PMS 419 2018 RANGER EV Owner's Manual for Maintenance and Safety
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2018 Owner’s Manual RANGER® EV
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.
WELCOME 4
Introduction . . . . . Safety . . . . . . . . Features and Controls Operation . . . . . . Winch Guide. . . . . 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 DECLARATION OF CONFORMITY Polaris Sales Europe Sàrl Route de l’Etraz Business Center A5 1180 Rolle, Switzerland Telephone +41213–218–700 DECLARATION OF CONFORMITY October 1, 2016 Polaris Sales Europe Sàrl declares that the vehicle(s) listed below conform to the essential requirements to all terrain vehicles.
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.
SAFETY 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 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. The approval number and serial number will also be displayed on the label.
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 any label becomes illegible or comes off, contact your POLARIS dealer to purchase a replacement. Replacement safety labels are provided by POLARIS at no charge.
SAFETY PASSENGER / TIRE PRESSURE WARNING WARNING • • • • Passengers can be thrown off. This can cause serious injury or death. Never carry passengers in cargo box. Read the Owner’s Manual. Never carry fuel on this vehicle. WARNING 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 BATTERY CHARGING WARNING (7185977) WARNING • Explosive gases are released when batteries are charged. Keep sparks, flames and cigarettes away. Shield eyes when working near batteries. • Do not charge batteries in a non-ventilated enclosed area or near flammable materials. • Do not attempt to charge frozen, leaking, or damaged batteries. • Connect battery charger to properly rated electrical receptacle with GFCI.
SAFETY SAFETY LABEL LOCATIONS q General Alert w Battery Charging Warning e Pass.
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 entire manual and all labels carefully. Follow the operating procedures described. • Never allow anyone under the age of 16 to operate this vehicle and never allow anyone without a valid driver's license to operate this vehicle.
SAFETY • Always follow the proper procedures outlined in this manual for traveling downhill and for braking on hills. See page 37. Check the terrain carefully before descending a hill. Never travel downhill at high speed. Avoid going downhill at an angle, which would cause the vehicle to lean sharply to one side. Travel straight down the hill where possible. • Always check for obstacles before operating in a new area. Never attempt to operate over large obstacles such as large rocks or fallen trees.
SAFETY PROPER OPERATION WARNING Failure to operate the RANGER 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. See the OPERATION section of the owner’s manual for proper operating procedures. OPERATING WITHOUT INSTRUCTION Operating this vehicle without proper instruction increases the risk of an accident.
SAFETY AGE RESTRICTIONS This vehicle is an ADULT VEHICLE ONLY. NEVER operate this vehicle if you are under age 16 and NEVER operate without a valid driver’s license. Never operate with a passenger under the age of 12. All riders must be able to sit with backs against the seat, both feet flat on the floor and both hands on the steering wheel (if driving) or on a passenger hand hold (if equipped).
SAFETY SEAT BELTS Riding in this vehicle without wearing the seat belt increases the risk of serious injury in the event of rollover, loss of control, other accident or sudden stop. Seat belts may reduce the severity of injury in these circumstances. All riders must wear seat belts at all times. PROTECTIVE APPAREL Riding in this vehicle without wearing an approved helmet and protective eyewear increases the risk of a serious injuries in the event of an accident.
SAFETY CARRYING A PASSENGER A passenger must always be seated in a passenger seat with seat belt secured. Carrying more than one passenger in a 2-seat vehicle can affect the operator’s ability to steer and operate the controls, which increases the risk of loss of control and accident or rollover. Never carry more than one passenger in a 2-seat vehicle. VENTILATION WHEN CHARGING BATTERIES Failure to provide adequate ventilation while charging batteries can result in an explosion.
SAFETY OPERATING WITH A LOAD ON THE VEHICLE The weight of both cargo and passengers impacts vehicle operation. For your safety and the safety of others, carefully consider how your vehicle is loaded and how to safely operate the vehicle. Follow the instructions in this manual for loading, tire pressure, gear selection and speed. • Do not exceed vehicle weight capacities. The vehicle’s maximum weight capacity is listed in the specifications section of this manual and on a label on the vehicle.
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 AT EXCESSIVE SPEEDS Operating this vehicle at excessive speeds increases the operator's risk of losing control.
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.
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. HOT DRIVE SYSTEMS The motor and controller are very hot during and after use of the vehicle. Hot components can cause burns and fire. Do not touch hot drive system components.
FEATURES AND CONTROLS FEATURES AND CONTROLS COMPONENT LOCATIONS q ROPS Frame w Hip Bars e Seat Belt r Cargo Box t Headlight y Front Bumper/Brush Guard u Cargo Box Release Lever i Tailgate Latches o Taillights a Receiver Hitch 27
FEATURES AND CONTROLS CONSOLE q Indicator Lights w Hour Meter e Battery Discharge Indicator r Direction Selector t AWD Switch 28 y Drive Mode Switch u 12V Auxiliary Outlet i Charge Status Indicator o Headlight Switch a Key Switch
FEATURES AND CONTROLS INDICATOR PANEL LIGHTS The indicator lights activate when the key is in the ON position.
FEATURES AND CONTROLS BATTERY DISCHARGE INDICATOR The battery discharge indicator displays the amount of charge removed (used) from fully charged batteries. When the batteries are fully charged, the gauge will display 100%. The charge status indicator will be solid green. NOTE Avoid discharging the batteries below 20% on the discharge indicator. HOUR METER The hour meter records and displays the hours of actual vehicle movement since manufacture.
FEATURES AND CONTROLS SWITCHES KEY SWITCH Turn the key to the ON position to activate the electrical circuits. Turn the key to the OFF position to disable all electrical circuits. The key can be removed from the switch when it is in the OFF position. HEADLIGHT SWITCH Press the top of the switch to turn the headlights on. Press the bottom of the switch to turn the headlights off. DIRECTION SELECTOR SWITCH When the direction selector is in the center position, the vehicle is in neutral.
FEATURES AND CONTROLS AWD SWITCH The AWD switch has three positions: All Wheel Drive (AWD), Differential Lock/Two Wheel Drive (2WD) and Off (1WD/Turf Mode). Press the top of the switch to engage All Wheel Drive (AWD). See page 42 for operating instructions. Move the switch to the center position to lock the differential and operate in two wheel drive (2WD). Press the bottom of the switch to unlock the differential and allow the rear drive wheels to operate independently (1WD).
FEATURES AND CONTROLS DRIVE MODE SWITCH CAUTION Changing the drive mode switch position while driving could result in an automatic increase or decrease in speed without a change to accelerator pedal pressure. Press the top of the switch to select high mode. Use high mode for most trail-riding conditions. The vehicle will operate at speeds up to 25 MPH (40 km/h). Press the bottom of the switch to select low mode. Low mode is recommended for short-term operation in extreme load conditions.
FEATURES AND CONTROLS BATTERIES This vehicle is equipped with eight 12-volt batteries that supply the power needed to operate the vehicle. The batteries are located under the seat. See page 63 for battery access instructions. Always observe all battery safety warnings and safe handling procedures as outlined on vehicle safety labels and in this manual. BATTERY HANDLING PRECAUTIONS • Always make sure that all electrical accessories are grounded directly to the negative (-) post on the terminal board.
FEATURES AND CONTROLS AMBIENT TEMPERATURE IMPLICATIONS ON BATTERIES • Battery range decreases as ambient temperature decreases. This can affect the range by up to 30%. • Batteries discharge when left uncharged. They can discharge up to 13% per month (higher rates in warmer climates) with the key off and much faster if the key is left on. • Batteries can freeze if left uncharged at low ambient temperatures. Percent Charged 100% 50% 0% Approx.
FEATURES AND CONTROLS MAIN POWER CONNECTOR NOTE Damage to electrical connections and components will occur if they are unplugged before the main power connector is disconnected. Always disconnect the main power connector before servicing or unplugging any electrical components. When disconnected, the main power connector disconnects the battery pack from all electrical components, with the exception of the contactor.
FEATURES AND CONTROLS TRAILER RECEIVER 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.
FEATURES AND CONTROLS PARK BRAKE LEVER (IF EQUIPPED) Always apply the service brakes before engaging or releasing the park brake. To help prevent the vehicle from rolling, set the park brake when parking the vehicle. When the park brake is set and the park brake indicator is illuminated, engine speed is limited. If the accelerator is applied, this limiting feature prevents operation, which protects the park brake pads from excessive wear.
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 ON position. 2. Apply the brakes. The brake light should come on after about 10 mm (0.4 in.) of pedal travel.
FEATURES AND CONTROLS SEATS 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 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.
FEATURES AND CONTROLS 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. The driver’s seat belt is equipped with a seat belt interlock. Vehicle speed will be limited to 15 MPH (24 km/h) if the seat belt is not secured. The center of the seat is NOT equipped with a seat belt. Never allow a passenger to ride between the operator and passenger seats.
FEATURES AND CONTROLS MALFUNCTION INDICATOR TROUBLESHOOTING GUIDE The malfunction codes will blink on the controller. The code definitions provided here are for informational purposes only. TIP If the indicator illuminates due to a minor issue such as a low voltage condition or a sequence fault (reversing direction without releasing the accelerator), select neutral and turn the key off and on to clear the error. If the error does not clear, please see your dealer for diagnosis and repair.
FEATURES AND CONTROLS CHARGE STATUS INDICATOR TROUBLESHOOTING GUIDE The code definitions provided are for informational purposes only. Please see your dealer for diagnosis and repair.
FEATURES AND CONTROLS CHARGING CORD The charging cord is located under the hood on the right side of the vehicle. See page 62 for charging instructions. AUXILIARY OUTLET The 12-volt receptacle can be used to power accessories, but is limited to 10 amps (the terminal board and 12-volt outlet are fused together at 10 amps. AUXILIARY 12-VOLT TERMINAL BOARD The 12-volt terminal board is located under the hood.
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. PRE-RIDE INSPECTION Failure to inspect and verify that the vehicle is in safe operating condition before operating increases the risk of an accident.
OPERATION ITEM REMARKS REF.
OPERATION DRIVING PROCEDURE 1. Disconnect the charging cable (if connected). 2. Wear a helmet, eye protection, gloves, long-sleeve shirt, long pants and over-the-ankle boots. 3. Sit in the driver's seat and fasten the seat belt. 4. Apply the brakes. 5. Turn the key to the ON position. Wait about a second for the contactor to close before continuing. 6. Move the direction selector to forward or reverse. 7. Move the drive mode switch to the desired setting. 8. Release the park brake. 9.
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. Always travel straight uphill. 2. Avoid excessively steep hills. 3. Keep both feet on the floor. 4. Always check the terrain carefully before ascending any hill. Never climb hills with excessively slippery or loose surfaces. 5. Proceed at a steady rate of speed. 6. Never go over the crest of a hill at high speed. An obstacle, a sharp drop, or another vehicle or person could be on the other side of the hill. 7.
OPERATION DRIVING THROUGH WATER Your vehicle can operate through water up to a maximum recommended depth equal to the floorboards. NOTICE Serious damage can occur to the electrical system and batteries if the vehicle is operated in water deeper than the floorboards. Follow these procedures when operating through water: 1. Determine water depths and current before entering water. 2. Choose a crossing where both banks have gradual inclines. 3. Proceed slowly, avoiding rocks and obstacles. 4.
OPERATION DRIVING IN REVERSE Follow these precautions when operating in reverse: 1. Always check for obstacles or people behind the vehicle. Always inspect left and right fields of vision before backing. 2. Always avoid backing downhill. 3. Back slowly. 4. Apply the brakes lightly for stopping. 5. Avoid turning at sharp angles. 6. Never open the throttle suddenly. PARKING ON AN INCLINE Avoid parking on an incline if possible. If it's unavoidable, follow these precautions: 1. Apply the brakes. 2.
OPERATION 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: Never exceed the maximum weight capacity of the vehicle. When determining the weight you are adding to the vehicle, include the weight of the operator, passenger, accessories, loads in the rack or box and the load on the trailer tongue.
OPERATION The RANGER has been designed to carry or tow specific capacities. Always read and understand the load distribution warnings listed on the warning labels. Move the drive mode switch to low mode if needed. The total load (operator, passenger, accessories, cargo and weight on hitch) must not exceed the maximum weight capacity of the vehicle. Never exceed the following capacities. MODEL RANGER EV MAXIMUM CAPACITIES (LEVEL GROUND) CARGO BOX 454 kg (1000 lbs.) 226 kg 500 lbs.
OPERATION TOWING LOADS Towing improperly can alter vehicle handling and may cause loss of control or brake instability. Always follow these precautions when towing: 1. Never load more than 68.1 kg (150 lbs.) tongue weight on the towing bracket. 2. Do not operate the vehicle faster than 16 km/h (10 MPH) when towing. Towing a trailer increases braking distance. 3. Do not tow more than the recommended weight for the vehicle. See the towing capacity chart below and the Specifications section. 4.
OPERATION DUMPING THE CARGO BOX WARNING If the weight distribution on the box is located toward the rear of the box when the release lever is pulled forward, the box may dump unexpectedly and cause serious injury to the operator or bystanders. Never operate the dump lever without ensuring that the load is positioned evenly or at the front of the box. 1. Select a level site to dump the cargo box. Do not attempt to dump or unload the vehicle while parked on an incline. 2. Apply the brakes. 3.
OPERATION TRANSPORTING THE VEHICLE When transporting the RANGER for a long distance or on public streets, always use a trailer with an approved load rating greater than the RANGER’s curb vehicle weight of 771 kg (1700 lbs.) plus any installed accessories or cargo. Follow these guidelines when transporting the RANGER. 1. Set the park brake. 2. Remove the key to prevent loss. 3. Secure the seat, hood and tailgate latches. Ensure that the seats are attached correctly and are not loose. 4.
OPERATION ALL WHEEL DRIVE (AWD) Press the top of the rocker switch to engage All Wheel Drive (AWD). Once enabled, the AWD remains enabled until the switch is turned off. The AWD switch may be turned on or off while the vehicle is moving. When the AWD switch is on, the front gearcase will automatically engage any time the rear wheels lose traction. When the rear wheels regain traction, the front gearcase will automatically disengage.
OPERATION LOCKING THE DIFFERENTIAL NOTICE Damage to the differential can occur if it is engaged while the vehicle is traveling at high speeds or while the rear wheels are spinning. Slow the vehicle to nearly stopped before engaging the differential. Locking the differential in slippery or low traction conditions helps improve traction. Move the rocker switch to the center position (2WD) to lock the differential and operate in rear wheel drive.
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 67. 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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MAINTENANCE 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 dealer. Record maintenance and service in the Maintenance Log.
MAINTENANCE MAINTENANCE CHART KEY SYMBOL XU DESCRIPTION Perform these procedures more often for vehicles subjected to severe use. Have an authorized Polaris dealer or other qualified person perform these services. D WARNING Improperly performing the procedures marked with a D could result in component failure and lead to serious injury or death. Have an authorized POLARIS dealer or other qualified person perform these services.
MAINTENANCE MAINTENANCE INTERVAL (WHICHEVER COMES FIRST) HOURS CALENDAR KM (MILES) General lubrication 50 H 3M – Lubricate all fittings, pivots, cables, etc.
MAINTENANCE GEARCASES GEARCASE SPECIFICATION CHART GEARCASE LUBRICANT CAPACITY FILL PLUG TORQUE DRAIN PLUG TORQUE Main Gearcase (Transaxle) ATV Angle Drive Fluid 20.3 oz. (600 ml) 14 ft lbs. (19.4 Nm) 14 ft lbs (19.4 Nm) Front Gearcase Demand Drive Fluid 5.1 oz. (150 ml) 8–10 ft lbs. (11–13.6 Nm) 11 ft lbs. (15 Nm) MAIN GEARCASE (TRANSAXLE) Always check and change the main gearcase oil at the intervals outlined in the Periodic Maintenance Chart.
MAINTENANCE OIL CHANGE The drain plug w is located on the lower right side of the main gearcase, near the fill plug q. Refer to the Gearcase Specifications Chart for recommended lubricants, capacities and torque specifications. To change the oil, do the following: 1. Remove the fill plug. 2. Place a drain pan under the drain plug. Remove the drain plug. Allow the oil to drain completely. 3. Wipe the magnetic end of the drain plug clean to remove accumulated metallic filings. 4. Reinstall the drain plug.
MAINTENANCE FRONT GEARCASE Always check and change the front gearcase oil at the intervals outlined in the Periodic Maintenance Chart. Maintain the oil level even with the bottom thread of the fill plug hole q. Refer to the Gearcase Specifications Chart for recommended lubricants, capacities and torque specifications. OIL CHECK The front gearcase fill plug is located on the left side of the front gearcase. To check the oil, do the following: 1. Position the vehicle on a level surface. 2.
MAINTENANCE OIL CHANGE The drain plug w is located on the lower right side of the main gearcase, near the fill plug q. Refer to the Gearcase Specifications Chart for recommended lubricants, capacities and torque specifications. To change the oil, do the following: 1. Support the vehicle securely with a jackstand. 2. Remove the front tire on the driver's side. 3. Place a drain pan under the drain plug. Remove the drain plug. Allow the oil to drain completely. 4.
MAINTENANCE BRAKES The front and rear brakes are hydraulic disc type brakes activated by the brake pedal. Always check brake pedal travel and the brake fluid reservoir level before each use of the vehicle. When applied, the brake pedal should feel firm. Any sponginess would indicate a possible fluid leak or low brake fluid level, which must be corrected before riding. Proceed to the next page for brake fluid information.
MAINTENANCE To check the brake fluid level, do the following: 1. Position the vehicle on a level surface. 2. View the brake fluid level at the reservoir in the driver’s side wheel well. The level should be between the upper (MAX) q and lower (MIN) w level lines. 3. If the fluid level is lower than the upper level line, add brake fluid to the upper (MAX) line q. 4. Apply the brake forcefully for a few seconds and check for fluid leakage around the fittings.
MAINTENANCE BRAKE INSPECTION WARNING Do not apply WD-40 or any petroleum product to brake discs. These types of products are flammable and may also reduce the friction between the brake pad and caliper. To inspect the brakes, do the following: 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. Check brake discs for signs of cracks, excessive corrosion, warping or other damage.
MAINTENANCE SUSPENSION ADJUSTMENT Adjust the front and rear shock absorber springs by rotating the adjustment cam either clockwise or counter-clockwise to increase or decrease spring tension. Always heed the following rules if you make adjustments to this suspension. • Always return the suspension to the lowest (softest) setting after the load is removed from the vehicle. The increased suspension height will negatively impact vehicle stability when operating without a load.
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 Spindle Nut Hub Retaining Nut Front 70 ft. lbs. (95 Nm) Center and Rear 110 ft. lbs.
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 5. Reinstall the harness assembly into the headlight assembly. 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.
MAINTENANCE INDICATOR LAMP REPLACEMENT To replace the indicator lamp, do the following: 1. Lift the hood. 2. Reach in behind the console panel and lift the release to unplug the light from the harness. 3. Using a flathead screwdriver, press on the tab on the top of the light to remove the indicator light assembly from the console panel. 4. Locate the expired lamp. Using a screwdriver, rotate the lamp 1/4 turn counter-clockwise. 5. Grip the lamp with a needle-nose pliers and remove it from the assembly. 6.
MAINTENANCE BATTERY WARNING Battery electrolyte is poisonous. It contains sulfuric acid. Serious burns can result from contact with skin, eyes or clothing. Antidote: External: Flush with water. Internal: Drink large quantities of water or milk. Follow with milk of magnesia, beaten egg, or vegetable oil. Call physician immediately. Eyes: Flush with water for 15 minutes and get prompt medical attention. Batteries produce explosive gases. Keep sparks, flame, cigarettes, etc. away.
MAINTENANCE Always follow these precautions when charging the batteries: 1. Position the vehicle on a level surface. 2. Make sure the charging area is well ventilated. 3. Make sure the key is off. 4. Open the hood and any door enclosures or zippers. 5. Always use a extension cord with a minimum rating of 20 amps. 6. Inspect the charging cord and extension cord for cracks, loose connections and frayed wiring. Replace any damaged components promptly. 7.
MAINTENANCE BATTERY INSPECTIONS Inspect battery terminal connections monthly. Clean batteries as recommended. Using an insulated wrench, torque bolts to 8 ft. lbs. (11 Nm). BATTERY CLEANING Always keep battery terminals and connections free of corrosion. To clean, remove corrosion with a stiff wire brush. Wash with a solution of one tablespoon baking soda and one cup water. Rinse well with tap water and dry off with clean shop towels. Coat battery terminals with dielectric grease or petroleum jelly.
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. NOTE High water pressure may damage components. POLARIS recommends washing the vehicle by hand or with a garden hose, using mild soap. NOTE Certain products, including insect repellents and chemicals, will damage plastic surfaces. Do not allow these types of products to contact the vehicle.
MAINTENANCE If an informational or graphic label becomes illegible or comes off, contact your POLARIS dealer to purchase a replacement. Replacement safety labels are provided by POLARIS at no charge. 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.
MAINTENANCE 5. Turn the key off. 6. DO NOT set the park brake. 7. Verify that tire pressure is at specification. 8. Block the wheels to prevent rolling. 9. Fully charge the batteries. Leave the charger connected to maintain a full charge during the storage period, or check battery voltage each month during storage and recharge as needed to maintain a full charge. If the charger remains connected, check it monthly to verify proper operation. TIP Do not use plastic or coated materials.
MAINTENANCE STORAGE AREA / COVERS Be sure the storage area is well ventilated. Cover the vehicle with a genuine POLARIS cover. Do not use plastic or coated materials. They do not allow enough ventilation to prevent condensation, and may promote corrosion and oxidation. REMOVAL FROM STORAGE 1. Inspect all battery connections. 2. Verify that batteries are fully charged. 3. Verify that tire pressure is at specification. 4. Perform the pre-ride inspection. 5.
MAINTENANCE 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. Secure the fuel cap (if equipped) and seat. Ensure that the seat is attached correctly and is not loose.
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SPECIFICATIONS SPECIFICATIONS RANGER EV SPECIFICATIONS DIMENSIONS Dry Weight 1750 lbs. (793.8 kg) Test GVW - Rollover Protection System (ROPS) 2750 lbs. (1247 kg) per OSHA 29 CFR 1928.53 Ground Clearance 10 in. (25.4 cm) Length 108 in. (274.3 cm) Width 56.5 in. (143.5 cm) Height 73 in. (185.4 cm) Wheelbase 72 in. (183 cm) Turning Radius 150 in. (381 cm) LOAD CAPACITY Box Dimensions (Inside) 32 x 42 x 11.5 in. (81 x 107 x 29 cm) Box Capacity 500 lbs. (227 kg) Payload Capacity 1000 lbs.
SPECIFICATIONS PERFORMANCE Battery pack 11.7 kw battery pack at 48V DC with 8 12-volt, US12VXC batteries in series-parallel configuration Maximum speed 25 MPH (40.2 km/h) Range (in Max Range mode on flat ground) 50 miles (80.
SPECIFICATIONS FEATURES Cup holders Dual cup holders Indicator panel Indicates directional selection, park brake, and motor or controller malfunction Charge indicator Digital, indicates battery discharge Hour meter Digital, indicates cumulative hours of vehicle movement Auxiliary power 12-volt accessory outlet Rider restraints Automotive-style 3-point seat belts Multi-mode switch L/M/H (Low/Max Range/High) Headlights/taillights/brake lights Dual 50-watt Storage Glove box 99
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POLARIS PRODUCTS POLARIS PRODUCTS PART NUMBER DESCRIPTION Engine Lubricant 2870791 Fogging Oil (355 ml/12 oz. Aerosol) 2876244 PS-4 Full Synthetic 5W-50 4-Cycle Oil (.95 l/1 qt.) 2876245 PS-4 Full Synthetic 5W-50 4-Cycle Oil (3.8 l/1 gal.) 2878920 PS-4 Extreme Duty Synthetic 10W-50 4-Cycle Oil (.95 l/1 qt.) 2878919 PS-4 Extreme Duty Synthetic 10W-50 4-Cycle Oil (3.8 l/1 gal.) 2878068 AGL Full Synthetic Gearcase Lubricant & Transmission Fluid (.95 l/1 qt.
POLARIS PRODUCTS PART NUMBER 102 DESCRIPTION 2871956 Loctite™ 565 Thread Sealant 2859044 POLARIS Battery Tender™ Charger
TROUBLESHOOTING TROUBLESHOOTING DRIVE BELT WEAR/BURN POSSIBLE CAUSE SOLUTION Driving at low RPM or ground speed 5–11 km/h (3-7 MPH) Drive at a higher speed. Insufficient warm-up at low ambient temperatures Warm the engine at least 5 minutes. With the transmission in neutral, advance the throttle to about 1/8 throttle in short bursts, 5 to 7 times. The belt will become more flexible and prevent belt burning. Slow/easy clutch engagement Use the throttle quickly and effectively.
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 LUBRICANTS AND FLUIDS 1. Mixing oil brands or using non-recommended oil may cause engine damage. We recommend the use of POLARIS engine oil. 2. Damage or failure resulting from the use of non-recommended lubricants or fluids is not covered by this warranty.
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.
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MAINTENANCE LOG MAINTENANCE LOG MAINTENANCE LOG Use the following chart to record periodic maintenance.
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A Accelerator Pedal ...................... 39 Age Restrictions ........................ 20 All Wheel Drive (AWD)................ 57 Auxiliary 12-Volt Terminal Board ... 44 Axle and Wheel Nut Torque Specifications.......................... 82 B Batteries .................................. 34 Battery .................................... 88 Battery Charging ....................... 88 Battery Charging Warning (7185977) .............................. 15 Battery Conditioning...................
H Hauling Cargo........................... 52 Headlight Beam Adjustment......... 86 Headlight Lamp Replacement ...... 85 Headlight Switch ....................... 31 Hot Drive Systems ..................... 26 Hour Meter............................... 30 How To Obtain Warranty Service .................................110 I Oil Change............................... 75 Oil Change – Front Gearcase ....... 77 Oil Check................................. 74 Oil Check – Front Gearcase .........
Seat Removal ........................... 40 Severe Use Definition ................. 71 Shock Loading the Winch ............ 67 Signal Words .............................. 7 Specifications ........................... 97 Stalling While Climbing a Hill ........ 25 Steering Wheel Inspection ........... 80 Storage ................................... 93 Storage Area ............................ 94 Suspension Adjustment .............. 81 Winch Shock Loading ................. 67 T Tire Tread Depth ...............
PMS 419 For your nearest Polaris dealer, visit www.polaris.com Polaris Sales Europe Sarl Route de l’Etraz Business Center A5 1180 Rolle, Switzerland Part No.
