owner’s manual. 7075741 WARNING/AVERTISSEMENT This vehicle is designed for operator and “ONE” passenger only Ce Vehicule est concu pour ne transporter que le conducteur et “UN SEUL” passager. 7075439 WARNING DO NOT ATTEMPT ENGINE OR CLUTCH MODIFICATION.
SAFETY WARNING AND OPERATION DECALS 7077683 Text found below OPERATOR/LOAD DISTRIBUTION WARNINGS VIOLATION OF ANY OF THE FOLLOWING WARNINGS COULD CAUSE LOSS OF CONTROL AND RESULT IN SEVERE INJURY OR DEATH. MAKE STARTS, STOPS, TURNS AND DIRECTIONS CHANGES IN A SMOOTH MANNER so as not to shift the load or overturn the vehicle. THE FOOT BRAKE PEDAL CONTROLS THE PRIMARY BRAKING for this vehicle.
SAFETY WARNING AND OPERATION DECALS THE ABILITY TO STEER THIS MACHINE IS REDUCED WHEN OPERATING IN A LOADED CONDITION on rough or hilly terrain. When climbing hills always having the cargo in the rear box securely fastened and located as far forward in the box as possible. Loaded vehicles will experience reduced steering and front brake effectiveness when operating on hills.
SAFETY WARNING AND OPERATION DECALS 7077680 Text found below READ AND UNDERSTANDING WARNINGS AND OWNER’S MANUAL BEFORE OPERATION. SEVERE INJURY OR DEATH CAN RESULT FROM IGNORING WARNINGS OR IMPROPER USE. If you do not have the Owner’s Manual for this vehicle, call 1-800-324-3674 to have one provided at no extra charge. This vehicle REQUIRES SPECIAL RIDING SKILLS due to its handling. Ride within your skill. THIS VEHICLE SHOULD BE OPERATED ONLY BY PERSONS WITH A VALID DRIVER’S LICENSE.
SAFETY WARNING AND OPERATION DECALS OPERATION ON HILLS IS DANGEROUS, especially when loaded. This vehicle is designed for utility usage on moderate terrains. Turning, braking and uneven terrain can induce rollovers especially if a maneuver is abrupt. Under no circumstances should you climb, descend or traverse hills greater than 15°∠. Vehicle stability is greatly reduced during operating on hills, creating the possibility of vehicle rollover and serious injury, including death or paralysis.
LABEL LOCATION 4 1 3 5 2 6 1. 2. Warning (General) Warning (Vehicle roll-over) 3. 4. 5. 6.
DAILY PRE-RIDE INSPECTION Inspect your vehicle each time before riding to ensure it is in proper working order. If proper inspection is not done, severe injury or death could result. WARNING If a proper inspection is not performed serious injury or death can result. Always inspect your RANGER before riding following the checklist carefully. Before riding your vehicle, inspect all operating controls and parts. Item/Inspection Procedure 1. Tires - check condition and pressures 2.
OPERATION WARNINGS WARNING POTENTIAL HAZARD Operating this vehicle without proper instruction. WHAT CAN HAPPEN The risk of an accident is greatly increased if the operator does not know how to operate the vehicle properly in different situations and on different types of terrain. HOW TO AVOID THE HAZARD Read and understand the Owner’s Manual and all warning and instruction labels on the vehicle. WARNING POTENTIAL HAZARD Failure to follow the age recommendations for this vehicle.
OPERATION WARNINGS WARNING POTENTIAL HAZARD Operating this vehicle on paved surfaces. WHAT CAN HAPPEN This vehicle’s tires are designed for off-road use only; not for use on pavement. Paved surfaces may seriously affect handling and control of the vehicle, and may cause the vehicle to go out of control. HOW TO AVOID THE HAZARD Always avoid operating the vehicle on any paved surfaces, including sidewalks, driveways, parking lots and streets.
OPERATION WARNINGS WARNING POTENTIAL HAZARD Operating this vehicle after consuming alcohol or drugs. WHAT CAN HAPPEN Could seriously affect your judgment. Could cause you to react more slowly. Could affect your balance and perception. Could result in an accident. HOW TO AVOID THE HAZARD Never consume alcohol or drugs before or while driving this vehicle. WARNING POTENTIAL HAZARD Operating this vehicle at excessive speeds.
OPERATION WARNINGS WARNING POTENTIAL HAZARD Failure to inspect the vehicle before operating. Failure to properly maintain the vehicle. WHAT CAN HAPPEN Increases the possibility of an accident or equipment damage. HOW TO AVOID THE HAZARD Always inspect your RANGER each time you use it to make sure it is in safe operating condition. Always follow the inspection and maintenance procedures and schedules described in the Owner’s Manual. WARNING POTENTIAL HAZARD Attempting jumps and other stunts.
OPERATION WARNINGS WARNING POTENTIAL HAZARD Failure to use extra care when operating on excessively rough, slippery or loose terrain. WHAT CAN HAPPEN Could cause loss of traction or vehicle control, which could result in an accident, including an overturn. HOW TO AVOID THE HAZARD Do not operate on excessively rough, slippery or loose terrain until you have learned and practiced the skills necessary to control the vehicle on such terrain. Always be especially cautious on these kinds of terrain.
OPERATION WARNINGS WARNING POTENTIAL HAZARD Climbing hills improperly. WHAT CAN HAPPEN Could cause loss of control or cause vehicle to overturn. HOW TO AVOID THE HAZARD Always check the terrain carefully before you start up any hill. Never climb hills with excessively slippery or loose surfaces. Never open the throttle suddenly. The vehicle could go out of control. Never go over the top of any hill at high speed.
OPERATION WARNINGS WARNING POTENTIAL HAZARD Improperly operating over obstacles. WHAT CAN HAPPEN Could cause loss of control or a collision. Could cause vehicle to overturn. HOW TO AVOID THE HAZARD Before operating in a new area, check for obstacles. Use extreme caution when riding over large obstacles, such as large rocks or fallen trees. WARNING POTENTIAL HAZARD Skidding or sliding. WHAT CAN HAPPEN You may lose control of the vehicle.
OPERATION WARNINGS WARNING POTENTIAL HAZARD Operating this vehicle through deep or fast flowing water. WHAT CAN HAPPEN Tires may float, causing loss of traction and loss of control, which could lead to an accident. HOW TO AVOID THE HAZARD Never operate this vehicle in fast flowing water or in water deeper than that specified in your Owner’s Manual. See page 52. Remember that wet brakes may have reduced stopping ability. Test your brakes after leaving water.
OPERATION WARNINGS WARNING POTENTIAL HAZARD Operating this vehicle with improper modifications. WHAT CAN HAPPEN Improper installation of accessories or modification of this vehicle may cause changes in handling which in some situations could lead to an accident. HOW TO AVOID THE HAZARD Never modify this vehicle through improper installation or use of accessories. All parts and accessories added to this vehicle should be genuine Polaris Industries Inc.
OPERATION WARNINGS WARNING POTENTIAL HAZARD Overloading this vehicle or carrying or towing cargo improperly. WHAT CAN HAPPEN Could cause changes in vehicle handling which could lead to an accident. HOW TO AVOID THE HAZARD Never exceed the stated load capacity for this vehicle. Cargo should be properly distributed and securely attached. Reduce speed when carrying cargo or pulling a trailer. Allow greater distance for braking.
VEHICLE IDENTIFICATION NUMBERS 1 Important: Record these numbers from your vehicle in the spaces provided. 1. Frame VIN: 2. Vehicle Model Number: 3. Engine Serial Number (Right front side of engine crankcase) Remove the spare key and store in a safe place. Record your ignition key number here. It is a four digit number found stamped on the key. In the event the key is lost, replacement can be made by supplying your dealer with this number.
CONTROL PARTS AND FUNCTIONS Fuel Gauge The fuel gauge on the instrument panel shows the amount of fuel in the fuel tank. When the red indicator needle comes near the E (empty) mark, refuel at the earliest opportunity. Ignition Switch This is a three-position, key-operated switch. The key can be removed from the switch when it is in the OFF position. OFF Engine off. All electrical circuits off except Acc. 12V. ON All electrical equipment can be used.
CONTROL PARTS AND FUNCTIONS Parking Brake Lever The parking brake lever is located at the right side of the driver’s seat. Pull the lever up and to the rear to apply the parking brake. To release, push in and hold the knob on the end of the lever and push the lever all the way down. Spring pressure helps return the lever to the released position. Auxiliary Lighting/Electrical Accessory Terminals The auxiliary lighting/electrical accessory 12 volt terminals (1) are located under the instrument panel.
CONTROL PARTS AND FUNCTIONS Seat Belts The vehicle is equipped with lap-style seat belts for the operator and passenger. WARNING Seat belts reduce injury. Always were your seat belt. Minimum age recommendation for passengers if five years old. Passengers under five years of age require special restraints which are not available with this vehicle. To wear the seat belt properly, follow this procedure: 1. Place the belt across your lap as low on your hips as possible taking care that the belt is not twisted.
CONTROL PARTS AND FUNCTIONS Engine Fuel and Oil System The fuel tank filler cap (1) is located on the left side by the drivers seat. Use either leaded or unleaded gasoline with a minimum pump octane number of 87 R+ M/2 octane. The fuel supply valve (2), located in the center console storage compartment (A) has three positions: OFF: For vehicle storage and whenever transporting. ON: For normal operation. RES: For reserve supply in the event of main supply exhaustion. NOTE: There is about a 7 to 10 mile (11.
CONTROL PARTS AND FUNCTIONS WARNING Gasoline is highly flammable and explosive under certain conditions. Always exercise extreme caution whenever handling gasoline. Always refuel with the engine stopped and outdoors or in a well ventilated area. Do not smoke or allow open flames or sparks in or near the area where refueling is performed or where gasoline is stored. Do not over fill the tank. Do not fill the tank neck.
CONTROL PARTS AND FUNCTIONS WARNING The engine exhaust from this product contains chemicals known to cause cancer, birth defects or other reproductive harm. Never use gasohol with an octane rating lower than the minimum octane rating specified for this product. Never use gasohol containing more than 10% ethanol (grain alcohol). Never use gasohol containing more than 5% methanol (wood alcohol). Gasoline containing methanol must also be blended with cosolvents and corrosion inhibitors.
CONTROL AND PARTS FUNCTIONS VEHICLE NOMENCLATURE - Left View 2 1 7 3 4 6 5 10 11 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.
CONTROL AND PARTS FUNCTIONS VEHICLE NOMENCLATURE - Front View 13 14 12 12 16 12. 13. 14. 15. 16.
CONTROL AND PARTS FUNCTIONS VEHICLE NOMENCLATURE - Rear View 17 17 18 21 17. 18. 19. 20. 21.
CONTROL AND PARTS FUNCTIONS VEHICLE NOMENCLATURE - Instrument Panel 4 3 6 5 7 8 9 2 1 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12.
CONTROL AND PARTS FUNCTIONS Demand 6 Drive Exclusive Demand 6 Drive System (All Wheel Drive) This Polaris AWD is equipped with a unique, Polaris exclusive, Demand 6 Drive (AWD) system which is activated by a switch on the dash. When the switch is “off” the RANGER is in 4 wheel drive at all times. When the switch is “on” the RANGER is in Demand 6 Drive and the front wheels will automatically engage anytime the rear wheels lose traction.
CONTROL AND PARTS FUNCTIONS Transmission Gear Selector Operation The transmission gear selector is located to the right of the vehicle driver’s seat. The transmission selector lever has four posiShift Pattern tions: high forward (D2); reverse; neutral; and low forward (D1). D-2 D-1 Use of (low forward gear - D1) is recommended in heavy pulling situations to extend belt life. N To change gears, stop the vehicle and with the engine idling, move the lever to the desired gear.
CONTROL AND PARTS FUNCTIONS Disengaging Wheel Hubs When backing uphill while in Demand 6 Drive and then going forward downhill, one or both hubs may remain engaged. If one or both hubs remain engaged they can be disengaged by stopping, shifting to and moving in reverse. Then proceed in forward again. You can tell if only one front hub is engaged if the steering pulls to one side.
CONTROL AND PARTS FUNCTIONS Engine Cooling System Coolant Level The recovery bottle (1), located on the left side of the machine must be maintained between the minimum and maximum levels indicated on the recovery bottle. The engine coolant level is controlled or maintained by the recovery system. The recovery system components are the recovery bottle, radiator filler neck, radiator pressure cap and connecting hose.
CONTROL AND PARTS FUNCTIONS Engine Cooling System Radiator Coolant Level Inspection NOTE: This procedure is only required if the cooling system has been drained for maintenance and/or repair. However, if the recovery bottle has run dry, the level in the radiator should be inspected and coolant added if necessary. WARNING Never remove the pressure cap when the engine is warm or hot. Escaping steam can cause severe burns. The engine must be cool before removing the pressure cap.
CONTROL AND PARTS FUNCTIONS Engine Cooling System To insure that the coolant maintains its ability to protect the engine, it is recommended that the system be completely drained every two years and a fresh mixture of antifreeze and water be added. Polaris recommends the use of Polaris Premium 60/40 anti-freeze/coolant or a 50/50 mixture of high quality aluminum compatible anti-freeze/coolant and distilled water. NOTE: Polaris Premium 60/40 is already premixed and ready to use. Do not dilute with water.
CONTROL AND PARTS FUNCTIONS 4 Cycle Premium 4 Synthetic Lubricant Polaris Premium 4 All Season Synthetic engine oil has been specially formulated for use in Polaris 4 cycle engines. It is a fully synthetic, high performance, multi-viscosity oil designed to provide the ultimate in lubrication performance and protection. Premium 4 possesses unsurpassed film strength over the widest possible temperature range. It resists viscosity and frictional breakdown in ambient temperatures from -40° F to 120° F.
CONTROL AND PARTS FUNCTIONS Oil and Filter Change The recommended oil change interval is 100 hours, 1000 miles, or every six months, whichever comes first. Suggested break in oil change is at 20 hours, 500 miles, or one month, whichever comes first. Severe use operation requires more frequent service. Severe use includes continuous duty in dusty or wet conditions, and cold weather riding.
CONTROL AND PARTS FUNCTIONS Oil and Filter Change (Cont.) 14. Reinstall drain plug. 15. Remove dipstick (2) and add 2 quarts (1.9 l) of Polaris Premium 4 synthetic oil. Reinstall dipstick. NOTE: If sump is not drained, add about 1 3/4 quarts initially. 16. Place gear selector in neutral and set parking brake. 17. Start engine and let it idle for one to two minutes. Stop engine and inspect for leaks. 18.
STARTING THE ENGINE Stopping the Engine 1. Release the throttle pedal completely. 2. Put the gear shift lever into (N) Neutral. 3. Apply the parking brake to help prevent the vehicle from rolling. 4. Turn the ignition switch key to the OFF position. Procedure for Starting a Cold Engine WARNING Do not start or operate this vehicle with sticking or improperly operating throttle pedal. A stuck or improperly operating throttle could cause an accident resulting in severe injury or death.
STARTING THE ENGINE 7. If engine does not start, release ignition switch and wait five seconds; then turn the ignition switch to start for another five seconds. Repeat this procedure until engine starts. NOTE: Do not press the throttle pedal while starting the engine. After the Engine Starts 1. If the engine slows or stops, use of the choke lever at its HALF position will allow proper engine warm up. 2. Vary the engine RPM slightly with the throttle to aid in warm up until the engine idles smoothly.
STARTING THE ENGINE Procedure for Starting a Warm Engine Warm engines do not normally require the use of the choke since the spark plug can easily become wet fouled. 1. Place the transmission in neutral and move the vehicle to a level surface. 2. Lock the parking brake 3. Turn the fuel tank valve to ON. 4. Sit in the vehicle in the driver’s seat. 5. Turn the ignition key to START. “HALF” “OFF” Choke Lever Side View 6.
STARTING THE ENGINE Recoil Starter Recoil Starter If the battery is weak and cannot start the engine, use of the recoil starter located on the right side of the machine will allow vehicle operation until repairs can be made. 1. Be certain the parking brake is set. See page 27. 2. Remove right side engine access panel. See page 35. 3. Grasp the recoil starter tightly and pull slightly until the starter mechanism engages. 4. Pull the rope abruptly to start the engine.
VEHICLE BREAK-IN PERIOD The break in period for your new Polaris RANGER is defined as the first twenty hours of operation, or the time it takes to use the first two tanks full of gasoline. No single action on your part is as important as a proper break in period. Careful treatment of a new engine will result in more efficient performance and longer life for the engine. Perform the following procedures carefully. CAUTION: Use only Polaris Premium 4 All Season synthetic oil, or API certified “SH” oil.
CARRYING LOADS The RANGER has been designed to carry or tow a certain amount of load. Always read and understand the load distribution warnings listed on the warning labels. Never exceed the following weights. Maximum Capacities (Level Ground) Cargo Box RANGER - 1500 lbs. (681 kg) 1000 lbs. (454 kg) 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.
OPERATING SAFETY Load Distribution 1. Always load the cargo box placing the load as far forward as possible. 2. Always operate the vehicle with extreme care whenever hauling or towing loads. 3. Slow down and drive in D-1 only. 4. The cargo box dump latch must be securely latched before loading and operating. Unintentional box tilting will result if weight is placed in the rear of the box and the latch is not secured. WARNING: Never operate this vehicle with the cargo box in the raised position.
OPERATING SAFETY 1. Sit in the driver’s seat with the seatbelt fastened. 2. After starting the engine and allowing it to warm up, shift the transmission into gear. 3. Check your surroundings and determine your path of travel. 4. Release the parking brake. 5. Keeping both hands on the steering wheel, slowly depress the throttle with your right foot and begin driving. Vehicle speed is controlled by the amount of throttle opening and PVT shifting is done automatically. 6.
OPERATING SAFETY Riding On Slippery Surfaces Whenever driving on slippery surfaces such as wet trails or loose gravel, or during cold freezing weather, special attention must be paid to prevent vehicle turnover. Always: 1. Slow down when entering slippery areas. 2. Maintain a high level of alertness, reading the trail and avoiding quick, sharp turns which can cause skids. 3. Correct a skid by turning the steering wheel in the direction of the skid. 4.
OPERATING SAFETY Operating on Hills WARNING Improperly crossing hills or turning on hills can be dangerous! Loss of vehicle control or overturning of the vehicle could occur. Avoid crossing the side of a steep hill if possible. Use extreme care when operating your RANGER in hilly terrain. Whenever descending a hill always: 1. Drive directly downhill. 2. Slow down. 3. Apply the brakes lightly to aid in slowing. WARNING Loss of vehicle control due to excessive speed can occur.
OPERATING SAFETY WARNING indicates a potential hazard which could result in serious injury or death. WARNING Braking and handling are greatly affected whenever operating in hilly terrain. Loss of vehicle control or overturning of the vehicle could occur. Avoid climbing steep hills (15 maximum). Use extreme care when operating your vehicle in hilly terrain. WARNING Avoid climbing steep hills. Loss of vehicle control or overturning of vehicle could occur.
OPERATING SAFETY WARNING Going down a hill improperly could cause loss of control or cause the vehicle to overturn. Always check the terrain carefully before you start down any hill. Never go down a hill at high speed. Avoid going down a hill at an angle which would cause the vehicle to lean sharply to one side. Go straight down the hill where possible. WARNING Climbing hills improperly can cause loss of control or cause vehicle to overturn. Always check the terrain carefully before you start up any hill.
OPERATING SAFETY Crossing Streams Your Polaris RANGER can operate through water up to depths reaching the floorboards. Before fording streams always: 1. Determine water depths and current. 2. Choose a crossing where both banks have gradual inclines. 3. Proceed slowly, avoiding rocks and obstacles if possible. 4. After crossing, dry the brakes by applying light pressure to the lever until braking action is normal.
OPERATING SAFETY Trail Obstacles Keep Alert! Look ahead and learn to read the trail as you ride. Stay on the right side of the trail, if possible, and be constantly alert for hazards such as logs, rocks and low hanging branches. WARNING Hidden or unseen hazards on the trail can be dangerous. Personal injury or the vehicle overturning can occur from unseen obstacles. Keep alert and constantly look for obstacles on the trail.
OPERATING SAFETY Backing Up 1. When backing up, always avoid backing downhill. 2. Back slowly. 3. When in reverse, apply the brakes lightly for stopping. 4. Avoid turning at sharp angles in reverse. 5. Never open the throttle suddenly while backing. 6. Always inspect left and right fields of vision before backing. WARNING Backing your RANGER can be dangerous! You could hit an obstacle or person behind you; or the vehicle could tip over on a steep incline. Always back slowly, avoiding excessive speed.
OPERATING SAFETY Dumping the Cargo Box 1. Select a level site to dump the cargo box. Do not attempt to dump or unload the vehicle while parked on an incline. 2. Set the parking brake. 3. Dismount the vehicle. 4. Stand clear and pull the cargo box release mechanism lever (1) forward. Lift the front of the cargo box to dump. 1 WARNING If the weight distribution on the box is located toward the rear of the box and the release lever is pulled forward, the box will want to dump on its own.
NOISE EMISSION CONTROL SYSTEM REGULATION TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED! U.S.
BATTERY Battery CAUTION Whenever removing the battery, disconnect the negative (black) cable first. When reinstalling the battery, connect the negative (black) cable last. Replenishing the Battery Fluid A poorly maintained battery will deteriorate rapidly. Check the battery fluid level often. The fluid level should be kept between the upper and lower level marks. Maintain between upper and lower level marks To refill use only distilled water. Tap water contains minerals which are harmful to a battery.
BATTERY Battery Removal 1. Disconnect hold down straps holding the battery (1) in position and remove battery retainer. 1 2. Remove the battery vent tube from the battery. 3. Disconnect the black (negative) battery cable first. 4. Disconnect the red (positive) battery cable next. 5. Lift the battery out of the vehicle, being careful not to tip it sideways and spill any electrolyte.
MAINTENANCE Periodic Maintenance Schedule Careful periodic maintenance will help keep your vehicle in the safest, most reliable condition. Inspection, adjustment and lubrication intervals of important components are explained in the following chart: Maintenance intervals are based upon average riding conditions and a vehicle speed of approximately 10 miles per hour. Vehicles subjected to severe use, such as operation in wet or dusty areas, should be inspected and serviced more frequently.
MAINTENANCE Periodic Maintenance Schedule (Cont.) Item Hours or Odometer Frequency Remarks Fuel System 100 hours 12 months Check for leaks at fuel cap, lines, fuel valve, filter, pump and carburetor. Replace lines every two years.
MAINTENANCE Periodic Maintenance Schedule (Cont.
MAINTENANCE Lubrication Recommendations Item Lube Rec. Method Frequency* 1.Engine Oil Polaris Premium 4 Synthetic 0W40 Add to proper level on dipstick. See page 37. Check level daily. 2. Brake Fluid DOT 3 Only Maintain level between fill lines. See page 78. As required; change every two years or 200 hours 3. Transmission Oil Polaris Premium Synthetic chain case lube Add to FULL level on dipstick. See page 66. Change annually or at 100 hours 4.
MAINTENANCE Lubrication Recommendations 4. Front Gear Case 3. Transmission Full Fill plug Operating Range 6. Front Prop Shaft (U-Joint) 7. Propshaft Yoke 9. Axle Cardan Front Drive (AWD Models) 5. Center Halfshaft (U Joint) 8. Demand Hubs Upper 11. Front A-Arm Pivot Shaft 10. Ball Joint 8.
MAINTENANCE Lubrication Recommendations 11. Front A Arm Pivot Shaft Grease**∆ Locate fitting on pivot shaft and grease with grease gun. Every 3 months or 50 hours 12. Swing Arm Bushings Grease** Locate fittings on swing arm and grease with grease gun. Monthly or at 20 hours 13. Upper Control Arms Grease**∆ Locate fittings and grease Semi-annually 14. Lower Control Arms Grease**∆ Locate fittings and grease Semi-annually 15.
MAINTENANCE Lubrication Recommendations 13. Upper Control Arm 16. 17.
MAINTENANCE WARNING Vehicle operation with insufficient, deteriorated, or contaminated engine oil will cause accelerated wear and may result in engine seizure, accident, and injury. Engine Oil In order for the engine to function properly, maintain the engine oil at the proper level, and change the oil and oil filter in accordance with the Periodic Maintenance Schedule. Not only do dirt and metal particles collect in the oil, but the oil itself loses its lubricative quality if used too long.
MAINTENANCE Transmission Oil Changing Procedure 1. Locate and remove fill plug/ dipstick. 2. Remove transmission drain plug located on the bottom right hand side and drain the oil. Catch and discard used oil properly. 3. Clean and reinstall the drain plug. 4. Add Polaris Premium Synthetic Gearcase Lubricant (PN 2871478) to full mark on the fill plug/dipstick. Full Operating Range 5. Check for leaks. CAUTION: Be careful not to allow any dirt or foreign materials to enter the transmission case.
MAINTENANCE Front Gearcase Lubrication Fill plug/Dipstick Front Gearcase Lubrication The front gearcase fill plug is located on the right side of the front gearcase. The front gearcase lubricant level should be checked every six months or 1000 miles (1600 km), whichever comes first. Front gearcase oil should be changed annually. With the RANGER on a level surface, remove fill plug and check the lubricant level. Lubricant should be kept at the bottom thread of the fill plug hole.
MAINTENANCE The following items should be checked occasionally for tightness; or if they have been loosened for maintenance service. Axle and Wheel Nut Torque Specifications Front Spindle Nut(s) Dealer Performed Service Front Wheel Nuts 15 Ft. Lbs. Center and Rear Hub Retaining Nut(s) 120 Ft. Lbs. Rear Wheel Nuts 15 Ft. Lbs. Front Wheel Hub Tightening Front wheel bearing tightness and spindle nut retention are critical component operations.
MAINTENANCE Rear Spring Adjustment The rear shock absorber springs are adjusted by rotating the adjuster in the direction required to increase or decrease spring tension. Rear Spring Adjustment Cam Air Filter Service It is recommended that the air filter be replaced yearly. When riding in extremely dusty conditions replacement will be required more often. 1. Open the hood. 2. Remove the cover. Inspect the gasket. It should adhere tightly to the cover and seal all the way around. 3. Remove the air filter.
MAINTENANCE CAUTION: Operation of your vehicle without a breather filter can cause engine damage. Breather Filter and Hoses Do not perform this operation immediately after the engine has been run. The exhaust system becomes very hot and can cause severe burns. WARNING 1. Open hood and locate the airbox (1). 2. Follow right hand breather line out of the back of the airbox and locate filter (2). 3. Inspect filter for debris. Blow through gently in direction of arrow on filter to check for clogging.
MAINTENANCE Coolant Level Inspection NOTE: Check the coolant level when the engine is cold (room or atmospheric temperature). 1. Situate the vehicle on level ground. Radiator Cap 2. Check the coolant level through the coolant level gauge on the reserve tank located Behind the left hand engine compartment panel. The coolant level should be between the F (Full) and L (Low) marks. 3. If the amount of coolant is not within the operating range, unscrew the cap from the reserve tank.
MAINTENANCE Spark Plugs Proper electrode gap is .028″/.7mm. Spark plug torque is 17 ft. lbs. (2.3 kg/m). Use NGK BKR5ES spark plugs. Proper electrode gap is .025″ (.06 cm). Spark plug torque is 17 ft. lbs.(2.3 kg/m) for a used spark plug, 11 ft. lbs (1.52 kg/m) for a new spark plug. 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.
MAINTENANCE Spark Arrestor The exhaust pipe must be periodically purged of accumulated carbon as follows: 1. Remove the clean out plugs located on the bottom of the muffler as shown above. 2. Place the transmission in neutral and start the engine. Purge accumulated carbon from the system by momentarily revving the engine several times. Clean Out Plug 3. If some carbon is expelled, cover the exhaust outlet and rap on the pipe around the clean out plugs while revving the engine several more times. 4.
MAINTENANCE Tool Kit To help you perform routine maintenance, a tool kit is provided in the storage compartment under the seat. Items included in the kit are: screwdriver open end wrench (8-10 mm) open end wrench (12-14 mm) tire pressure gauge spark plug wrench and handle NOTE: Other tools are also necessary to perform maintenance work. They are called out later in this manual. PVT System WARNING The PVT system rotates at high speeds, creating large amounts of force on clutch components.
MAINTENANCE Throttle Pedal If the throttle pedal (1) has excessive play due to cable stretch or cable misadjustment, it will cause a delay in throttle response, especially at low engine speed. Also, the throttle may not open fully. If the throttle pedal has no play, the throttle may be hard to control, and the idle speed may be erratic. Check the throttle pedal play periodically in accordance with the Periodic Maintenance Chart and adjust the play if necessary. Throttle Freeplay Inspection 1.
MAINTENANCE Carburetor The idle speed adjustment should be performed in accordance with the Periodic Maintenance Chart or whenever the idle speed is changed. The following procedure covers the idle speed adjustment: Carburetor/Engine Idle RPM Adjustment Recommended engine idle RPM is 1200 +/- 200. If the engine idle speed is not satisfactory, and all other conditions are favorable, the carburetor can be adjusted as follows: 1. Apply the parking brake. 2.
MAINTENANCE Front and Rear Brakes The front and brakes are hydraulic disc type brakes activated by the brake pedal. The following checks are recommended to keep the brake system in good operating condition. How often they need checking depends upon the type of driving that has been done. Inspect the level of the brake fluid before each ride. Change the brake fluid according to the Periodic Maintenance Chart. The brake fluid should also be changed if it becomes contaminated with dirt or water.
MAINTENANCE Rear Brake The rear brake is a hydraulic disc type brake which is activated by the same pedal which activates the front brake system. The rear brake system is self adjusting and requires no maintenance other than periodic checks of the pads for wear. Wear Line Pads should be changed when worn to 3/64″ (.1 cm) which is about the thickness of a dime. 3/64″ (.1 cm) Inspect the brake disc spline and pad wear surface for excessive wear.
MAINTENANCE Parking Brake Lever The parking brake helps hold the vehicle from rolling while parked. Make sure the parking brake lever is functioning properly before each ride. Inspection: Pull the parking brake lever up and to the rear. After 8 to 12 clicks of lever travel, the vehicle should not roll while parked.
MAINTENANCE Wheel Removal Procedure 1. Stop the engine, place the transmission in gear and lock the parking brake. 2. Loosen the wheel nuts slightly. 3. Elevate the side of the vehicle by placing a suitable stand under the frame. 4. Remove the wheel nuts and remove the wheel. Wheel Installation 1. With the transmission in gear and the parking brake locked, place the wheel in the correct position on the wheel hub.
MAINTENANCE WARNING Operating your vehicle with worn tires will increase the possibility of the vehicle skidding easily with possible loss of control. Worn tires can cause an accident. Always replace tires when the tread depth measures 1/8″ (.3 cm) or less. Tire Inspection CAUTION: Maintain proper tire pressure according to charts below. Improper tire inflation may affect vehicle maneuverability. When replacing a tire always use original equipment size and type.
MAINTENANCE Seat Belts Make certain each seat belt functions properly before each ride. Push the latch plate into the buckle until it clicks. The latch plate must slide smoothly into the buckle. The click sound shows it is securely latched. Push the red button in the middle of the buckle to make sure it releases freely. Also check the belt webbing for wear, cuts or damage.
MAINTENANCE Headlight Beam The headlight beam can be adjusted up and down. 1. Place the vehicle on a level surface with the headlight approximately 25’ (7.6 m) from a wall. 2. Measure the distance from the floor to the center of the headlight and make a mark on the wall at the same height. 3. Start the engine and turn the headlight switch to high beam. 4. Observe headlight aim. The most intense part of the headlight beam should be aimed 2″ (5.1 cm) below the mark placed on the wall in step 2.
MAINTENANCE WARNING Gasoline is highly flammable and explosive under certain conditions. Always exercise extreme caution whenever handling gasoline. Always refuel with the engine stopped and outdoors or in a well ventilated area. Do not smoke or allow open flames or sparks in or near the area where refueling is performed or where gasoline is stored. Do not over fill the tank. If you should get gasoline on your skin or clothing, immediately wash it off with soap and water and change clothing.
MAINTENANCE Cleaning Your RANGER Keeping your vehicle clean will not only improve its appearance but it can also extend the life of various components. With a few precautions, your vehicle can be cleaned much like an automobile. Washing If a high pressure type car wash system is used, extreme care must be taken to avoid water damage to the wheel bearings, transmission seals, body panels, brakes, headlights and warning labels.
MAINTENANCE Storage If your vehicle is to be placed in extended or off season storage, the following steps should be taken to preserve its condition. 1. Perform all necessary repairs and thoroughly clean the vehicle. 2. Turn the fuel valve to “off” and drain the carburetor. 3. Remove the spark plug and pour approximately one ounce of Premium 4 oil into the cylinder. Operate the starter for a few seconds and reinstall the spark plug. Drain tube attached here Drain Screw 4. Remove the battery.
MAINTENANCE WARNING Do not run the engine in a closed area. Exhaust gases contain carbon monoxide; a colorless, odorless, poisonous gas. Breathing exhaust gas leads to carbon monoxide poisoning, asphyxiation and death. Bolt and Nut Tightening Tightness of the bolts, nuts and other fasteners should be checked by an authorized Polaris dealer in accordance with the Periodic Maintenance Chart.
TROUBLESHOOTING Procedures The following information is provided to help you identify probable causes for questions you may have about the operation of your vehicle. See your Polaris dealer with any additional questions you may have.
SPECIFICATIONS C A P A C I T I E S E N G I N E 90 Gross Vehicle Weight 3020 lbs. Fuel Capacity 9.5 Gallons Towing Capacity 1500 lbs. Maximum Cargo Box Load 1000 lbs. Overall Length 113 in. Overall Width 58 in. (Tires) 60″ (Cargo Box) Overall Height 75 in. Wheelbase 81 in. Ground Clearance 8.5 in. Dry Weight 1520 lbs. Cargo Box (L x W x H) 40 x 59.75 x 9 Minimum Turning Radius 168 in. Engine Oil Capacity 2 Quarts Coolant Capacity 2.
SPECIFICATIONS D R I V E T R A I N T I R E S B R A K E S Driving System Type PVT Shift Type Single Lever/Center Console Gear Reduction - Low 24.16:1 Gear Reduction - Reverse 18.67:1 Gear Reduction - High 11.97:1 Drive Ratio - Front: 2:1 Drive Ratio - Final 3.5:1 Drive Ratio - Center 1:3.
WARRANTY 92
WARRANTY LIMITED WARRANTY Polaris Industries Inc., 1225 Highway 169 North, Minneapolis, Minnesota 55441-5078, 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 parts which are covered by this warranty. This warranty begins on the date of purchase. This warranty is transferrable to another consumer during the warranty period through a Polaris dealer.
WARRANTY WARRANTY OR ANY OTHER CONTRACT, NEGLIGENCE, OR OTHER TORT OR OTHERWISE. Some states do not permit the exclusion or limitation of incidental or consequential damages or implied warranties, so the above limitations or exclusions may not apply to you if inconsistent with controlling state law. ALL IMPLIED WARRANTIES (INCLUDING BUT NOT LIMITED TO THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE) ARE LIMITED IN DURATION TO THE ABOVE SIX MONTH WARRANTY PERIOD.
INDEX Air Cleaner . . . . . . . . . . . . . . . . . . . . . . 70 All Wheel Drive . . . . . . . . . . . . . . . . . . . 31 Backing Up . . . . . . . . . . . . . . . . . . . . . . 54 Battery Installation . . . . . . . . . . . . . . . . 58 Battery Maintenance . . . . . . . . . . . . . . 57 Battery Removal . . . . . . . . . . . . . . . . . . 58 Brake, Front . . . . . . . . . . . . . . . . . . . . . 78 Brake, Rear . . . . . . . . . . . . . . . . . . . . . . 79 Break In Period . . . . . . . . . . . . . . . . . . .