WARNING Read, understand, and follow all of the instructions and safety precautions in this manual and on all product labels. Failure to follow the safety precautions could result in serious injury or death. WARNING The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects or other reproductive harm.
WELCOME Thank you for purchasing a Polaris vehicle, and welcome to our worldwide family of Polaris owners. We proudly produce an exciting line of utility and recreational products. • Snowmobiles • All-terrain vehicles (ATVs) • RANGER utility vehicles • Victory motorcycles We believe Polaris sets a standard of excellence for all utility and recreational vehicles manufactured in the world today.
POLARIS and POLARIS THE WAY OUT are registered trademarks of Polaris Industries Inc. Copyright 2006 Polaris Sales Inc. All information contained within this publication is based on the latest product information at the time of publication. Due to constant improvements in the design and quality of production components, some minor discrepancies may result between the actual vehicle and the information presented in this publication.
TABLE OF CONTENTS Vehicle Identification Numbers. . . . . . . . . . . . . 4 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Features and Controls . . . . . . . . . . . . . . . . . . . 22 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 Emission Control Systems . . . . . . . . . . . . . . . 57 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . 108 Polaris Products. . . . . . . .
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 existing keys. The ignition switch must be replaced if all keys are lost.
Safety Decals and Locations SAFETY 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 instructions of the decals on the vehicle. If any decal becomes illegible or comes off, contact your Polaris dealer to purchase a replacement. Replacement safety decals are provided by Polaris at no charge.
SAFETY Safety Decals and Locations Cab Frame/Seat Belt Warning Clutch Cover Warning Clutch Cover Warning WARNING NO 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 which can result in serious injury or death. Cab Frame/Seat Belt Warning WARNING • VEHICLE ROLLOVER could cause severe injury or death.
Safety Decals and Locations SAFETY Shift Caution CAUTION To avoid transmission damage, shift only when vehicle is stationary and at idle. Discretionary Warning Shift Caution WARNING Improper vehicle use can result in SEVERE INJURY or DEATH. NEVER: • Operate on public roads. A collision can occur with a another vehicle. • Carry more than two passengers, or passengers under age five. • Use ALCOHOL or DRUGS before or while operating this vehicle.
SAFETY Operator Safety WARNING 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, even during routine maneuvers like turning, or driving on hills or over obstacles, if you fail to take proper precautions.
Operator Safety SAFETY The following signal words and symbols appear throughout this manual and on your vehicle. Your safety is involved when these words and symbols are used. Become familiar with their meanings before reading the manual. The safety alert symbol, on your vehicle or in this manual, alerts you to the potential for injury. WARNING The safety alert warning indicates a potential hazard that may result in serious injury or death.
SAFETY Operator Safety WARNING 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 procedures described. • Never allow anyone without a valid driver's license to operate this vehicle. • Minimum age recommendation for passengers is five years old.
Operator Safety SAFETY • Always follow proper procedures for turning as described in this manual. Practice turning at slow speeds before attempting to turn at faster speeds. Never turn at excessive speeds. • Always have this vehicle checked by an authorized Polaris dealer if it has been involved in an accident. • Never operate this vehicle on hills too steep for the vehicle or for your abilities. Practice on smaller hills before attempting larger hills.
SAFETY Operator Safety • Never modify this vehicle through improper installation or use of accessories. • Never exceed the stated load capacity for this vehicle. Cargo should be properly distributed and securely attached. Reduce speed and follow the instructions in this manual for hauling cargo or pulling a trailer. Allow a greater distance for braking. • Always wear the seat belts when operating this vehicle. Seat belts reduce the severity of injury in case of a sudden stop or collision.
SAFETY Operator Safety WARNING Make sure your RANGER is in excellent operating condition at all times. We strongly recommend that the operator check all safety components before each ride. Polaris RANGERs are designed to provide safe operation when used as directed. Failure of critical machine components may result from operation with any modifications, especially those that increase speed or power. The RANGER may become aerodynamically unstable at speeds higher than those for which it is designed.
SAFETY Operator Safety WARNING POTENTIAL HAZARD Stalling, rolling backwards while climbing a hill WHAT CAN HAPPEN Vehicle overturn HOW TO AVOID THE HAZARD Maintain a steady speed when climbing a hill. If you lose all forward speed: Apply the brakes. Engage the park brake after fully stopped. If you begin rolling backwards: Never apply engine power. Apply the brakes gradually. When fully stopped, engage the park brake.
SAFETY Operator Safety WARNING POTENTIAL HAZARD Operating this vehicle without proper instruction WHAT CAN HAPPEN Loss of control, accident HOW TO AVOID THE HAZARD 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. All operators must read and understand the Owner's Manual and all warning and instruction labels before operating the vehicle.
SAFETY Operator Safety 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 Driving a RANGER requires your full attention. DO NOT drink alcohol or use drugs or medications before or while driving. They will reduce your alertness and slow your reaction time.
SAFETY Operator Safety WARNING POTENTIAL HAZARD Attempting jumps and other stunts WHAT CAN HAPPEN Loss of control, accident and/or vehicle overturn HOW TO AVOID THE HAZARD Never attempt jumps and other stunts. Avoid exhibition driving. WARNING POTENTIAL HAZARD Operating on frozen bodies of water. WHAT CAN HAPPEN Severe injury or death can result if the vehicle and/or the operator fall through the ice. HOW TO AVOID THE HAZARD Never operate the RANGER on a frozen body of water.
SAFETY Operator Safety WARNING POTENTIAL HAZARD Failure to inspect the vehicle before operating Failure to properly maintain the vehicle WHAT CAN HAPPEN Accident, equipment damage HOW TO AVOID THE HAZARD Always inspect your RANGER before each use to make sure it's in safe operating condition. Always follow the inspection and maintenance procedures and schedules described in the Owner's Manual.
SAFETY Operator Safety WARNING POTENTIAL HAZARD Failure to follow the minimum age recommendations for this vehicle WHAT CAN HAPPEN Serious injury or death (the child or others) HOW TO AVOID THE HAZARD Only persons with a valid driver's license should operate a Polaris RANGER. Even though a child may be within the age group for which some vehicles are recommended, he or she may not have the skills, abilities, or judgment needed to operate the vehicle safely and may be involved in a serious accident.
SAFETY Operator Safety WARNING Leaving the keys in the ignition can lead to unauthorized use of the vehicle resulting in serious injury or death. Always remove the ignition key when the vehicle is not in use. WARNING After any overturn or accident, have a qualified service dealer inspect the entire vehicle for possible damage, including (but not limited to) brakes, throttle and steering systems. WARNING Exhaust system components are very hot during and after use of the vehicle.
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 near the refueling area or where gasoline is stored. Do not over fill the tank. Do not fill the tank neck.
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.
FEATURES AND CONTROLS Component Locations Headlights Radiator (if equipped) Hood Hold-Down Strap Front Bumper/Brush Guard 23
FEATURES AND CONTROLS Component Locations Tailgate Latch Release Taillights Taillights Tailgate Air Box Receiver Hitch CV Boot/Rear Caliper Muffler (Spark Arrestor) 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 pages 50-53.
FEATURES AND CONTROLS Component Locations Instrument Cluster Your RANGER is equipped with an instrument cluster that senses vehicle 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 location of the instrument cluster.
FEATURES AND CONTROLS Instrument Cluster Rider Information Center The rider information center is located in the instrument cluster. All segments 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 instrument cluster may have shut off to protect the electronic speedometer. If this occurs, take the vehicle to your Polaris dealer for proper diagnosis. 1.
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 the miles traveled by the vehicle on each trip if it's reset before each trip. To reset the trip meter, select the trip meter mode. Press and hold the mode button (override button) until the total changes to 0.
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 movement of the tires will also cause the gauge to exit the diagnostic mode. To enter the diagnostics mode: 1. Turn the key switch off and wait 10 seconds. 2. Lock the parking brake. 3. Place the transmission in neutral. 4. Hold the mode/reverse override button and turn the key switch on.
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 through the AWD coil (only on models with switchable AWD). This screen is for informational purposes only. Please see your dealer for all major repairs.
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 either ON or OFF appears in the Rider Information Center, depending on your preference. To reset the service interval: 1. Enter the diagnostic mode. 2. Toggle to the service interval screen. 3.
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 following procedure to download blink codes (failure codes) from the EFI module. 1. Engage the parking brake. 2. Stop the engine. 3. Turn the key switch to the ON position. 4.
FEATURES AND CONTROLS Instrument Cluster Rider Information Center Downloading Codes Blink Code -21 45 46 22 22 23 42 42 51 51 51 52 52 52 53 53 53 54 54 54 55 55 55 56 56 56 57 57 57 58 58 58 41 41 61 32 Failure Description No RPM Signal Loss of Synchronization Barometric Pressure Sensor: Circuit Low Input Barometric Pressure Sensor: Circuit High Input TPS: Open or Short Circuit to Ground TPS: Short Circuit to Battery RAM Error: Defective ECU Engine Temp Sensor Circuit: Short to Ground Engine Temp Sensor
Seat Removal FEATURES AND CONTROLS 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 filler cap is located on the right-hand side of the vehicle near the passenger seat. When refueling, always use either leaded or unleaded gasoline with a minimum pump octane number of 87 R+M/2 octane.
FEATURES AND CONTROLS Console Cup Holder Storage Box Instrument Gauge Ignition Switch Storage Tray AWD/Differential Switch Light (if equipped) Switch Cup Holder 12V Accessory Storage Outlet Compartment (with lid) Mode Button 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.
Gear Selector FEATURES AND CONTROLS H: High Gear L: Low Gear N: Neutral R: Reverse H L NOTE: Low gear is the primary Gear Selector driving range for the RANGER. High gear is intended for use on hardpacked surfaces with light loads. N R To change gears, stop the vehicle, and with the engine idling, move the lever to the desired gear. Do not attempt to shift gears with engine speed above idle or while the vehicle is moving.
FEATURES AND CONTROLS Brake Pedal Depress the brake pedal to slow or stop the vehicle. Apply the brakes while starting the engine. Brake Pedal Throttle Pedal Park Brake Push the pedal down Release to increase engine speed. Spring pressure Park Brake Throttle returns the pedal to the Pedal Pedal rest position when released. Always check that the throttle pedal returns normally before starting the engine. Make sure there's adequate throttle pedal freeplay.
Switches FEATURES AND CONTROLS Ignition Switch WARNING Leaving the keys in the ignition can lead to unauthorized use of the vehicle resulting in serious injury or death. Always remove the ignition key when the vehicle is not in use. 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. AWD/Differential Switch (if equipped) Light Switch Ignition Switch OFF The engine is off. Electrical circuits are off, except Acc, 12V.
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 breakin period. Careful treatment of a new engine will result in more efficient performance and longer life for the engine. Perform the following procedures carefully.
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.
OPERATION Starting the Engine WARNING Engine exhaust contains poisonous carbon monoxide and can cause loss of consciousness resulting in severe injury or death. Never run an engine in an enclosed area. 1. 2. 3. 4. Sit in the driver's seat and fasten the seat belt. Engage the park brake. Shift the transmission to neutral. 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.
Stopping the Engine OPERATION 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 property damage and serious injury. Always engage the park brake after stopping the engine. Braking 1. Release the throttle pedal completely. 2. Press on the brake pedal evenly and firmly. NOTE: Practice starting and stopping (using the brakes) until you're familiar with the controls.
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 service brakes, and shift the transmission into gear. 3. Check your surroundings and determine your path of travel. 4. Release the park brake. 5. Keeping both hands on the steering wheel, slowly release the brakes and depress the throttle with your right foot to begin driving. 6. Drive slowly.
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 conditions, follow these precautions: 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.
OPERATION Driving Safely Driving Uphill Whenever traveling uphill, follow these precautions: 1. Always travel straight uphill. 2. Avoid steep hills (15° maximum). 3. Keep both feet on the floor. 4. Proceed at a steady rate of speed and throttle opening. 15° maximum WARNING Climbing hills improperly can cause loss of control or vehicle overturn. Always check the terrain carefully before climbing a hill. Braking and handling are greatly affected when operating in hilly terrain.
OPERATION Driving Safely Driving on a Sidehill (Sidehilling) WARNING Crossing hillsides or turning on hills can result in loss of control or vehicle overturn, resulting in severe injury or death. Avoid crossing the side of a hill when possible. When unavoidable, exercise extreme caution. Avoid operating on steep hills (15° maximum). 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.
OPERATION Driving Safely Driving Through Water WARNING The large tires on your RANGER may cause the vehicle to float in deep or fast-flowing water, which could result in loss of control and lead to serious injury or death. Never cross deep or fast-flowing water with your RANGER. Your Polaris RANGER can operate through water up to a maximum recommended depth equal to the floorboards. Follow these procedures when operating through water: 1. Always determine water depths and current before entering. 2.
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 all obstacles are immediately visible. Reduce speed and travel with caution in unfamiliar terrain.
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 right fields of vision before backing. WARNING Failure to use caution when operating in reverse can result in serious injury or death.
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 cause property damage and serious injury. Always engage the park brake after stopping the engine.
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 BRAKING WHEN HAULING CARGO. Always load the cargo box with the load as far forward and as low as possible. When operating over rough or hilly terrain, reduce speed and cargo to maintain stable driving conditions.
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 1500 lbs. (681 kg) 1000 lbs. (454 kg) RANGER 6X6 EFI 1750 lbs. (794 kg) 1250 lbs (567 kg) WARNING Driving with passengers in the cargo box can result in severe injury or death.
OPERATION Driving Safely Dumping the Cargo Box WARNING Operating the vehicle while the cargo box is raised could result in severe injury. The box could close unexpectedly and cause injury to the driver or passenger. The rear tires will also catch the rear of a raised box, damaging the vehicle and creating hazardous driving conditions. Never operate this vehicle with the cargo box in the raised position. 1. Select a level site to dump the cargo box.
OPERATION Driving Safely Towing Loads 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 these precautions when towing: Never load more than 150 lbs. (68.1 kg) tongue weight on the towing bracket. Do not operate the vehicle faster than 10 mph (16 km/h) when towing. See page 50. Towing a trailer increases braking distance. Do not tow more than the recommended weight for the vehicle.
OPERATION Driving Safely Parking the Vehicle WARNING A rolling vehicle can cause property damage and serious injury. Always engage the park brake after stopping the engine. 1. 2. 3. 4. Stop the vehicle on a level surface. Turn the engine off. Engage the park brake. Remove the ignition switch key to prevent unauthorized use. WARNING Gasoline is extremely flammable and can be explosive under certain conditions.
Differential Lock (4X4 Models) OPERATION 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 traction. Press the top of the rocker switch to engage All Wheel Drive (AWD). Move the rocker switch to the center position to lock the differential and operate in two wheel drive (2WD).
OPERATION All Wheel Drive (AWD) The illuminated amber AWD AWD Switch 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. There is no limit to the length of time the vehicle may remain in AWD. When the RANGER 6X6 AWD switch is in the off position, the vehicle is in two-wheel drive at all times.
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 has a spark arrestor that was tested and qualified to be in accordance with the USDA Forest Service Standard 5100-1C.
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 parts as necessary. When inspection reveals the need for replacement parts, use genuine Polaris parts available from your Polaris dealer. Record maintenance and service in the Maintenance Log beginning on page 126.
Periodic Maintenance Chart MAINTENANCE 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 procedures marked with a Q could result in component failure and lead to serious injury or death. Have an authorized Polaris dealer perform these services.
MAINTENANCE Periodic Maintenance Chart Perform all services at whichever maintenance interval is reached first. Item Maintenance Interval (whichever comes first) Hours Calendar Miles (Km) Q Steering - Pre-Ride - X Front suspension - Pre-Ride - X Rear suspension - Pre-Ride - - Pre-Ride - - Pre-Ride - Brake system - Pre-Ride - Wheels/fasteners - Pre-Ride - Tires X Brake fluid level Remarks Make adjustments as need ed. See Pre-Ride Checklist on page 39.
Periodic Maintenance Chart Item MAINTENANCE Maintenance Interval Remarks (whichever comes first) Hours Calendar Miles (Km) X Engine breather E filter (if equipped) 25 H Monthly - Inspect; replace if necessary X Engine oil change (break-in) 25 H 1M - Perform a break-in oil change at one month X General lubrication 50 H 3M - Lubricate all fittings, pivots, cables, etc.
MAINTENANCE Periodic Maintenance Chart Item Maintenance Interval Remarks (whichever comes first) Hours Calendar Miles (Km) Q Fuel system 100 H 12 M - Check for leaks at tank cap, lines, fuel valve, filter, pump, throttle body; re Q Fuel filter 100 H 12 M - Replace yearly X Radiator (in applicable) 100 H 12 M - Inspect; clean external surfaces X Cooling Hoses 100 H 12 M - Inspect for leaks X Engine mounts 100 H 12 M - Inspect 100 H 12 M - Inspect X Spark plug E 100 H 12M
Lubrication Recommendations MAINTENANCE Check and lubricate all components at the intervals outlined in the Periodic 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 lubrication interval. Item Lube Method Engine Oil Polaris Premium 4 Synthetic Add to proper level on dipstick. 0W40 See page 66. Brake Fluid DOT 3 or DOT 4 Maintain level between fill lines. See page 87.
MAINTENANCE Lubrication Recommendations 6X6 Prop Shaft U-Joints 4X4 6X6 6X6 4X4 6X6 Ball Joint 6X6 Swing Arm Bushings 64
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 formulated for use in Polaris 4-cycle engines. It's a fully synthetic, high performance, multi-viscosity oil designed to provide the ultimate in lubrication performance and protection.
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 NOTE: Due to the dipstick entry angle into the crankcase, the oil level will read higher on the bottom side of the dipstick. Always read the level on the upper surface of the dipstick. 6. After reinstalling the dipstick, be sure to seat the lever lock.
MAINTENANCE Engine Oil Oil and Filter Change CAUTION Hot oil can cause serious burns to skin. Do not allow hot oil to come into contact with skin. 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 until warm. Stop the engine. 3. Clean the area around the drain plug. 4.
MAINTENANCE Engine Oil Oil and Filter Change 1. Remove the dipstick and fill the sump with two quarts (1.9 l) of recommended 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. Inspect for leaks. 6. Re-check the oil level on the dipstick and add oil as necessary to bring the level to the upper mark on the dipstick. 7. Dispose of used filter and oil properly.
Gearcases MAINTENANCE 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 for recommended lubricants, capacities and torque specifications. See page 112 for the part numbers of Polaris products. The fill plug is located at the rear of the vehicle. Oil Check 1.
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. Dispose of used oil properly. 3. Wipe the magnetic end of the drain plug clean to remove accumulated metallic filings. 4. After the oil has drained completely, install a new sealing Drain Plug washer. 5.
Gearcases MAINTENANCE 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 for recommended lubricants, capacities and torque specifications. See page 112 for the part numbers of Polaris products. The front gearcase fill plug is located on the right side of the front gearcase. Oil Check 1.
MAINTENANCE Gearcases Middle Gearcase (6X6) Always check and change the middle 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 for recommended lubricants, capacities and torque specifications. See page 112 for the part numbers of Polaris products. The middle gearcase fill plug is located on the side of the gearcase. Oil Check 1.
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 for the part numbers of Polaris products. The rear gearcase fill plug is on the driver's side of the rear gearcase.
MAINTENANCE Gearcases Rear Gearcase Oil Change 1. Remove the fill plug. 2. Place a drain pan under the drain plug. Remove the drain plug. 3. Drain the oil. Dispose of used oil properly. 4. Clean the drain plug. Reinstall the drain plug. Torque to specification. 5. Add the recommended oil. 6. Reinstall the fill plug. Torque to specification. 7. Check for leaks.
MAINTENANCE Spark Plugs CAUTION Using non-recommended spark plugs can result in serious engine damage. Always use Polaris-recommended spark plugs. Refer to the specifications section beginning on page 108. Spark Plug Gap/Torque Model RANGER 4X4 EFI RANGER 6X6 EFI Electrode Gap .035" (.9 mm) .035" (.9 mm) New Plug Torque 18 ft. lbs. (24 Nm) 18 ft. lbs. (24 Nm) Used Plug Torque 18 ft. lbs. (24 Nm) 18 ft. lbs. (24 Nm) Spark plug condition is indicative of engine operation.
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 indicates the proper type and heat range for the engine and the service. NOTE: The tip should not be white. A white insulator tip indicates overheating, caused by use of an improper spark plug or incorrect throttle body adjustments. Wet Fouled Plug The wet fouled insulator tip is black.
Cooling System MAINTENANCE Operation The engine coolant level is controlled or maintained by the recovery system. The recovery system components are the overflow bottle, radiator filler neck, radiator pressure cap and connecting hose. As coolant operating temperature increases, the expanding (heated) excess coolant is forced out of the radiator, past the pressure cap, and into the overflow bottle.
MAINTENANCE Cooling System Radiator and Cooling Fan Always check and clean the screen and radiator fins at the intervals outlined in the Periodic Maintenance Chart beginning on page 58. Do not obstruct or deflect air flow through the radiator by installing unauthorized accessories in front of the radiator or behind the cooling fan. Interference with the radiator air flow can lead to overheating and consequent engine damage.
MAINTENANCE Cooling System Radiator Coolant Level Always check and clean the screen and radiator fins at the intervals outlined in the Periodic Maintenance Chart beginning on page 58. Do not obstruct or deflect air flow through the radiator by installing unauthorized accessories in front of the radiator or behind the cooling fan. Interference with the radiator air flow can lead to overheating and consequentially, engine damage. WARNING Escaping steam can cause severe burns.
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, cover, etc.). When To Use Low Range and High Range Condition Range to Use Operating at speeds less than 7 MPH (11 km/h) Low Towing heavy loads Low Operating in rough terrain (swamps, mountains, etc.
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 modification will cause the system to be out of balance, creating vibration and additional loads on components. The PVT system rotates at high speeds, creating large amounts of force on clutch components.
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 operating. 1. Loosen the bottom screws that secure the clutch cover. 2. Allow the water to drain. 3. Tighten the screws. 4. Apply the brakes. Start the engine. 5. Engage the park brake. 6. Shift the transmission to neutral. 7. Apply varying throttle for 10-15 seconds to expel the moisture and air-dry the belt and clutches.
Filter Systems MAINTENANCE 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 Air Filter cover and inspect the gasket. It should adhere tightly to the cover and seal all the way around. 3. Remove the air filter. 4. Do not attempt to clean the main element. Install a new air filter.
MAINTENANCE Spark Arrestor WARNING Failure to heed the following warnings while servicing the spark arrestor could result in serious injury or death. Do not perform service on the spark arrestor while the system is hot. Exhaust system temperatures can reach 1000° F. Allow components to cool sufficiently before proceeding. Remove any combustible materials from the area. Wear eye protection and gloves. Do not stand behind or in front of the vehicle while purging. Never run the engine in an enclosed area.
MAINTENANCE Throttle System WARNING 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. Never start or operate this vehicle if it has a sticking or improperly operating throttle pedal. Immediately contact your dealer for service if throttle problems arise. Always check the pedal for free movement and return before starting the engine and occasionally during operation.
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 rubber boot and slide it far enough to expose the end of the inline cable adjuster. 4. Loosen the adjuster lock nut. 5. Rotate the boot to turn the adjuster until 1/16" to 1/8" (1.
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 rouBrake Fluid tinely. Inspect the level of the Reservoir brake fluid before each operation. Change the brake fluid every two years and any time the fluid becomes contaminated, the fluid level is below the minimum, or if the type and brand of the fluid in the reservoir are unknown. 1. Position the vehicle on a level surface. 2.
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 worn to 3/64" (1 mm). 3/64" (1mm) Park Brake Inspection 1. Slowly push the park brake pedal down with your foot. 2. After 8 to 12 clicks of pedal travel, check the vehicle for movement.
Steering Wheel Inspection MAINTENANCE 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 0.8"-1.0" (20-25 mm) of freeplay. 4. If there is excessive freeplay or strange noises, or the steering feels rough or "catchy," have the steering system inspected by an authorized Polaris dealer.
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 of the buckle to make sure it releases freely. 3. Check the belt webbing for wear, cuts or damage.
MAINTENANCE Tires WARNING Operating your vehicle with worn tires will increase the possibility of skidding, loss of control and an accident, which could result in serious injury or death. Always replace tires when the tread depth measures 1/8" (3 mm) or less. Improper tire inflation or the use of non-standard size or type of tires may adversely affect vehicle handling, which could result in vehicle damage or personal injury. Always maintain proper tire pressure.
MAINTENANCE Tires WARNING Improperly installed wheels can adversely affect tire wear and vehicle handling, which can result in serious injury or death. Always ensure that all nuts are torqued to specification. Do not service axle nuts that have a cotter pin installed. See your Polaris dealer. 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.
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. WARNING Poor lighting while driving can result in severe injury or death. Headlight and taillight lenses become dirty during normal operation. Wash the headlights frequently to maintain lighting quality. Hot components can cause serious burns to skin. Do not service the headlamps until they've cooled sufficiently.
MAINTENANCE Lights Headlight Beam Adjustment X 25 ft. (7.6 m) X 8" (20 cm) 1. Place the vehicle on a level surface with the headlight approximately 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 engine. Turn on the headlights. 4. Observe the headlight aim. The most intense part of the headlight beam should be aimed 8" (20 cm) below the mark placed on the wall in step 2.
MAINTENANCE Vehicle Immersion CAUTION 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, follow 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 water is present. 4.
MAINTENANCE Battery Your vehicle may have either a sealed battery, which requires little maintenance, or a conventional battery. A sealed battery can be identified by its flat covers on the top of the battery. A conventional battery has six filler caps on the top of the battery. Conventional Battery Always keep battery terminals and connections free of corrosion. If cleaning is necessary, remove the corrosion with a stiff wire brush. Wash with a solution of one tablespoon baking soda and one cup water.
MAINTENANCE Battery WARNING 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) cable last. Battery Removal 1. Open the hood. 2. On conventional batteries, remove the battery vent tube. 3. Disconnect the black (negative) battery cable first. 4. Disconnect the red (positive) battery cable last. 5.
MAINTENANCE Battery Battery Installation Using a new battery that has not been fully charged can damage the battery 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 is fully charged. 2. Place the battery in the battery holder. 3. With conventional batteries, install the battery vent tube (sealed batteries do not have a vent tube).
Battery MAINTENANCE 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 to maintain a full charge. See page 100. NOTE: Battery charge can be maintained by using a Polaris Battery Tender charger or by charging about once a month to make up for normal selfdischarge.
MAINTENANCE Battery Battery Charging (Conventional Battery) 1. Remove the battery from the vehicle to prevent damage from leaking 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 needed to raise the specific gravity to 1.270 or greater. 3. Reinstall the battery. See page 98. Make sure the positive terminal is toward the front of the vehicle.
MAINTENANCE Battery Battery Charging (Sealed Battery) NOTE: Always verify battery condition before and 1-2 hours after the end of charging. Charge Time State of Charge Voltage Action (Using constant current charger @ standard amps specified on top of battery) 100% 12.8-13.0 volts None required 75%-100% 12.5-12.8 volts 50%-75% 25%-50% 12.0-12.5 volts 11.5-12.0 volts None, check at 3 mos.
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. CAUTION High water pressure may damage components. Polaris recommends washing the vehicle by hand or with a garden hose, using mild soap. Certain products, including insect repellents and chemicals, will damage plastic surfaces. Do not allow these types of products to contact the vehicle.
Cleaning and Storage MAINTENANCE 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 following items: • Wheel bearings • Radiator • Transmission seals • Brakes • Cab and body panels • Labels and decals • Electrical components and wiring NOTE: If warning and safety labels are damaged, contact your Polaris dealer for free replacement.
MAINTENANCE Cleaning and Storage Chrome Wheel Care (if equipped) Proper maintenance will protect chrome wheels from corrosion, preserve 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 susceptible to corrosion if not properly cleaned. Clean chrome wheels more often if they're exposed to salt or other corrosive elements. 1. Wash chrome wheels frequently. Use a mild detergent.
Cleaning and Storage MAINTENANCE Storage Tips CAUTION 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 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 for the recommended amount.
MAINTENANCE Cleaning and Storage Storage Tips Fog the Engine 1. Treat the fuel system with Polaris Carbon Clean. Follow the instructions 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 plugs and add 2-3 tablespoons of Premium 4 Synthetic 0W40 engine oil. To access the plug holes, use a section of clear 1/4" hose and a small plastic squeeze bottle filled with the premeasured amount of oil.
Removal from Storage MAINTENANCE 1. Check the battery electrolyte level and charge the battery if necessary. Install it in the vehicle. Make sure the battery vent hose is routed properly and that it's not pinched or restricted in any way. 2. Make sure the spark plug is tight. 3. Fill the fuel tank with fuel. 4. Check all the points listed in the Daily Pre-Ride Inspection section on page 39. NOTE: Tightness of the bolts, nuts and other fasteners should be checked by an authorized Polaris dealer. 5.
SPECIFICATIONS RANGER 4X4 EFI Gross Vehicle Weight Fuel Capacity Engine Oil Capacity Coolant Capacity Towing Capacity Hitch Tongue Capacity Max. Cargo Box Load Overall Length Overall Width (box) Overall Width (tires) Overall Height Wheelbase Cargo Box (L x W x H) Ground Clearance Min. Turning Radius Engine Displacement Bore x Stroke Alternator Output Compression Ratio Starting System Fuel System Ignition System Spark Plug / Gap Front Suspension Rear Suspension 108 2750 lbs. (1247 kg) 9 gal. (34 l) 2 qts.
SPECIFICATIONS RANGER 4X4 EFI Lubrication System Engine Oil Driving System Type Shift Type Gear Reduction - Low Gear Reduction - Reverse Gear Reduction - High Drive Ratio - Front: Drive Ratio - Final Tire Size - Front Tire Size - Rear Tire Pressure - Front Tire Pressure - Rear Brakes, Front/Rear Brake, Park Hood Headlight Taillights Brake Light Indicator Light Pressurized Wet Sump 0W/40 PVT, 4-wheel independent shaft, lockable differential Single Lever (H/L/N/R) 8.71:1 5.94:1 3.14:1 3.83:1 3.
SPECIFICATIONS RANGER 6X6 EFI Gross Vehicle Weight Fuel Capacity Engine Oil Capacity Coolant Capacity Towing Capacity Max. Cargo Box Load Overall Length Overall Width (box) Overall Width (tires) Overall Height Wheelbase Cargo Box (L x W x H) Ground Clearance Min. Turning Radius Engine Displacement Bore x Stroke Alternator Output Compression Ratio Starting System Fuel System Ignition System Spark Plug / Gap Front Suspension Center Suspension Rear Suspension 110 2900 lbs. (1317 kg) 9 gal. (34 l) 2 qts. (2.
SPECIFICATIONS RANGER 6X6 EFI Lubrication System Engine Oil Driving System Type Shift Type Gear Reduction - Low Gear Reduction - Reverse Gear Reduction - High Drive Ratio - Front: Drive Ratio - Final Tire Size - Front Tire Size - Center/Rear Tire Pressure - Front Tire Pressure - Rear Brakes, Front/Rear Brake, Park Hood Headlight Taillights Brake Light Indicator Light Pressurized Wet Sump 0W/40 PVT Single Lever, Console (H/L/N/R) 8.71:1 5.9:1 3.14:1 3.83:1 3.
POLARIS PRODUCTS Part Number 2870791 2871281 2871844 2873602 2873603 2871653 2872276 2870465 2871654 2872277 2871323 2871534 2871312 2871322 2871423 2871460 2871515 2871551 2871329 2872073 2872348 Description Engine Lubricant Fogging Oil (12 oz. Aerosol) Premium 4 Synthetic 0W-40 (4-Cycle) Engine Oil (qt.) Premium 4 Synthetic 0W-40 (4-Cycle) Engine Oil (gal.) Gearcase / Transmission Lubricants Premium AGL Synthetic Gearcase Lubricant (qt.) Premium AGL Synthetic Gearcase Lube (gal.
Drive Belt Wear/Burn Possible Cause Driving onto a pickup or tall trailer in high range Starting out going up a steep incline Driving at low RPM or ground speed (3-7 MPH) Insufficient warm-up at low ambient temperatures TROUBLESHOOTING Solution Use low range during loading. Use low range. See warnings on page 44. Drive at a higher speed or use low range more frequently. See page 80. Warm the engine at least 5 minutes.
TROUBLESHOOTING Engine Doesn't Turn Over Possible Cause Low battery voltage Loose battery connections Loose solenoid connections Loose electronic control box connections Solution Recharge the battery to 12.
Engine Pings or Knocks Possible Cause Poor quality or low octane fuel Incorrect ignition timing Incorrect spark plug gap or heat range TROUBLESHOOTING Solution Replace with recommended fuel See your dealer Set gap to specs or replace plugs Engine Runs Irregularly, Stalls or Misfires Possible Cause Fouled or defective spark plugs Worn or defective spark plug wires Incorrect spark plug gap or heat range Loose ignition connections Water present in fuel Low battery voltage Kinked or plugged fuel tank vent lin
TROUBLESHOOTING Engine Stops or Loses Power Possible Cause Out of fuel Kinked or plugged fuel vent line Water is present in fuel Fouled or defective spark plugs Worn or defective spark plug wires Incorrect spark plug gap or heat range Loose ignition connections Low battery voltage Incorrect fuel Clogged air filter Other mechanical failure Overheated engine 116 Solution Refuel Inspect and replace Replace with new fuel Inspect, clean and/or replace spark plug See your dealer Set gap to specs or replace plu
LIMITED WARRANTY WARRANTY Polaris Sales Inc., 2100 Highway 55, Medina, MN 55340, gives a SIX MONTH LIMITED WARRANTY on all components of the Polaris RANGER against defects in material or workmanship. Polaris also gives a one year limited warranty on the final drive chain for failure due to defects. 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.
WARRANTY LIMITATIONS OF WARRANTIES AND REMEDIES 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. POLARIS FURTHER DISCLAIMS ALL EXPRESS WARRANTIES NOT STATED IN THIS WARRANTY. Some states do not allow limitations on how long an implied warranty lasts, so the above limitation may not apply to you if inconsistent with controlling state law.
Exported Vehicles WARRANTY EXCEPT WHERE SPECIFICALLY REQUIRED BY LAW, THERE IS NO WARRANTY OR SERVICE BULLETIN COVERAGE ON THIS VEHICLE IF IT IS SOLD OUTSIDE THE COUNTRY OF THE SELLING DEALER'S AUTHORIZED LOCATION. This policy does not apply to vehicles that have received authorization for export from Polaris Industries. Dealers may not give authorization for export. You should consult an authorized dealer to determine this vehicle's warranty or service bulletin coverage if you have any questions.
WARRANTY U.S.A. EPA Emissions Limited Warranty This All Terrain Vehicle (ATV) or Off Road Utility Vehicle (ORUV) emissions limited warranty is in addition to the Polaris standard limited warranty for this vehicle. Polaris warrants that this vehicle is; (1) designed, built, and equipped to conform at the time of initial sale with the requirements of 40 CFR 1051 and, (2) free from defects in materials and workmanship that may keep it from meeting these requirements.
WARRANTY California Emission Control Warranty Statement The Air Index of this Engine is 3 0 2 Most Clean 4 6 8 10 Least Clean Note: The lower the Air Index, the less pollution. This engine is certified to be emission compliant for 1000 hours of use. Your Warranty Rights and Obligations The California Air Resources Board and Polaris Industries Inc.
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 that you retain all receipts covering maintenance on your LSI engine, but POLARIS cannot deny warranty solely for the lack of receipts or for your failure to ensure the performance of all scheduled maintenance.
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 enrichment system, if applicable (iv) Regulator assy (gaseous fuel, if applicable) (2) Air Induction System (i) Intake manifold, if applicable (ii) Air filter (3) Ignition System (i) Spark plugs (ii) Magneto or
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 being serviced under warranty, POLARIS and any of its authorized dealers shall not be liable for any loss of use of the LSI engine, for any damage to goods, or loss of time or inconvenience.
WARRANTY X Perform these procedures more often for vehicles subjected to severe use. E Emission-Related Service.
MAINTENANCE LOG Use the following chart to record periodic maintenance.
MAINTENANCE LOG DATE MILES (KM) OR HOURS TECHNICIAN SERVICE PERFORMED / COMMENTS 127
INDEX A C Accessory Outlet . . . . . . . . . . . . . . . 34 Adding Coolant . . . . . . . . . . . . . . . . 77 Adjustment, Headlight Beam. . . . . . 94 Adjustment, Park Brake. . . . . . . . . . 88 Adjustment, Rear Spring . . . . . . . . . 89 Adjustment, Rear Suspension . . . . . 89 Adjustment, Throttle Freeplay. . . . . 86 Age Restrictions. . . . . . . . . . . . . . . . . 8 Air Filter . . . . . . . . . . . . . . . . . . . . . 83 Air Filter Cleaning. . . . . . . . . . . . . . 83 All Wheel Drive. . . . . . .
INDEX D F Driving on Slippery Surfaces . . . . . . 43 Driving Over Obstacles . . . . . . . . . . 47 Driving Procedure. . . . . . . . . . . . . . . 42 Driving Safely. . . . . . . . . . . . . . . 42-54 Driving Through Water . . . . . . . . . . 46 Driving Uphill. . . . . . . . . . . . . . . . . . 44 Driving, After Driving in Water . . . . 82 Drying the Transmission. . . . . . . . . . 82 Dumping the Cargo Box . . . . . . . . . . 52 Fuel Cap . . . . . . . . . . . . . . . . . . . . . . 33 Fuel Filter . . . . .
INDEX L O Lamp Replacement, Headlight . . . . 93 Level, Coolant . . . . . . . . . . . . . . . 78-79 Light Switch. . . . . . . . . . . . . . . . . . . 37 Lights . . . . . . . . . . . . . . . . . . . . . . 93-94 Lights, Brake . . . . . . . . . . . . . . . . . . 94 Load Capacity . . . . . . . . . . . . . . . . . 51 Loads, Towing . . . . . . . . . . . . . . . . . 53 Lock, Differential . . . . . . . . . . . . . . 55 Lubricant Part Numbers. . . . . . . . . 112 Lubrication for Storage . . . . . . . . .
INDEX R Receiver Hitch . . . . . . . . . . . . . . . . . 24 Release, Park Brake . . . . . . . . . . . . . 36 Removal, Battery . . . . . . . . . . . . . . . 97 Removal, Seat . . . . . . . . . . . . . . . . . . 33 Removal, Wheels . . . . . . . . . . . . . . . 92 Removing the Vehicle from Storage 107 Replacement, Headlight Lamp . . . . . 93 Reverse . . . . . . . . . . . . . . . . . . . . . . . 48 Rider Information Center . . . . . . 26-32 RPM, Idle, Throttle Body . . . . . . . . . 86 S Safety Decals . . . . .