2018 OWNER’S MANUAL RANGER CREW® XP 1000 NorthStar Edition
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. For videos and more information about a safe riding experience with your Polaris vehicle, scan this QR code with your smartphone.
2018 Owner’s Manual RANGER CREW® XP 1000 NorthStar Edition
POLARIS® and RANGER® are trademarks of POLARIS Industries Inc. Copyright 2017 Polaris Industries 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. Depictions and/or procedures in this publication are intended for reference use only.
WELCOME Thank you for purchasing a POLARIS vehicle, and welcome to our world-wide family of POLARIS enthusiasts. Be sure to visit us online at www.polaris.com for the latest news, new product introductions, upcoming events, career opportunities and more. Here at POLARIS we proudly produce an exciting line of utility and recreational products.
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Introduction . . . . . . . Safety . . . . . . . . . . Features and Controls . . Operation . . . . . . . . Winch Guide. . . . . . . Emission Control Systems . Maintenance . . . . . . Specifications . . . . . . POLARIS Products . . . . Troubleshooting . . . . . Warranty . . . . . . . . Maintenance Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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INTRODUCTION INTRODUCTION This POLARIS vehicle is an off-road vehicle. Familiarize yourself with all laws and regulations concerning the operation of this vehicle in your area. 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.
INTRODUCTION WARNING Failure to heed the warnings and safety precautions contained in this manual can result in severe injury or death. Your POLARIS vehicle is not a toy and can be hazardous to operate. This vehicle handles differently than cars, trucks or other off-road vehicles. 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.
INTRODUCTION VEHICLE IDENTIFICATION NUMBERS Record your vehicle's identification numbers and key number in the spaces provided. Remove the spare key and store it in a safe place. An ignition key can be duplicated only by ordering a POLARIS key blank (using your key number) and mating it with one of your existing keys. The ignition switch must be replaced if all keys are lost.
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SAFETY SAFETY SAFETY TRAINING Safety training is a top priority for POLARIS. POLARIS strongly encourages you and any family members who will be riding this vehicle to take a training course. ROHVA (Recreational Off-Highway Vehicle Association) provides both an online safety e-course and a hands-on safety course. Visit www.rohva.org or call 866267-2751. Your POLARIS vehicle is considered an off-road vehicle.
SAFETY SAFE RIDING GEAR Always wear helmet, eye protection, gloves, long-sleeve shirt, long pants, overthe-ankle boots and seat belt at all times. Protective gear reduces the chance of injury. RIDER COMFORT Under certain operating conditions, heat generated by the engine and exhaust system can elevate temperatures in the rider cab area.
SAFETY HELMET Wearing a helmet can prevent a severe head injury. Whenever riding this POLARIS vehicle, always wear a helmet that meets or exceeds established safety standards. Approved helmets in the USA and Canada bear a U.S. Department of Transportation (DOT) label. Approved helmets in Europe, Asia and Oceania bear the ECE 22.05 label. The ECE mark consists of a circle surrounding the letter E, followed by the distinguishing number of the country which has granted approval.
SAFETY SAFETY LABELS AND LOCATIONS Warning labels have been placed on the vehicle for your protection. Read and follow the instructions of the labels on the vehicle carefully. If any of the labels depicted in this manual differ from the labels on your vehicle, always read and follow the instructions of the labels on the vehicle. If an informational or graphic label becomes illegible or comes off, contact your POLARIS dealer to purchase a replacement.
SAFETY PAYLOAD WARNING/SHIFT CAUTION WARNING RANGER NEVER EXCEED IF TOTAL PAYLOAD EXCEEDS 4x4 40 mph (64 kph) 25 mph (40 kph) 550 lbs. (250 kg) 1050 lbs (476 kg) 4x4 CA 40 mph (64 kph) 550 lbs. (250 kg) CREW 35 mph (56 kph) 1280 lbs. (582 kg) CREW CA 43 mph (70 kph) 1280 lbs. (582 kg) CAUTION To avoid transmission damage, shift only when vehicle is stationary and at idle. When vehicle is stopped, place shift in parked position.
SAFETY LOAD/PASSENGER/TIRE PRESSURE WARNING WARNING • Never carry passengers in cargo box. • Passengers can be thrown off. This can cause serious injury or death. • If total payload is greater than 500 lbs., the vehicle must be operated in LOW range. IMPROPER TIRE PRESSURE OR OVERLOADING CAN CAUSE LOSS OF CONTROL RESULTING IN SERIOUS INJURY OR DEATH. • Reduce speed and allow greater distance for braking when carrying cargo.
SAFETY CLUTCH COVER WARNING WARNING The Clutch Cover Warning q is located on the clutch cover. • Moving parts hazard under beltclutch 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. BELT WARNING WARNING Improper service or maintenance of this PVT system can result in vehicle damage, SEVERE INJURY or DEATH.
SAFETY SAFETY WARNINGS WARNING Failure to operate this vehicle properly can result in a collision, loss of control, accident or rollover, which may result in serious injury or death. Heed all safety warnings outlined in this section of the owner’s manual and in the safety DVD provided with your vehicle. See the OPERATION section of the owner’s manual for proper operating procedures.
SAFETY • Always follow proper procedures for turning. 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. • Always follow proper procedures for climbing hills as described in this manual.
SAFETY OPERATING WITHOUT INSTRUCTION Operating this vehicle without proper instruction increases the risk of an accident. The operator must understand how to operate the vehicle properly in different situations and on different types of terrain. Review the Operator Driving Procedures outlined in the manual. All operators must read and understand the owner's manual and all warning and instruction labels before operating the vehicle.
SAFETY FAILURE TO INSPECT BEFORE OPERATING Failure to inspect and verify that the vehicle is in safe operating condition before operating increases the risk of an accident. Always perform the pre-ride inspection before each use of your vehicle to make sure it's in safe operating condition. Always follow the inspection and maintenance procedures and schedules described in this owner’s manual.
SAFETY CARRYING A PASSENGER This POLARIS vehicle is a single-rider vehicle. Carrying a passenger greatly reduces the operator's ability to control the vehicle, which may result in an accident or rollover. Carrying a passenger in the cargo box could result in a fall from the vehicle or contact with moving components. Never carry a passenger on this vehicle. IMPROPER TIRE MAINTENANCE Operating this vehicle with improper tires or with improper or uneven tire pressure could cause loss of control or accident.
SAFETY IMPROPER HILL CLIMBING Improper hill climbing could cause loss of control or rollover. Use extreme caution when operating on hills. Always follow proper procedures for hill climbing as described in this owner's manual. DESCENDING HILLS IMPROPERLY Improperly descending a hill could cause loss of control or rollover. Always follow proper procedures for traveling down hills as described in this owner’s manual. CROSSING HILLSIDES Driving on a sidehill is not recommended.
SAFETY SKIDDING OR SLIDING Failure to use extra caution when operating on excessively rough, slippery or loose terrain could cause loss of traction, loss of control, accident or rollover. Do not operate on excessively slippery surfaces. Always slow down and use additional caution when operating on slippery surfaces. Skidding or sliding due to loss of traction can cause loss of control or rollover (if tires regain traction unexpectedly).
SAFETY OPERATING A DAMAGED VEHICLE Operating a damaged vehicle can result in an accident. After any rollover or other accident, have a qualified service dealer inspect the entire machine for possible damage, including (but not limited to) seat belts, rollover protection devices, brakes, throttle and steering systems. OPERATING WITH A LOAD ON THE VEHICLE The weight of both cargo and operator impacts vehicle operation and stability.
SAFETY POOR VISIBILITY Operating this vehicle in darkness or inclement weather could result in a collision or accident, especially if operating on a road or street. This vehicle is not equipped with highway-approved lights. Operate this vehicle off-road only. Use caution and drive at reduced speeds in conditions of reduced visibility such as fog, rain and darkness. Clean headlights frequently and replace burned out headlamps promptly.
SAFETY UNAUTHORIZED USE OF THE VEHICLE Leaving the keys in the ignition can lead to unauthorized use of the vehicle by someone under the age of 16, without a drivers license, or without proper training. This could result in an accident or rollover. Always remove the ignition key when the vehicle is not in use. EQUIPMENT MODIFICATIONS Your POLARIS vehicle is designed to provide safe operation when used as directed. Modifications to your vehicle may negatively impact vehicle stability.
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FEATURES AND CONTROLS FEATURES AND CONTROLS COMPONENT LOCATIONS q Console y Cargo Box w Headlights u Tailgate e Bumper/Brush Guard i Taillights r Radiator o Receiver Hitch t ROPS Cab Frame a CV Boot/Rear Caliper 29
FEATURES AND CONTROLS CONSOLE STEERING WHEEL The steering wheel can be tilted upward or downward for rider preference. Lift and hold the steering wheel adjustment lever while moving the steering wheel upward or downward. Release the lever when the steering wheel is at the desired position. Always make sure the steering wheel position does not impede proper operation of the brake pedal, throttle pedal and all other controls.
FEATURES AND CONTROLS SWITCHES Refer to the illustrations below to identify the switches present on your model. Switch operation is outlined on the following pages.
FEATURES AND CONTROLS LIGHT SWITCH The ignition switch key must be in the ON/RUN position to operate the headlights. Press the top of the rocker switch toward the dash to place the headlights on high beam. Move the rocker switch to the center position to place the headlights on low beam. Press the bottom of the rocker switch to turn off the headlights. AWD SWITCH The AWD switch has three positions: All Wheel Drive (AWD), Differential Lock/Two Wheel Drive (2WD) and Off (1WD/Turf Mode).
FEATURES AND CONTROLS POLARIS 3-MODE THROTTLE CONTROL SWITCH (IF EQUIPPED) The Polaris 3-Mode Throttle Control Switch has three positions: • Performance (PERF) • Standard (STND) • Work (WORK) PERFORMANCE The performance (PERF) setting maximizes throttle response for quick acceleration along with full horsepower and torque. STANDARD The standard (STND) setting provides a balance of throttle, full horsepower, and torque for everyday activities.
FEATURES AND CONTROLS WINCH SWITCH Press the top of the rocker switch to spool line out from the winch. Press the bottom of the rocker switch to spool line in to the winch. Move the rocker switch to the center position to stop spooling. REMOTE WINCH SWITCH Pull the remote winch switch and cable out from the dash storage area. Press and hold the left side of the switch to spool line out from the winch. Press and hold the right side of the switch to spool line in to the winch.
FEATURES AND CONTROLS GEAR SELECTOR To change gears, stop the vehicle, and with the engine idling, move the lever r to the desired gear. Do not attempt to shift gears with engine speed above idle or while the vehicle is moving. H: High Gear L: Low Gear N: Neutral R: Reverse P: Park Low gear is the primary driving range for the RANGER. High gear is intended for use on hard-packed surfaces with light loads. Whenever the vehicle is left unattended, always place the transmission in PARK.
FEATURES AND CONTROLS NOTICE Do not attempt to shift the transmission while the vehicle is moving or damage to the transmission could result. Always shift when the vehicle is stationary and the engine is at idle. USING LOW GEAR Always shift into low gear for any of the following conditions.
FEATURES AND CONTROLS INSTRUMENT CLUSTER q Speedometer w Rider Information Center e Indicator Lamps r Mode Button SPEEDOMETER The speedometer displays vehicle speed in either miles per hour (MPH) or kilometers per hour (km/h). RIDER INFORMATION CENTER The rider information center is located in the instrument cluster. All segments will light up for one second at start-up.
FEATURES AND CONTROLS q Gear Indicator This indicator displays gear shifter position. w Fuel Gauge The segments of the fuel gauge show the level of fuel in the fuel tank. When the last segment clears, a low fuel warning is activated. All segments including the fuel icon will flash. Refuel immediately. e Information Display Area This area displays odometer, trip meter, engine hour meter and programmable service hour interval.
FEATURES AND CONTROLS INDICATOR LAMPS LAMP INDICATES CONDITION Vehicle Speed When standard mode is selected, speed displays in miles per hour. When metric mode is selected, speed displays in kilometers per hour. Over Temperature This lamp illuminates to indicate an overheated engine. If the indicator flashes, the overheating condition remains, and the system will automatically reduce engine power.
FEATURES AND CONTROLS MODE BUTTON The yellow button located near the instrument cluster is used to toggle through mode options available. DISPLAY UNITS The display can be changed to display either standard or metric units of measurement. TIP To exit the set-up mode at any time, wait 10 seconds. The display automatically exits and returns to the odometer display. MEASUREMENT STANDARD METRIC Distance Miles Kilometers Fuel U.S.
FEATURES AND CONTROLS 4. Press and hold the MODE button until the next segment flashes. Release the button. 5. Repeat steps 3-4 twice to set the 10-minute and 1-minute segments. After completing the 1-minute segment, step 4 will save the new settings and exit the clock mode. 6. Turn the key to the OFF position. ODOMETER MODE The odometer records and displays the distance traveled by the vehicle. TRIP METER MODE The trip meter records the distance traveled by the vehicle if reset before each trip.
FEATURES AND CONTROLS DIAGNOSTIC DISPLAY MODE The EFI diagnostic display mode is for informational purposes only. Your POLARIS dealer can provide for all major repairs. The diagnostic mode is accessible only when the check engine warning indicator activates after the key has been turned on. Leave the key on if you want to view the active code (failure code). The diagnostic mode becomes inaccessible if the key is turned off and on and the warning indicator is no longer active.
FEATURES AND CONTROLS FOOT PEDALS BRAKE PEDAL Depress the brake pedal q to slow or stop the vehicle. Apply the brakes while starting the engine. When the brake pedal is depressed, the brake light comes on. Check the brake light before each ride. 1. Turn the ignition switch to the LIGHTS ON position. 2. Apply the brakes. The brake light should come on after about 10 mm (0.4 in.) of pedal travel. THROTTLE PEDAL Push the throttle pedal w down to increase engine speed.
FEATURES AND CONTROLS SEAT SEAT REMOVAL Pull up on the front of the seat and slide it toward the front of the vehicle. Install the seat by sliding the tabs into the rear of the seat base. Push down firmly on the front of the seat until the pins are fully seated into the grommets. SEAT BELTS This vehicle is equipped with three-point lap and diagonal seat belts for the operator and passenger. Always make sure the seat belts are secured for all riders before operating.
FEATURES AND CONTROLS 3. Release the strap, it will self tighten. 4. To release the seat belt, press the square red button in the buckle’s center. SEAT BELT INSPECTION Inspect all seat belts for proper operation before each use of the vehicle. 1. Push the latch plate into the buckle until it clicks. The latch plate must slide smoothly into the buckle. A click indicates that it's securely latched. 2. Push the red release latch in the middle of the buckle to make sure it releases freely. 3.
FEATURES AND CONTROLS CAB NETS (IF EQUIPPED) Riding in this vehicle without using the cab nets (or doors, if equipped) increases the risk of serious injury or death in the event of an accident or rollover. Cab nets (or doors) must be used by both operator and passengers at all times. Make sure all latches are secure before operating the vehicle. Always inspect cab nets and latches for tightness, wear and damage before each use of the vehicle. Use the strap adjusters to tighten any loose straps.
FEATURES AND CONTROLS HOOD LATCHES To remove the hood, rotate the hood latchesq 1/4-turn and lift the hood away from the vehicle. 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. WINDSHIELD If equipped, the windshield on your model may be a fixed windshield or a tip-out windshield.
FEATURES AND CONTROLS To close the windshield, firmly grasp the windshield handle. Pull the handle downward until the windshield is fully closed. Align the front handle ring (nearest the hinge) over the dash pin and press the handle downward to secure the closed windshield. REAR WINDOW PANEL WINDOW REMOVAL 1. Rotate the upper window latches counter-clockwise to release the locks. 2.
OPERATION OPERATION WARNING Failure to operate the vehicle properly can result in a collision, loss of control, accident or rollover, which may result in serious injury or death. Read and understand all safety warnings outlined in the safety section of this owner’s manual. VEHICLE BREAK-IN PERIOD The break-in period for your new vehicle is the first 20 hours of operation, or the time it takes to use the first 2 tanks full of gasoline.
OPERATION BRAKE SYSTEM BREAK-IN Apply only moderate braking force for the first 50 stops. Aggressive or overly forceful braking when the brake system is new could damage brake pads and rotors. PVT BREAK-IN (CLUTCHES/BELT) A proper break-in of the clutches and drive belt will ensure a longer life and better performance. Break in the clutches and belt by operating at slower speeds during the break-in period as recommended. Pull only light loads.
OPERATION ITEM REMARKS PAGE Headlamps Check operation, apply POLARIS dielectric grease when lamp is replaced Brake light/tail lamps Check operation - Seat Latch Push down on the seat back to ensure the latch is secure - Seat Belt Check length of belt for damage, check latches for proper operation Cab Doors (If equipped) Check doors and latches for wear or damage.
OPERATION NOTICE Operating the vehicle immediately after starting could cause engine damage. Allow the engine to warm up for several minutes before operating the vehicle. COLD WEATHER OPERATION If the vehicle is used year-round, check the oil level frequently. A rising oil level could indicate the accumulation of contaminates such as water or excess fuel in the bottom of the crankcase. Water in the bottom of the crankcase can lead to engine damage and must be drained.
OPERATION 3. Turn the engine off. 4. Slowly release the brake pedal and make sure the transmission is in PARK before exiting the vehicle. 5. Remove the ignition key to prevent unauthorized use. DRIVING PROCEDURES NEW OPERATOR DRIVING PROCEDURES 1. Read and understand the owner's manual and all warning and instruction labels before operating this vehicle. 2. Visit the Recreational Off-Highway Vehicle Association web site and take the free on-line training course. Visit www.rohva.org or call 866-267-2751.
OPERATION 16. After you become skilled at making turns and begin to operate at faster speeds, follow these precautions: • Avoid sharp turns. • Never turn while applying heavy throttle. • Never make abrupt steering maneuvers. • Operate at speeds appropriate for your skills, the conditions and the terrain. • DO NOT do power slides, “donuts”, jumps or other driving stunts. DRIVING WITH A PASSENGER 1. Perform the pre-ride inspection. 2.
OPERATION DRIVING ON SLIPPERY SURFACES WARNING Skidding or sliding can cause loss of control or rollover (if tires regain traction unexpectedly). When operating on slippery surfaces such as ice or loose gravel, reduce speed and use extra caution to reduce the chance of skidding or sliding out of control. Do not operate on excessively slippery surfaces. When driving on slippery surfaces such as wet trails, loose gravel, or ice, be alert for the possibility of skidding and sliding.
OPERATION DRIVING UPHILL Whenever traveling uphill, follow these precautions: 1. Avoid excessively steep hills. 2. ADC Models: Always operate in low gear and engage ADC 4X4 before ascending or descending a hill. 3. Always travel straight uphill. 4. Keep both feet on the floor. 5. Always check the terrain carefully before ascending any hill. Never climb hills with excessively slippery or loose surfaces. 6. Proceed at a steady rate of speed and throttle opening. Never open the throttle suddenly. 7.
OPERATION DRIVING THROUGH WATER Your vehicle can operate through water up to a maximum recommended depth equal to the floorboards. NOTE If your vehicle becomes immersed or is operated in water that exceeds the floor level, service is required before starting the engine. Your dealer can provide this service. If it's impossible to bring the vehicle in before starting the engine, perform the service outlined on page 99, and take the vehicle in for service at the first opportunity.
OPERATION 6. Never open the throttle suddenly. PARKING THE VEHICLE To park the vehicle, do the following: 1. Apply the brakes. Stop the vehicle on a level surface. 2. When parking inside a garage or other structure, be sure that the structure is well ventilated and that the vehicle is not close to any source of flame or sparks, including any appliance with pilot lights. 3. Place the transmission in PARK. 4. Turn the engine off. 5.
OPERATION HAULING CARGO WARNING Overloading the vehicle or carrying or towing cargo improperly can alter vehicle handling and may cause loss of control or brake instability. Always follow these precautions when hauling cargo: Never exceed the stated load capacity for this vehicle. REDUCE SPEED AND ALLOW GREATER DISTANCES FOR BRAKING WHEN HAULING CARGO. NEVER EXCEED THE MAXIMUM WEIGHT CAPACITY of the vehicle.
OPERATION Loads should be centered and carried as low as possible in the box. For stability on rough or hilly terrain, reduce both speed and cargo. Exercise caution if the cargo load extends over the side of the box. Always read and understand the load distribution warnings listed on warning labels and in this manual. Never exceed the maximum capacities specified for your vehicle. BELT LIFE To extend belt life, use low gear when hauling or towing heavy cargo.
OPERATION DUMPING THE CARGO BOX To dump the cargo box, do the following: 1. Select a level site to dump the cargo box. Do not attempt to dump or unload the vehicle while parked on an incline. 2. Apply the brakes. 3. Set the park brake. 4. Turn the key to the off position. 5. Dismount vehicle. 6. Ensure that the cargo is positioned evenly or toward the front of the cargo box. 7. Release the tailgate latches.
OPERATION ALL WHEEL DRIVE/REAR DIFFERENTIAL SYSTEM If your model is equipped with a lockable differential, you can choose to operate with an open differential or a closed differential. ENGAGING AWD Press the top of the switch to engage All Wheel Drive (AWD). The 4X4 indicator illuminates in the rider information center to indicate that the vehicle is in AWD. When the AWD switch is on, the front gearcase will automatically engage any time the rear wheels lose traction.
OPERATION 3. Stop completely. 4. Shift into low gear and drive forward. 5. If the front gearcase remains locked after following these instructions, see your dealer or other qualified service person for service. LOCKING THE DIFFERENTIAL Move the rocker switch to the center position to lock the differential and operate in two wheel drive (2WD). Locking the differential in slippery or low traction conditions helps improve traction.
OPERATION POLARIS 3-MODE THROTTLE CONTROL SWITCH (IF EQUIPPED) The Polaris 3-Mode Throttle Control Switch has three positions: • Performance (PERF) • Standard (STND) • Work (WORK) PERFORMANCE The performance (PERF) setting maximizes throttle response for quick acceleration along with full horsepower and torque. STANDARD The standard (STND) setting provides a balance of throttle, full horsepower, and torque for everyday activities.
WINCH GUIDE WINCH GUIDE These safety warnings and instructions apply if your vehicle came equipped with a winch or if you choose to add an accessory winch to your vehicle. WARNING Improper winch use can result in SEVERE INJURY or DEATH. Always follow all winch instructions and warnings in this manual. Your winch may have a cable made of either wire rope or specially designed synthetic rope. The term “winch cable” will be used for either unless noted otherwise. WINCH SAFETY PRECAUTIONS 1.
WINCH GUIDE 13. Never winch up or down at sharp angles. This can destabilize the winching vehicle and possibly cause it to move without warning. 14. Never attempt to winch loads that weigh more than the winch’s rated capacity. 15. The winch motor may become hot during winch use. If you winch for more than 45 seconds, or if the winch stalls during operation, stop winching and permit the winch to cool down for 10 minutes before using it again. 16.
WINCH GUIDE WINCH OPERATION Read the Winch Safety Precautions in the preceding pages before using your winch. TIP Consider practicing the operation and use of your winch before you actually need to use it in the field. WARNING Improper winch use can result in SEVERE INJURY or DEATH. Always follow all winch instructions and warnings in this manual. Each winching situation is unique. • • • • • • • Take your time to think through the winching you are about to do. Proceed slowly and deliberately.
WINCH GUIDE 4. Always use the hook strap when handling the hook. WARNING Never put your fingers into the hook. This could lead to SEVERE INJURY. • Attach the hook itself onto the load or use a tow strap or chain to secure the load to the winch cable. No Yes TIP A “tow strap” is NOT intended to stretch. A “recovery strap” is designed to stretch. WARNING Never use a recovery strap when winching due to the excessive energy that can be released if the winch cable breaks.
WINCH GUIDE WARNING Replace the winch cable at the first sign of damage to prevent SEVERE INJURY or DEATH in the event of failure. For your safety, always replace POLARIS winch parts (including the cable) with genuine POLARIS replacement parts available at your authorized POLARIS dealer. • If possible, keep the winch cable aligned with the centerline of the winching vehicle. This will help the spooling of the winch cable and reduce the load on the fairlead.
WINCH GUIDE 8. Read and adhere to the following information for winch damping to ensure safe winch use. a. In order to absorb energy that could be released by a winch cable failure, always place a “damper” on the winch cable. A damper can be heavy jacket, tarp, or other soft, dense object. A damper can absorb much of the energy released if a winch cable breaks when winching. Even a tree limb can help as a damper if no other items are available to you. b.
WINCH GUIDE 11. The ONLY time a winch-equipped vehicle should be moving when using the winch is when that vehicle itself is stuck. The winch equipped vehicle should NEVER be in motion to “shock” load the winch cable in an attempt to move a second stuck vehicle. See the Shock Loading section on page 73. For your safety, always follow these guidelines when winching a vehicle free: a. Release the winch clutch and spool out the necessary length of winch cable. b.
WINCH GUIDE 15. After winching is complete, especially if winching at an angle, it may be necessary to re-distribute the winch cable across the winch drum. You will need an assistant to perform this task. a. Release the clutch on the winch. b. Feed out the winch cable that is unevenly bunched up in one area. c. Re-engage the winch clutch. d. Have an assistant pull the winch cable tightly with about 100 lbs. (45 kg) of tension using the hook strap. e.
WINCH GUIDE 2. Always inspect your winch cable before each use. Inspect for worn or kinked winch cable. A kinked winch cable made of wire rope is shown at right. Even after being “straightened out,” this cable has already been permanently and severely damaged. Promptly discontinue use of a winch cable in this condition. A kinked winch cable made of wire rope that has been “straightened out” is shown at right. Even though it may look usable, the cable has been permanently and severely damaged.
WINCH GUIDE 2. Never quickly turn the winch ON and OFF repeatedly (“jogging”). This puts extra load on the winch, winch cable, and generates excessive heat from the motor. This is a form of shock loading. 3. Never tow a vehicle or other object with your winch. Towing an object with a winch produces shock loading of the cable even when towing at slow speeds. Towing from a winch also positions the towing force high on the vehicle. This can cause instability of the vehicle and possibly lead to an accident. 4.
WINCH GUIDE WINCH MAINTENANCE AND SERVICE SAFETY WARNING Improper or lack of winch maintenance and service could lead to SEVERE INJURY or DEATH. Always follow all winch instructions and warnings in this manual. 1. Always inspect your winch before each use. Inspect for worn or kinked winch cable. Also inspect for worn or loose parts including mounting hardware. 2. Permit your winch motor to cool down prior to servicing your winch. 3.
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EMISSION CONTROL SYSTEMS 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 vehicle has a spark arrester that was tested and qualified to be in accordance with the USFS standard 5100-1C.
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MAINTENANCE MAINTENANCE PERIODIC MAINTENANCE CHART Any qualified repair shop or person may maintain, replace or repair the emission control devices or systems on your vehicle. An authorized POLARIS dealer can perform any service that may be necessary for your vehicle. POLARIS also recommends POLARIS parts for emissions-related service, however equivalent parts can be used.
MAINTENANCE SEVERE USE DEFINITION • • • • • • Frequent immersion in mud, water or sand Frequent or prolonged operation in dusty environments Short trip cold weather operation Racing or race-style high RPM use Prolonged low speed, heavy load operation Extended idle Pay special attention to the oil level. A rise in oil level during cold weather can indicate contaminants collecting in the oil sump or crankcase. Change oil immediately if the oil level begins to rise.
MAINTENANCE MAINTENANCE INTERVAL (WHICHEVER COMES FIRST) REMARKS ITEM HOURS CALENDAR MILES (KM) XU Front Gearcase Fluid (Demand Drive Extreme Use) 25 H 1M - Change fluid every 25 hours if subjected to extreme use XU Front Gearcase Fluid (Demand Drive) 25 H 1M - Initial fluid level inspection; add lubricant if needed XU Transmission Fluid (AGL) 25 H 1M - Initial fluid level inspection; add lubricant if needed XU E Engine Oil / Filter Change (Break-In) 25 H - 500 (800) Perform brea
MAINTENANCE MAINTENANCE INTERVAL (WHICHEVER COMES FIRST) REMARKS ITEM HOURS CALENDAR MILES (KM) D E Fuel System 100 H 12 M 1000 (1600) Cycle key to pressurize fuel pump; check for leaks at fill cap, fuel line / rail, and fuel pump; replace lines every two years XU Cooling Hoses 100 H 12 M 1000 (1600) Inspect for leaks XU Engine Mounts 100 H 12 M 1000 (1600) Inspect Exhaust Muffler / Pipe 100 H 12 M 1000 (1600) Inspect Drive Shafts 100 H 12 M 1000 (1600) Remove and grease D E
MAINTENANCE MAINTENANCE INTERVAL (WHICHEVER COMES FIRST) REMARKS ITEM HOURS D CALENDAR MILES (KM) Toe Adjustment - Inspect periodically; adjust when parts are replaced Headlight Aim - Adjust as needed XU Engine Oil Lines/ Fasteners 50 H 6M 1000 (1600) Inspect for leaks and loose fittings XU Engine Oil/Filter Change 100 H 6M 1000 (1600) Perform oil / filter change XU Front Gearcase Fluid (Demand Drive) 100 H 12 M 1000 (1600) Change fluid XU Transmission Fluid (AGL) 100 H 12 M
MAINTENANCE MAINTENANCE INTERVAL (WHICHEVER COMES FIRST) REMARKS ITEM D HOURS CALENDAR MILES (KM) Ratcheting Cam Chain Tensioner 200 H - 2000 (3200) Check; replace as needed Brake Fluid 200 H 24 M 2000 (3200) Change every two years Suspension Bushings 250 H 24 M 2000 (3200) Inspect; replace if necessary Spark Arrestor 300 H 36 M 3000 (4800) Clean out Inspect; adjust as needed D E Valve Clearance - - 5000 (8000) XU Coolant - 60 M - D Toe Adjustment - Inspect periodicall
MAINTENANCE LUBRICATION RECOMMENDATIONS Check and lubricate all components at the intervals outlined in the Periodic Maintenance Chart beginning on page 80, 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 PS-4 5W-50 4-Cycle Oil Add to proper level on dipstick. See page 85. Brake Fluid DOT 4 Brake Fluid Maintain level between fill lines. See page 99.
MAINTENANCE NOTICE Mixing brands or using a non-recommended oil may cause serious engine damage. Always use the recommended oil. Never substitute or mix oil brands. OIL CHECK CAUTION Always remove all cargo from the cargo box before lifting the box to access engine components. Always check the oil when the engine is cold. If the engine is hot when the oil is checked, the level will appear to be overfull. Access the oil fill cap q, dipstick and filter under the cargo box. 1.
MAINTENANCE CAUTION Always remove all cargo from the cargo box before lifting the box to access engine components. CAUTION Hot oil can cause burns to skin. Do not allow hot oil to contact skin. Access the oil fill cap, dipstick and filter under the cargo box. 1. Remove all cargo from the cargo box. 2. Position the vehicle on a level surface. 3. Place the transmission in PARK. 4. Stand clear and pull up on the cargo box release lever. Lift the front of the cargo box. 5.
MAINTENANCE GEARCASES GEARCASE SPECIFICATION CHART RANGER CREW® XP 1000 NORTHSTAR EDITION GEARCASE LUBRICANT CAPACITY FILL PLUG TORQUE DRAIN PLUG/ LEVEL CHECK PLUG TORQUE Main Gearcase (Transmission) AGL Gearcase Lubricant & Transmission Fluid 40.6 oz. (1200 ml) 12 ft-lbs (16.3 Nm) 12 ft-lbs (16.3 Nm) Front Gearcase Demand Drive Fluid 6.76–7.6 oz. (200–225 ml) 8-10 ft-lbs (1113.6 Nm) 8-10 ft-lbs (1113.
MAINTENANCE TRANSMISSION (MAIN GEARCASE) Always check and change the transmission oil at the intervals outlined in the Periodic Maintenance Chart. Maintain the oil level even with the bottom thread of the fill plug hole. OIL CHECK The fill plug is located on the rear of the gearcase. Maintain the fluid level at the bottom of the fill plug hole. To check the transmission fluid, do the following: 1. Position the vehicle on a level surface. 2. Remove the fill plug q. 3. Check the fluid level. 4.
MAINTENANCE FRONT GEARCASE (DEMAND DRIVE) Always check and change the demand drive fluid at the intervals outlined in the Periodic Maintenance Chart. Maintain the oil level even with the bottom thread of the fill plug hole. Refer to the Gearcase Specifications Chart for recommended lubricants, capacities and torque specifications. ADC Models: Change the front gearcase fluid every 25 hours if the ADC unit is exposed to extreme use.
MAINTENANCE SPARK PLUGS SPARK PLUG RECOMMENDATIONS Refer to the specifications section beginning on for the recommended spark plug type for your vehicle. Always torque spark plugs to specification. NOTICE Using non-recommended spark plugs can result in serious engine damage. Always use POLARIS-recommended spark plugs or their equivalent. SPARK PLUG GAP/TORQUE ELECTRODE GAP NEW OR USED PLUG TORQUE 0.7 – 0.9 mm 10 ft. lbs. (13.
MAINTENANCE WET FOULED PLUG The wet fouled insulator tip is black. A damp oil film covers the firing end. There may be a carbon layer over the entire nose. Generally, the electrodes are not worn. General causes of fouling are excessive oil, use of non-recommended oil or poor fuel quality. COOLING SYSTEM 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.
MAINTENANCE RADIATOR COOLANT LEVEL Always check and clean the screen and radiator fins at the intervals outlined in the Periodic Maintenance Chart. 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. 1. Lift the hood. CAUTION Escaping steam can cause burns.
MAINTENANCE OVERFLOW BOTTLE COOLANT LEVEL Always check and change the coolant at the intervals outlined in the Periodic Maintenance Chart. Maintain the coolant level between the minimum and maximum marks on the bottle (when the fluid is cool). 1. Position the vehicle on a level surface. 2. Lift the hood. View the coolant level in the overflow bottle w. 3. If the coolant level is below the safe operating range, lift the hood and locate the overflow bottle lid.
MAINTENANCE POLARIS VARIABLE TRANSMISSION (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.
MAINTENANCE 2. Lift the cargo box. 3. Remove the clutch cover q using a 3/8” socket with ratcheting wrench and extension. 4. Pull the bottom of the cover outward and over the suspension to remove it. 5. Make sure the cover gasket does not fall out of the groove when removing the cover. 6. Squeeze the belt w together so that it submarines further into the driven clutch, creating slack in the belt between the clutches. 7. Remove the belt by using the slack to pull part of the belt off the driven clutch. 8.
MAINTENANCE There may be some instances when water is ingested into the PVT system. Use the following instructions to dry it out before operating: 1. Position the vehicle on a level surface. 2. Remove the red drain plug on the outer clutch cover. Allow the water to drain completely. Reinstall the drain plug. 3. Place the transmission in PARK. 4. Start the engine. 5. Apply varying throttle for 10-15 seconds to expel the moisture and air-dry the belt and clutches.
MAINTENANCE VEHICLE IMMERSION WARNING If your vehicle becomes immersed, major engine damage can result if the machine is not thoroughly inspected. Take the vehicle in for service before starting the engine. Your POLARIS dealer can provide this service. 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.
MAINTENANCE SPARK ARRESTER WARNING Failure to heed the following warnings while servicing the spark arrester could result in serious injury or death. • Do not perform service on the spark arrester 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.
MAINTENANCE WARNING After opening a bottle of brake fluid, always discard any unused portion. Never store or use a partial bottle. Brake fluid is hygroscopic, meaning it rapidly absorbs moisture from the air. The moisture causes the boiling temperature of the brake fluid to drop, which can lead to early brake fade and the possibility of accident or severe injury.
MAINTENANCE STEERING WHEEL INSPECTION Check the steering wheel for specified freeplay and smooth operation at the intervals outlined in the Periodic Maintenance Chart beginning on . 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 dealer.
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 WHEEL REMOVAL 1. Position the vehicle on a level surface. 2. Place the transmission in PARK. Stop the engine. 3. Loosen the wheel nuts slightly. 4. Elevate the side of the vehicle by placing a suitable stand under the frame. 5. Remove the wheel nuts and washers. Remove the wheel. WHEEL INSTALLATION 1. Place the transmission in PARK. 2. Place the wheel on the hub with the valve stem toward the outside and rotation arrows on the tire pointing toward forward rotation.
MAINTENANCE LIGHTS Poor lighting can result in reduced visibility when driving. Headlight and taillight lenses become dirty during normal operation. Clean lights frequently and replace burned out lamps promptly. Do not operate this vehicle at night or in low light conditions until the headlight is replaced. Always make sure lights are adjusted properly for best visibility. When servicing a halogen lamp, don't touch the lamp with bare fingers.
MAINTENANCE HEADLIGHT BEAM ADJUSTMENT To adjust the headlight beam, do the following: 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.
MAINTENANCE FUSES If the engine stops or will not start, or if you experience other electrical failures, a fuse may need replacement. Locate and correct any short circuits that may have caused the blown fuse, then replace the fuse. The RANGER XP CREW 1000 fuse box is located under the right rearmost seat. Spare fuses are provided in the fuse box. The power steering fuse (if equipped) is located on the power steering wiring harness near the fuse box.
MAINTENANCE one tablespoon baking soda and one cup water. Rinse well with tap water and dry off with clean shop towels. Coat the terminals with dielectric grease or petroleum jelly. Be careful not to allow cleaning solution or tap water into a conventional 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.
MAINTENANCE 5. Lift the battery out of the vehicle. Be careful not to tip a conventional battery sideways, which could spill electrolyte. NOTICE If electrolyte spills, immediately wash it off with a solution of one tablespoon baking soda and one cup water to prevent damage to the vehicle. 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.
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 109. TIP Battery charge can be maintained by using a POLARIS Battery Tender charger or by charging about once a month to make up for normal self discharge.
MAINTENANCE 2. If the voltage is less than 12.8 volts, recharge the battery at 1.2 amps or less until battery voltage is 12.8 or greater. TIP When using an automatic charger, refer to the charger manufacturer's instructions for recharging. When using a constant current charger, use the guidelines on the next page for recharging. Always verify battery condition before and 1-2 hours after the end of charging.
MAINTENANCE NOTE Certain products, including insect repellents and chemicals, will damage plastic surfaces. Do not allow these types of products to contact the vehicle. The best and safest way to clean your POLARIS vehicle is with a garden hose and a pail of mild soap and water. 1. Use a professional-type washing cloth, cleaning the upper body first and the lower parts last. 2. Rinse with clean water frequently. 3. Dry surfaces with a chamois to prevent water spots.
MAINTENANCE POLISHING THE VEHICLE POLARIS recommends the use of common household aerosol furniture polish for polishing the finish on your POLARIS vehicle. Follow the instructions on the container. POLISHING TIPS • Avoid the use of automotive products, some of which can scratch the finish of your vehicle. • Always use clean cloths and pads for cleaning and polishing. Old or reused cloths and pads may contain dirt particles that will scratch the finish.
MAINTENANCE STORAGE TIPS NOTICE Starting the engine during the storage period will disturb the protective film created by fogging and damage could occur. Never start the engine during the storage period. CLEAN THE EXTERIOR Make any necessary repairs and clean the vehicle as recommended. STABILIZE THE FUEL 1. Fill the fuel tank. 2. Add POLARIS Carbon Clean Fuel Treatment or POLARIS Fuel Stabilizer or equivalent fuel treatments or stabilizers.
MAINTENANCE INSPECT AND LUBRICATE Inspect all cables and lubricate all areas of the vehicle as recommended in the Periodic Maintenance Chart. FOG THE ENGINE 1. Treat the fuel system with POLARIS Carbon Clean or other equivalent fuel treatment. 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 engine oil.
MAINTENANCE WARNING Engine exhaust contains poisonous carbon monoxide and can cause loss of consciousness or death. Never run an engine in an enclosed area. TRANSPORTING THE VEHICLE Follow these procedures when transporting the vehicle. 1. Apply the brakes. 2. Place the transmission in PARK. Stop the engine. 3. Slowly release the brake pedal and make sure the transmission is in PARK before exiting the vehicle. Engage the park brake. 4. Remove the key to prevent loss during transporting. 5.
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SPECIFICATIONS SPECIFICATIONS RANGER CREW® XP 1000 NORTHSTAR EDITION SPECIFICATIONS RANGER CREW® XP 1000 NORTHSTAR EDITION Maximum Weight Capacity (includes weight of operator, passenger, cargo, accessories) Dry Weight Test GVW Rollover Protection System (ROPS) 1500 lbs. (680 kg) (including operator, passengers, cargo, accessories) 2032 lbs. (922 kg) 3614 lbs. (1639 kg) per OSHA 29 CFR 1928.53 Fuel Capacity 10 gal. (37.8 l) Engine Oil Capacity 2.5 qts. (2.4 l) Coolant Capacity 5 qts. (4.
SPECIFICATIONS RANGER CREW® XP 1000 NORTHSTAR EDITION Displacement Bore x Stroke (mm) Alternator Output 999 cc 93 mm x 64.4 mm 660 W @ 3000 RPM Compression Ratio 10.8:1 Starting System Electric Fuel System Electronic Fuel Injection Ignition Timing ECU Controlled 32° +/- 2° @ 5000 RPM Spark Plug/ Gap Lubrication System Cooling MR7F / 0.7-0.8 mm Wet Sump Liquid Front Suspension Dual A-arm w/10 in. (25.4 cm) of travel Rear Suspension Independent w/10 in. (25.
SPECIFICATIONS RANGER CREW® XP 1000 NORTHSTAR EDITION Tire Pressure - Rear 16 psi (110 kPa) Brakes, Front/Rear Foot Activated, 4 wheel hydraulic disc Hood Headlights 2 single beam, 50W, quartz/halogen Taillights 10 L.E.D. (.28W) Brake Light 10 L.E.D. (3.
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POLARIS PRODUCTS POLARIS PRODUCTS LUBRICANTS / SERVICE PRODUCTS PRODUCT SIZE (QUANTITY) PART NUMBER 12 oz aerosol (12) 2870791 1 qt (12) 2871517 1 qt (12) 2876244 2 qt (8) 2877490 Fogging Oil PS-4 PS-4 Extreme Duty 1 gal (4) 2876245 1 qt (12) 2878920 2 qt (8) 2878922 1 gal (4) 2878919 1 qt (12) 2878068 1 gal (4) 2878069 AGL Pump for Gallon Jug 3.8 l 2870465 1 qt (12) 2877922 2.
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TROUBLESHOOTING TROUBLESHOOTING DRIVE BELT WEAR/BURN POSSIBLE CAUSE SOLUTION Driving onto a pickup or tall trailer in high range Use low range during loading. Starting out going up a steep incline Use low range. Driving at low RPM or ground speed (3-7 MPH) Drive at a higher speed or use low range more frequently. Insufficient warm-up at low ambient temperatures Warm the engine at least 5 minutes.
TROUBLESHOOTING ENGINE DOESN'T TURN OVER POSSIBLE CAUSE SOLUTION Low battery voltage Recharge the battery to 12.
TROUBLESHOOTING ENGINE PINGS OR KNOCKS POSSIBLE CAUSE SOLUTION Poor quality or low octane fuel Replace with recommended fuel Incorrect spark plug gap or heat range Set gap to specs or replace plug ENGINE RUNS IRREGULARLY, STALLS OR MISFIRES POSSIBLE CAUSE SOLUTION Fouled or defective spark plug Inspect, clean and/or replace spark plug Worn or defective spark plug wires Your dealer can assist Incorrect spark plug gap or heat range Set gap to specs or replace plug Loose ignition connections Ch
TROUBLESHOOTING ENGINE STOPS OR LOSES POWER POSSIBLE CAUSE SOLUTION Out of fuel Refuel Kinked or plugged fuel vent line Inspect and replace Water is present in fuel Replace with new fuel Fouled or defective spark plug Inspect, clean and/or replace spark plug Worn or defective spark plug wires Your dealer can assist Incorrect spark plug gap or heat range Set gap to specs or replace plug Loose ignition connections Check all connections and tighten Low battery voltage Recharge the battery to
WARRANTY WARRANTY LIMITED WARRANTY POLARIS Industries Inc., 2100 Highway 55, Medina, MN 55340 (POLARIS) gives a ONE YEAR LIMITED WARRANTY on all components of your POLARIS vehicle against defects in material or workmanship. POLARIS further warrants that the spark arrester in this product will meet the efficiency requirements of USFS standard 5100-1C for at least 1000 hours when subjected to normal use and when maintenance and installation are in accordance with POLARIS recommendations.
WARRANTY WARRANTY COVERAGE AND EXCLUSIONS LIMITATIONS OF WARRANTIES AND REMEDIES This POLARIS limited warranty excludes any failures that are not caused by a defect in material or workmanship. THIS WARRANTY DOES NOT COVER CLAIMS OF DEFECTIVE DESIGN. This warranty also does not cover acts of God, accidental damage, normal wear and tear, abuse or improper handling.
WARRANTY 2. Damage or failure resulting from the use of non-recommended lubricants or fluids is not covered by this warranty. This warranty provides no coverage for personal loss or expense, including mileage, transportation costs, hotels, meals, shipping or handling fees, product pick-up or delivery, replacement rentals, loss of product use, loss of profits, or loss of vacation or personal time.
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WARRANTY HOW TO OBTAIN WARRANTY SERVICE If your vehicle requires warranty service, you must take it to a POLARIS Servicing Dealer. When requesting warranty service you must present your copy of the Warranty Registration Form to the dealer. (THE COST OF TRANSPORTATION TO AND FROM THE DEALER IS YOUR RESPONSIBILITY.) POLARIS suggests that you use your original selling dealer; however, you may use any POLARIS Servicing Dealer to perform warranty service.
WARRANTY EXPORTED PRODUCTS EXCEPT WHERE SPECIFICALLY REQUIRED BY LAW, THERE IS NO WARRANTY OR SERVICE BULLETIN COVERAGE ON THIS PRODUCT IF IT IS SOLD OUTSIDE THE COUNTRY OF THE SELLING DEALER'S AUTHORIZED LOCATION. This policy does not apply to products that have received authorization for export from POLARIS. Dealers may not give authorization for export. You should consult an authorized dealer to determine this product's warranty or service coverage if you have any questions.
WARRANTY U.S.A. EPA EMISSIONS LIMITED WARRANTY This emissions limited warranty is in addition to the POLARIS standard limited warranty for your vehicle. POLARIS Industries Inc. warrants that at the time it is first purchased, this emissions-certified vehicle is designed, built and equipped so it conforms with applicable U.S. Environmental Protection Agency emission regulations.
WARRANTY The following parts are considered emission-related components for evaporative emissions: • • • • • • • • • Fuel Tank Fuel Cap Fuel Line Fuel Line Fittings Clamps* Pressure Relief Valves* Control Valves* Control Solenoids* Electronic Controls* • • • • • • • • • Vacuum Control Diaphragms* Control Cables* Control Linkages* Purge Valves Vapor Hoses Liquid/Vapor Separator Carbon Canister Canister Mounting Brackets Carburetor Purge Port Connector *As related to the evaporative emission control syste
WARRANTY Owners are responsible for performing the scheduled maintenance identified in the owner's manual. POLARIS may deny warranty claims for failures that have been caused by the owner's or operator's improper maintenance or use, by accidents for which POLARIS has no responsibility, or by acts of God. Any qualified repair shop or person may maintain, replace, or repair the emission control devices or systems on your vehicle.
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MAINTENANCE LOG MAINTENANCE LOG MAINTENANCE LOG Use the following chart to record periodic maintenance.
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A Adding or Changing Coolant ........ 92 Age Restrictions ........................ 20 Air Conditioning......................... 94 Air Filter................................... 98 Air Filter / Air Box......................113 All Wheel Drive/Rear Differential System ................... 62 AUX Switch .............................. 34 Auxiliary Outlet.......................... 34 Axle and Wheel Nut Torque Specifications........................ 102 B Battery .................................. 106 Charging ...
F K Failure to Inspect Before Operating ............................... 21 Fan, Cooling............................. 92 Fluid Levels.............................113 Fluid Part Numbers .................. 121 Fog the Engine ........................114 Front Gearcase (Demand Drive) ... 90 Fuel Cap.................................. 45 Fuel Safety............................... 26 Fuel Stabilizer..........................113 Fuel Transport Warning............... 17 Fuses ...................................
Parking on an Incline .................. 58 Parking the Vehicle ............... 52, 58 Part Numbers ......................... 121 Payload Warning/Shift Caution ..... 15 Periodic Maintenance Chart ......... 79 Plugs, Spark............................. 91 Polaris Products ...................... 121 POLARIS Variable Transmission System................ 95 Polishing the Vehicle .................112 Poor Visibility............................ 26 Power Steering ......................... 30 Pre-Ride Inspection ....
W Warning Symbols ........................ 7 Warranty Coverage And Exclusions Lubricants and Fluids ............ 128 Washing the Vehicle..................110 Wet Fouled Plug........................ 92 Wheel Installation .................... 103 Wheel Removal....................... 103 Winch Cable Care ..................... 72 Winch Maintenance and Service Safety ......................... 75 Winch Operation ....................... 67 Winch Safety Precautions ........... 65 Winch Shock Loading ...............
For your nearest Polaris dealer, call 1-800-POLARIS (765-2747) or visit www.polaris.com Polaris Industries Inc. 2100 Highway 55 Medina, MN 55340 Part No.
