Polaris Automobile 500 2X4 User Manual

Download from Www.Somanuals.com. All Manuals Search And Download.

WARNING

The engine exhaust from this

product contains chemicals known

to cause cancer, birth defects or

other reproductive harm.

Download from Www.Somanuals.com. All Manuals Search And Download.

WELCOME

Thank you for purchasing a Polaris vehicle, and welcome to our

world-wide family of Polaris owners. We proudly produce an exciting

line of utility and recreational products.

S Snowmobiles

S All-terrain vehicles (ATVs)

S RANGER utility vehicles

S Victory motorcycles

We believe Polaris sets a standard of excellence for all utility and

recreational vehicles manufactured in the world today. Many years of

experience have gone into the engineering, design, and development of

your Polaris vehicle, making it the finest machine we’ve ever

produced.

For safe and enjoyable operation of your vehicle, be sure to follow the

instructions and recommendations in this owner’s manual. Your

manual contains instructions for minor maintenance, but information

about major repairs is outlined in the Polaris Service Manual and

should be performed only by a Factory Certified Master Service Dealer

(MSD) Technician.

Your Polaris dealer knows your vehicle best and is interested in your

total satisfaction. Be sure to return to your dealership for all of your

service needs during, and after, the warranty period.

We also take great pride in our complete line of apparel, parts and

accessories, available through our online store at

www.purepolaris.com. Have your accessories and clothing delivered

right to your door!

Download from Www.Somanuals.com. All Manuals Search And Download.

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. No liability can be accepted for omissions or inaccuracies. Any reprinting or

reuse of the depictions and/or procedures contained within, whether whole or in part, is

expressly prohibited.

Printed in U.S.A.

2006 RANGER 2X4/4X4/TM Owner’s Manual P/N 9920210

Download from Www.Somanuals.com. All Manuals Search And Download.

TABLE OF CONTENTS

VEHICLE IDENTIFICATION NUMBERS . . . . . . . . 4

SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

FEATURES AND CONTROLS . . . . . . . . . . . . . . . 23

OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

EMISSION CONTROL SYSTEMS . . . . . . . . . . . . 51

MAINTENANCE AND LUBRICATION . . . . . . . . . 53

POLARIS PRODUCTS . . . . . . . . . . . . . . . . . . . . . 101

SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . 102

TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . 108

WARRANTY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111

MAINTENANCE LOG . . . . . . . . . . . . . . . . . . . . . . 120

INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122

Download from Www.Somanuals.com. All Manuals Search And Download.

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.

Your key can be duplicated only by mating a Polaris key blank with

one of your existing keys, so if both keys are lost, the ignition switch

must be replaced.

31XX

Vehicle Model Number:

(behind left front wheel)

Frame VIN (1):

(under hood)

Engine Serial Number (2):

(right front side of engine crankcase)

Key Number (3):

Download from Www.Somanuals.com. All Manuals Search And Download.

SAFETY

Operator Safety

WARNING

Failure to follow the warnings contained in this manual can result

in severe injury or death.

A Polaris RANGER is not a toy and can be hazardous to operate.

This vehicle handles differently than other vehicles, such as

motorcycles and cars. A collision or rollover can occur quickly,

even during routine maneuvers like turning, or driving on hills or

over obstacles, if you fail to take proper precautions.

Read and understand your owner’s manual and all warnings

before operating the vehicle.

Age Restrictions

This vehicle is an ADULT VEHICLE ONLY. Operation is prohibited

for anyone under 16 years of age. No person under the age of 5 may

ride as a passenger in this vehicle.

Know Your Vehicle

As the operator of the vehicle, you are responsible for your personal

safety, the safety of others, and the protection of our environment.

Read and understand your owner’s manual, which includes valuable

information about all aspects of your vehicle, including safe operating

procedures.

The RANGER is an off-road vehicle. Familiarize yourself with all laws

and regulations concerning the operation of this vehicle in your area.

We strongly advise you to strictly follow the recommended

maintenance program outlined in your owner’s manual. This

preventive maintenance program is designed to ensure that all critical

components on your vehicle are thoroughly inspected at specific

intervals.

Download from Www.Somanuals.com. All Manuals Search And Download.

SAFETY

Operator Safety

The following signal words and symbols appear throughout this

manual and on your RANGER. Your safety is involved when these

words and symbols are used. Become familiar with their meanings

before reading the manual.

The safety alert symbol, on your vehicle or in this manual, alerts

you to the potential for personal injury.

WARNING

The safety alert warning indicates a potential hazard that may

result in serious injury or death.

CAUTION

The safety alert caution indicates a potential hazard that may

result in minor personal injury or damage to the vehicle.

CAUTION

A caution indicates a situation that may result in damage to the

vehicle.

NOTE:

A note will alert you to important information or instructions.

Download from Www.Somanuals.com. All Manuals Search And Download.

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.

S Read this manual and all labels carefully. Follow the operating pro-

cedures described.

S Never allow anyone without a valid driver’s license to operate this

vehicle.

S Minimum age recommendation for passengers is five years old. Pas-

sengers under five years of age require special restraints which are

not available with this vehicle. Driver and passenger should wear

their seat belts at all times.

S Never permit a guest to operate this vehicle unless the guest has read

this manual and all product labels.

S To reduce tipover risk, be especially careful when encountering ob-

stacles and slopes and when braking on hills or during turns.

S This vehicle is for off road use only. Never operate on public roads.

Always avoid paved surfaces.

S Helmets are recommended whenever driving this vehicle in an

aggressive manner. Eye protection is recommended at all times.

S Never consume alcohol or drugs before or while operating this ve-

hicle.

S Never operate at excessive speeds. Always travel at a speed proper

for the terrain, visibility and operating conditions, and your experi-

ence.

S Never attempt wheelies, jumps or other stunts.

S Always inspect your vehicle each time you use it to make sure it’s in

safe operating condition. Always follow the inspection and mainte-

nance procedures and schedules described in this manual.

S Always keep both hands on the steering wheel and both feet on the

floorboards of the vehicle during operation.

S Always travel slowly and use extra caution when operating on unfa-

miliar terrain. Be alert to changing terrain.

S Never operate on excessively rough, slippery or loose terrain.

Download from Www.Somanuals.com. All Manuals Search And Download.

SAFETY

Operator Safety

S Always follow proper procedures for turning as described in this

manual. Practice turning at slow speeds before attempting to turn at

faster speeds. Never turn at excessive speeds.

S Always have this vehicle checked by an authorized Polaris dealer if

it has been involved in an accident.

S Never operate this vehicle on hills too steep for the vehicle or for

your abilities. Practice on smaller hills before attempting larger hills.

S Always follow proper procedures for climbing hills as described in

this manual. Check the terrain carefully before attempting to climb a

hill. Never climb hills with excessively slippery or loose surfaces.

Never open the throttle suddenly or make sudden gear changes.

Never go over the top of a hill at high speed.

S Always follow the proper procedures outlined in this manual for

traveling downhill and for braking on hills. Check the terrain care-

fully 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 pos-

sible.

S Always check for obstacles before operating in a new area. Never

attempt to operate over large obstacles such as rocks or fallen trees.

Always follow the proper procedures outlined in this manual when

operating over obstacles.

S Always be careful of skidding or sliding. On slippery surfaces such

as ice, travel slowly and exercise caution to reduce the chance of

skidding or sliding out of control.

S Never operate your vehicle in fast-flowing water or in water deeper

than that specified in this manual. Wet brakes may have reduced

stopping ability. Test your brakes after leaving water. If necessary,

apply them lightly several times to let friction dry out the pads.

S Always be sure there are no obstacles or people behind your vehicle

when operating in reverse. When it’s safe to proceed in reverse,

move slowly. Avoid turning at sharp angles in reverse.

S Always use the proper size and type of tires specified in this manual.

Always maintain proper tire pressure as specified on page 103.

Download from Www.Somanuals.com. All Manuals Search And Download.

SAFETY

Operator Safety

S Never modify this vehicle through improper installation or use of

accessories.

S Never exceed the stated load capacity for this vehicle. Cargo should

be properly distributed and securely attached. Reduce speed and

follow the instructions in this manual for hauling cargo or pulling a

trailer. Allow a greater distance for braking.

S Always wear the seat belts when operating this vehicle. Seat belts

reduce the severity of injury in case of a sudden stop or collision.

S Always keep arms and legs inside the cab frame while the vehicle is

in motion.

S Always apply the parking brake before getting out of the vehicle.

See page 31.

S Always activate the foot pedal brake before releasing the park brake.

S Always turn off the engine before refueling. Make sure the refueling

area is well ventilated and free of any source of flame or sparks.

Gasoline is extremely flammable. See page 22 for refueling instruc-

tions.

S Always remove the ignition key when the vehicle is not in use to

prevent unauthorized use or accidental starting.

FOR MORE INFORMATION ABOUT SAFETY, call Polaris at

1-800-342-3764.

Download from Www.Somanuals.com. All Manuals Search And Download.

SAFETY

Operator Safety

WARNING

Make sure your RANGER is in excellent operating condition at all

times. We strongly recommend that the operator check all safety

components before each ride.

Polaris RANGERs are designed to provide safe operation when

used as directed. Failure of critical machine components may

result from operation with any modifications, especially those that

increase speed or power. The RANGER may become

aerodynamically unstable at speeds higher than those for which it

is designed. Loss of control may occur at higher speeds.

Modifications may also create a safety hazard and lead to bodily

injury.

Do not make any modifications to your RANGER.

Equipment Modifications

We are concerned for the safety of our customers and for the general

public. Therefore, we strongly recommend that consumers do not

install on a Polaris RANGER any equipment that may increase the

speed or power of the vehicle, or make any other modifications to the

vehicle for these purposes. Any modifications to the original

equipment of the vehicle create a substantial safety hazard and increase

the risk of bodily injury.

The warranty on your Polaris RANGER is terminated if any equipment

has been added to the vehicle, or if any modifications have been made

to the vehicle, that increase its speed or power.

NOTE: The addition of certain accessories, including (but not limited

to) mowers, blades, tires, sprayers, or large racks, may

change the handling characteristics of the vehicle. Use only

Polaris-approved accessories, and familiarize yourself with

their function and effect on the vehicle.

Download from Www.Somanuals.com. All Manuals Search And Download.

SAFETY

Operator Safety

WARNING

POTENTIAL HAZARD

Stalling, rolling backwards while

climbing a hill

WHAT CAN HAPPEN

Vehicle overturn

HOW TO AVOID THE HAZARD

Maintain a steady speed when

climbing a hill.

If you lose all forward speed:

Apply the brakes.

Lock the parking brake after fully stopped.

If you begin rolling backwards:

Never apply engine power.

Apply the brake gradually.

When fully stopped, lock parking brake.

In the event of an accident, have a qualified service dealer check

the complete vehicle for possible damage, including (but not

limited to) brakes, throttle and steering.

Download from Www.Somanuals.com. All Manuals Search And Download.

SAFETY

Operator Safety

WARNING

POTENTIAL HAZARD

Operating this vehicle on paved surfaces

WHAT CAN HAPPEN

Loss of control

HOW TO AVOID THE HAZARD

This vehicle’s tires are designed for off-road use only, not for use

on pavement. Paved surfaces may seriously affect handling and

control of the vehicle, and may cause the vehicle to go out of

control.

Avoid operating the vehicle on pavement. If you must operate on

a paved surface, travel slowly and do not make sudden turns or

stops.

WARNING

POTENTIAL HAZARD

Operating this vehicle without proper instruction

WHAT CAN HAPPEN

Loss of control, accident

HOW TO AVOID THE HAZARD

The risk of an accident is greatly increased if the operator does

not know how to operate the vehicle properly in different

situations and on different types of terrain.

All operators must read and understand the Owner’s Manual and

all warning and instruction labels before operating the vehicle.

Download from Www.Somanuals.com. All Manuals Search And Download.

SAFETY

Operator Safety

WARNING

POTENTIAL HAZARD

Operating this vehicle on public streets, roads or highways

WHAT CAN HAPPEN

Collision with another vehicle

HOW TO AVOID THE HAZARD

Never operate this vehicle on any public street, road or highway,

including dirt or gravel.

In many states it’s illegal to operate vehicles of this type on public

streets, roads and highways.

WARNING

POTENTIAL HAZARD

Operating this vehicle after consuming alcohol or drugs

WHAT CAN HAPPEN

Could seriously affect your judgment.

Could cause you to react more slowly.

Could affect your balance and perception.

Could result in an accident.

HOW TO AVOID THE HAZARD

Driving a RANGER requires your full attention. DO NOT drink

alcohol or use drugs or medications before or while driving. They

will reduce your alertness and slow your reaction time. In most

states and provinces, it’s prohibited by law to drive while

intoxicated or under the influence of drugs.

Download from Www.Somanuals.com. All Manuals Search And Download.

SAFETY

Operator Safety

WARNING

POTENTIAL HAZARD

Operating this vehicle at excessive speeds

WHAT CAN HAPPEN

Loss of control, accident

HOW TO AVOID THE HAZARD

Always travel at a speed proper for the terrain, visibility and

operating conditions, and your experience.

WARNING

POTENTIAL HAZARD

Attempting jumps and other stunts

WHAT CAN HAPPEN

Loss of control, accident and/or vehicle overturn

HOW TO AVOID THE HAZARD

Never attempt jumps and other stunts. Avoid exhibition driving.

WARNING

POTENTIAL HAZARD

Operating on frozen bodies of water.

WHAT CAN HAPPEN

Severe injury or death can result if the vehicle and/or the operator

fall through the ice.

HOW TO AVOID THE HAZARD

Never operate the RANGER on a frozen body of water.

Download from Www.Somanuals.com. All Manuals Search And Download.

SAFETY

Operator Safety

WARNING

POTENTIAL HAZARD

Failure to inspect the vehicle before operating

Failure to properly maintain the vehicle

WHAT CAN HAPPEN

Accident, equipment damage

HOW TO AVOID THE HAZARD

Always inspect your RANGER before each use to make sure it’s

in safe operating condition.

Always follow the inspection and maintenance procedures and

schedules described in the Owner’s Manual.

WARNING

POTENTIAL HAZARD

Failure to use extra caution when operating this vehicle on

unfamiliar terrain

WHAT CAN HAPPEN

Loss of control, vehicle overturn

HOW TO AVOID THE HAZARD

Travel slowly and use extra caution when operating on unfamiliar

terrain.

Always be alert to changing terrain conditions when operating the

vehicle. You may come upon hidden rocks, bumps, or holes

suddenly, without enough time to react.

Download from Www.Somanuals.com. All Manuals Search And Download.

SAFETY

Operator Safety

WARNING

POTENTIAL HAZARD

Failure to follow the minimum age recommendations for this

vehicle

WHAT CAN HAPPEN

Serious injury or death (the child or others)

HOW TO AVOID THE HAZARD

Only persons with a valid driver’s license should operate a Polaris

RANGER.

Even though a child may be within the age group for which some

vehicles are recommended, he or she may not have the skills,

abilities, or judgment needed to operate the vehicle safely and

may be involved in a serious accident.

WARNING

POTENTIAL HAZARD

Operating this vehicle with improper tires or with improper or

uneven tire pressure

WHAT CAN HAPPEN

Loss of control, accident and/or overturn

HOW TO AVOID THE HAZARD

Always use the size and type of tires specified in the Owner’s

Manual for this vehicle. See page 103.

Always maintain proper tire pressure as described on the decal

and in the Owner’s Manual. See page 103.

Download from Www.Somanuals.com. All Manuals Search And Download.

SAFETY

Operator Safety

WARNING

Leaving the keys in the ignition can lead to unauthorized use of

the vehicle resulting in serious injury or death. Always remove

the ignition key when the vehicle is not in use.

WARNING

After any overturn or accident, have a qualified service dealer

inspect the entire vehicle for possible damage, including (but not

limited to) brakes, throttle and steering systems.

CAUTION

Always keep combustible materials away from the exhaust

system. Exposure to the hot components could result in a fire.

Download from Www.Somanuals.com. All Manuals Search And Download.

SAFETY

Safety Decals and Locations

Warning decals have been placed on the RANGER for your protection.

Read and follow the instructions of the decals on the RANGER

carefully. If any of the decals depicted in this manual differ from the

decals on your RANGER, always read and follow the instructions of the

decals on the RANGER.

If any decal becomes illegible or comes off, contact your Polaris dealer

to purchase a replacement. Replacement safety decals are provided by

Polaris at no charge. The part number is printed on the decal.

WARNING

S VEHICLE ROLLOVER could cause severe injury or death.

The cab frame is not designed or intended to provide rollover protection.

S ALWAYS WEAR YOUR SEAT BELT for maximum protection.

7172676

Location 1

WARNING

Moving parts hazard under belt-clutch guard. To

prevent serious injury, do not operate vehicle

with guard removed.

Do not modify engine or clutch. Doing so can

cause part failure, possible imbalance, and

excessive engine RPM, which can result in serious

injury or death.

NO STEP

7172563

Location 2

WARNING

IMPROPER TIRE PRESSURE OR OVERLOADING can cause loss of

control resulting in SEVERE INJURY OR DEATH.

TIRE PRESSURE (PSI): FRONT ___ REAR ___

MAXIMUM WEIGHT CAPACITY (Gross Vehicle Weight)

INCLUDING MACHINE, DRIVER AND CARGO IS _______ LBS.

Reduce speed and allow greater distance for braking when carrying

cargo. Overloading or carrying tall, off-center, or unsecured loads

will increase your risk of losing control. Loads should be centered

and carried as low as possible in box. For stability on rough or hilly

terrain, reduce speed and cargo. Be careful if load extends over the

side of the box.

Read Owner’s Manual for more detailed loading information.

Location 3

Download from Www.Somanuals.com. All Manuals Search And Download.

SAFETY

Safety Decals and Locations

WARNING

Passengers can be thrown off. This can

cause serious injury or death.

Never carry passengers in cargo box.

Maximum Box Load is ___ lbs.

Remove flammable containers from box before refueling.

WARNING

Location 4 (inside front of box)

Fuel / Passenger Warning Decal Text

Remove flammable containers from box before refueling.

S Passengers can be thrown off. This can cause serious injury or death.

S Never carry passengers in cargo box.

Maximum 2X4 (TM) Box Load 750 lbs. (340 kg)

Maximum 4X4 Box Load 1000 lbs. (454 kg)

Download from Www.Somanuals.com. All Manuals Search And Download.

SAFETY

Safety Decals and Locations

MANUFACTURED

BY: POLARIS IND INC.

DATE:

VIN:

THIS VEHICLE IS A GENERAL PURPOSE OFF-ROAD

UTILITY VEHICLE AND IS NOT INTENDED FOR USE ON

PUBLIC ROADS.

CE VÉHICULE USAGE GENERAL VEHICULE UTILIT-

AIRE POUR SERVICE HORS

ROUTE QUI NEST PAS DES-

TINE A ETRE UTILISE SUR LES

CHEMINS PUBLICS.

7078472

Location 5 (under hood)

ATTENTION

Operation of this vehicle without the

filter element will severely damage

the engine.

Clean air filter often, more frequent

cleaning required in dusty conditions

Operation of this vehicle without en-

gine breather filter(s) can cause en-

gine damage. Consult owner’s

manual for details.

Specific carburetor jetting and adjust-

ments are required depending on

temperature and altitude. See your

Owner’s Manual.

Factory setting:

40_ to 80_ F. at 0-3000 feet

(5_ to 27_ C. at 0-900 meters).

7079902

Location 6

CAUTION

To avoid transmission

damage, shift only when

vehicle is stationary and

at idle.

7172674

Location 7

Download from Www.Somanuals.com. All Manuals Search And Download.

SAFETY

Safety Decals and Locations

Discretionary Warning Decal

WARNING

7172675

Location 8

Improper vehicle use can result in SEVERE INJURY or DEATH.

NEVER:

S Operate on public roads. A collision can occur with another vehicle.

S Carry more than two passengers, or passengers under age five.

S Use ALCOHOL or DRUGS before or while operating this vehicle.

S Operate at speeds too fast for your skills or the conditions.

S Operate this vehicle on HILLS steeper than 15 degrees. To prevent

flipover on hilly terrain, use throttle and brakes gradually.

ALWAYS:

S Avoid paved surfaces, which may adversely affect handling and

control.

S Use proper RIDING TECHNIQUES to avoid vehicle overturns on

hills and rough terrain and in turns.

S Wear eye protection.

REVERSE operation can be dangerous, even at low speeds. Steering

becomes difficult. To prevent flipover, avoid sharp turns.

The park/emergency brake lever will supply increased braking, but

should be used as an emergency or parking brake only.

READ OWNER’S MANUAL. FOLLOW ALL INSTRUCTIONS

AND WARNINGS. IF OWNER’S MANUAL IS MISSING,

CONTACT A POLARIS DEALER FOR A REPLACEMENT.

THIS GENERAL PURPOSE OFF-ROAD UTILITY VEHICLE DOES

NOT MEET FEDERAL MOTOR VEHICLE SAFETY STANDARDS

FOR ON-ROAD VEHICLES.

Download from Www.Somanuals.com. All Manuals Search And Download.

SAFETY

Fuel Safety

WARNING

Gasoline is highly flammable and is explosive under certain

conditions. Always exercise extreme caution whenever handling

gasoline.

Always stop the engine when refueling.

Always refuel outdoors or in a well ventilated area.

Do not smoke or allow open flames or sparks in or near the

refueling area or where gasoline is stored.

Do not over fill the tank. Do not fill the tank neck.

If gasoline spills on your skin or clothing, immediately wash it off

with soap and water and change clothing.

Never start the engine or let it run in an enclosed area. Gasoline

powered engine exhaust fumes are poisonous and can cause

loss of consciousness and death in a short time.

Download from Www.Somanuals.com. All Manuals Search And Download.

FEATURES AND CONTROLS

Some Polaris vehicles are equipped with special features such as the

cab frame. Not all models come with all features. Refer to the

specifications section beginning on page 102.

Component Locations

1. Cab Frame (if equipped)

2. Hip Bar

3. Console

4. Steering Wheel

5. Seat

6. Cargo Box

7. Seat Belts

8. Fuel Tank Cap / Fuel Gauge

9. Battery

Download from Www.Somanuals.com. All Manuals Search And Download.

FEATURES AND CONTROLS

Component Locations

10. Headlights

11. Radiator (if equipped)

12. Front Bumper/Brush Guard

13. Hood Hold Down Strap

Download from Www.Somanuals.com. All Manuals Search And Download.

FEATURES AND CONTROLS

Component Locations

14. Taillights

15. Tailgate

16. Tailgate Latch Release

17. Muffler (Spark Arrester)

18. CV Boot/Rear Caliper

19. Air Box

20. Receiver Hitch

Download from Www.Somanuals.com. All Manuals Search And Download.

FEATURES AND CONTROLS

Indicator Lights

The indicator lights on the console display:

1. High Gear

2. Low Gear (if equipped)

3. Neutral Gear

4. Reverse Gear

5. High Temperature

6. Brakes

Trailer Hitch Bracket

This vehicle is equipped with a receiver hitch bracket for a trailer hitch.

Trailer towing equipment is not supplied with this vehicle.

To avoid injury and property damage, always heed the warnings and

towing capacities outlined on page 47.

Auxiliary Outlet (1)

The 12-volt receptacle has

spade connections on the

back that may be used to

power an auxiliary light or

other optional accessories or

lights. The connections are

behind the console, under

the hood.

Fuel Cap/Fuel Gauge (2)

The fuel tank filler cap is located on the

right-hand side of the vehicle near the

passenger seat. It has a built-in fuel

gauge that indicates the amount of fuel

remaining in the tank.

When the indicator needle nears the E

(empty) mark, refuel at the earliest

opportunity.

When refueling, always use either

leaded or unleaded gasoline with a

minimum pump octane number of 87

R+ M/2 octane.

Download from Www.Somanuals.com. All Manuals Search And Download.

FEATURES AND CONTROLS

Seat Removal

Pull up on the front of the seat

and slide it toward the front of

the vehicle.

Install the seat by sliding the

tabs into the rear of the seat

base. Push down firmly on the

front of the seat until the pins

are fully seated into the

grommets.

Seat Belts

The RANGER is equipped with

lap-style seat belts for the operator

and passenger.

WARNING

Falling from a moving vehicle could result in serious injury or

death. Always fasten your seat belt securely before operating or

riding in the RANGER.

Passengers under five years of age require special restraints,

which are not available with this vehicle. No person under the age

of five years may ride in the RANGER.

To wear the seat belt properly, follow this procedure:

1. Place the belt across your lap as low on your hips as possible,

taking care that the belt is not twisted.

2. Push the latch plate into the buckle until it clicks.

3. Release the strap, it will self tighten.

NOTE: The center belt must be tightened manually by pulling on the

strap.

To unfasten, press the square red button in the buckle’s center.

Download from Www.Somanuals.com. All Manuals Search And Download.

FEATURES AND CONTROLS

Console

1. Cup Holder

2. Indicator Lights

3. Shift Lever

4. Light Switch

5. AWD/Differential Switch (if equipped)

6. Hour Meter

7. Glove Box with Lid

8. 12V Accessory Plug

9. Storage Tray

10. Choke Knob

11. Ignition Switch

12. Differential Lock Lever (if equipped)

13. Storage Box

Download from Www.Somanuals.com. All Manuals Search And Download.

FEATURES AND CONTROLS

Gear Selector (1)

RANGER 2X4, 4X4

H: High Gear

L: Low Gear

N: Neutral

R: Reverse

RANGER TM

H: High Gear

N: Neutral

R: Reverse

NOTE: Low is the primary driving range for the

RANGER 2X4 and 4X4. High is intended

for use on hard-packed surfaces with light

loads.

To change gears, stop the vehicle and with the engine idling, move the

lever to the desired gear. Do not attempt to shift gears with engine

speed above idle or while the vehicle is moving.

Always place the transmission in gear with the parking brake locked

whenever the vehicle is left unattended.

Maintaining shift linkage adjustment is important to assure proper

transmission function. See your dealer if you experience any shifting

problems.

CAUTION

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.

Always place the transmission in gear with the parking brake

applied and turn the vehicle off whenever the vehicle is left

unattended.

Download from Www.Somanuals.com. All Manuals Search And Download.

FEATURES AND CONTROLS

AWD

2WD

Ignition Switch (1)

The ignition switch is a three-position, key-operated switch. The key

can be removed from the switch when it is in the OFF position.

OFF

The engine is off. Electrical circuits are off, except Acc. 12V.

Electrical circuits are on. Electrical equipment can be used.

START Turn the key to the START position to engage the electric

starter. The key returns to the ON position when released.

WARNING

Leaving the keys in the ignition can lead to unauthorized use of

the vehicle resulting in serious injury or death. Always remove

the ignition key when the vehicle is not in use.

Light Switch (2)

The ignition switch key must be in the ON position to operate the

headlights. The switch has three positions:

A: High Beam

B: Low Beam

C: Off

AWD/Differential Lock Switch (3) (2X4, 4X4)

The AWD/Differential Switch has three positions:

D: AWD (4X4 only) E: 2WD/Differential Lock

F: Off

See page 50 for AWD operating instructions. See page 49 for

differential operating instructions.

Differential Lock Lever (4) (TM)

To lock the differential on the TM, push the lock lever up. See page 49

for differential operating instructions.

Download from Www.Somanuals.com. All Manuals Search And Download.

FEATURES AND CONTROLS

Brake Pedal (1)

Depress the brake pedal to slow or stop the vehicle.

Throttle Pedal (2)

Push the pedal down to increase

engine speed. Spring pressure

returns the pedal to the rest

position when released. Always

check that the throttle pedal

returns normally before starting

the engine. Make sure there’s

adequate throttle pedal freeplay.

See page 85 for throttle pedal

adjustment procedures.

Parking Brake Lever (3)

Engage the parking brake when parking the vehicle to help prevent the

vehicle from rolling. To apply the parking brake, push down on the

pedal with your foot.

Parking Brake Release (4)

To release the parking brake, pull the release handle. Spring pressure

helps return the lever to the released position. Make sure the parking

brake lever is functioning properly before each operation.

Download from Www.Somanuals.com. All Manuals Search And Download.

OPERATION

Vehicle Break-In Period

The break-in period for your new Polaris RANGER is the first twenty

hours of operation, or the time it takes to use the first two tanks full of

gasoline. No single action on your part is as important as a proper

break-in period. Careful treatment of a new engine will result in more

efficient performance and longer life for the engine. Perform the

following procedures carefully.

CAUTION

Excessive heat build-up during the first three hours of operation

will damage close-fitted engine parts. Do not operate at full

throttle or high speeds for extended periods during the first three

hours of use.

Use of any oils other than those recommended by Polaris may

cause serious engine damage. We recommend the use of

Polaris Premium 4 Synthetic Oil for your 4-cycle engine.

1. Fill the fuel tank with gasoline. Heed the gasoline warnings on

page 22.

2. Check the oil level on the dipstick. See page 61. Add Polaris

Premium 4 Synthetic Oil if necessary to maintain the oil level in

the normal (safe) operating range.

3. Drive slowly at first. Select an open area that allows room to

familiarize yourself with vehicle operation and handling.

4. Vary throttle positions. Do not operate at sustained idle.

5. Perform regular checks on fluid levels, controls and areas outlined

on the daily pre-ride inspection checklist. See page 33.

6. Pull only light loads.

7. During the break-in period, change both the oil and the filter at 25

hours.

Download from Www.Somanuals.com. All Manuals Search And Download.

OPERATION

Pre-Ride Inspection

WARNING

If a proper inspection is not done before each use, severe injury

or death could result. Always inspect the vehicle before each use

to ensure it’s in proper operating condition.

Pre-Ride Checklist

Item

Remarks

See

Page

Brake system / lever travel

Brake fluid

Ensure proper operation

Ensure proper level

Front suspension

Rear suspension

Steering

Inspect, lubricate if necessary

Ensure free operation

Tires

Inspect condition and pressure

Inspect, ensure fastener tightness

90,107

Wheels / fasteners

Frame nuts, bolts, fasteners Inspect, ensure tightness

Fuel and oil

Ensure proper levels

Ensure proper level

Inspect for leaks

61, 65

Coolant level (4X4)

Coolant hoses (4X4)

Throttle

Ensure proper operation

Ensure operation

31, 85

26, 30

78, 80

Indicator lights / switches

Air filter, pre-filter

Air box sediment tube

Headlamp

Inspect, clean

Drain deposits whenever visible

Check operation, apply Polaris dielec-

tric grease when lamp is replaced

Brake light / tail lamp

Check operation, apply Polaris dielec-

tric grease when lamp is replaced

Download from Www.Somanuals.com. All Manuals Search And Download.

OPERATION

Starting the Engine

WARNING

Engine exhaust contains poisonous carbon monoxide and can

cause loss of consciousness resulting in severe injury or death.

Never run an engine in an enclosed area.

CAUTION

Operating the vehicle immediately after starting could cause

engine damage. Allow the engine to warm up for several minutes

before operating the vehicle.

Starting a Cold Engine

1. Place the transmission in neutral.

2. Lock the parking brake.

3. Sit in the driver’s seat and fasten the

seat belt.

NOTE: Do not use the choke before

attempting to start the TM model. If

the engine does not start on the first

attempt without choking, proceed to

step 4.

4. Pull the choke knob (1) all the way out (2).

NOTE: Do not press the throttle pedal while

starting the engine.

CAUTION

Do not operate the starter continuously for more

than five seconds or the starter will overheat and

the battery power will drop temporarily. Wait at

least five seconds between each operation of the

starter to allow it to cool and to allow battery power recovery.

Do not turn the ignition switch key to the START position while

the engine is running. Damage to the starter can result.

5. Turn the ignition key to START.

6. If the engine does not start within five seconds, release the ignition

switch and wait five seconds. Repeat steps 5 and 6 until the engine

starts.

7. After the engine starts, push the choke knob in half way (3).

8. Vary the engine RPM slightly with the throttle to aid in warm up

until the engine idles smoothly.

9. Push the choke completely in (4).

Download from Www.Somanuals.com. All Manuals Search And Download.

OPERATION

Starting the Engine

Starting a Warm Engine

Warm engines do not normally require the use of the choke. Overuse of

the choke can cause the spark plug to become wet fouled.

1. Place the transmission in neutral and move the vehicle to a level

surface.

2. Lock the parking brake.

3. Sit in the driver’s seat and fasten the seat belt.

4. Turn the ignition key to START.

5. If the engine has cooled and does not readily start, intermittent use

of the choke knob (pulled half way out) may be necessary.

6. If the engine is over-choked when warm, depress the throttle lever

fully while cranking to aid in starting.

7. Release the throttle lever immediately after the engine starts.

NOTE: If the engine does not start and all conditions are favorable,

change the spark plug.

Stopping the Engine

1. Release the throttle pedal completely and brake to a complete stop.

2. Put the gear shift lever into neutral.

3. Apply the parking brake.

WARNING

A rolling vehicle can cause property damage and serious injury.

Always apply the parking brake after stopping the engine.

Download from Www.Somanuals.com. All Manuals Search And Download.

OPERATION

Braking

1. Release the throttle pedal completely.

2. Press on the brake pedal evenly and firmly.

NOTE: Practice starting and stopping (using the brakes) until you’re

familiar with the controls.

NOTE: When the throttle pedal is released completely and the

engine speed drops near an idle, the vehicle has no engine

braking.

WARNING

Failure to allow for increased braking distance when hauling

cargo or towing a trailer may result in accident and injury. Always

slow down and allow additional braking distance when towing or

hauling cargo.

Download from Www.Somanuals.com. All Manuals Search And Download.

OPERATION

Driving Safely

Driving Procedures

1. Sit in the driver’s seat and fasten the seat belt.

2. After starting the engine and allowing it to warm up, shift the

transmission into gear.

3. Check your surroundings and determine your path of travel.

4. Release the parking brake.

5. Keeping both hands on the steering wheel, slowly depress the

throttle with your right foot and begin driving. Vehicle speed is

controlled by the amount of throttle opening and Polaris Variable

Transmission (PVT) shifting is automatic.

6. Drive slowly. Practice maneuvering and using the throttle and

brakes on level surfaces.

NOTE: Low is the primary gear for operating the RANGER 4X4.

High gear is intended for use on hard-packed surfaces with

light loads.

Download from Www.Somanuals.com. All Manuals Search And Download.

OPERATION

Driving Safely

Driving On Slippery Surfaces

When driving on slippery surfaces such as wet trails, loose gravel, or

ice, be alert for the possibility of skidding and sliding. Under these

conditions, follow these precautions:

1. Slow down when entering slippery areas.

2. Maintain a high level of alertness, reading the trail and avoiding

quick, sharp turns, which can cause skids.

3. Correct a skid by turning the steering wheel in the direction of the

skid.

4. Drive with AWD engaged (if equipped) to assist in controlling the

vehicle.

CAUTION

Severe damage to the drive train may occur if the AWD is

engaged while the wheels are spinning. Always allow the wheels

to stop spinning before engaging AWD.

WARNING

Failure to exercise care when operating on slippery surfaces can

result in loss of tire traction and cause loss of control, accident,

and serious injury or death.

Never apply the brakes during a skid.

Do not operate on excessively slippery surfaces.

Always reduce speed and use additional caution when operating

on slippery surfaces.

Download from Www.Somanuals.com. All Manuals Search And Download.

OPERATION

Driving Safely

Driving Uphill

15_ Maximum

Whenever traveling uphill, follow these precautions:

1. Always travel straight uphill.

2. Avoid steep hills (15_ maximum).

3. Keep both feet on the floor.

4. Proceed at a steady rate of speed and throttle opening.

WARNING

Climbing hills improperly can cause loss of control or vehicle

overturn. Always check the terrain carefully before climbing a hill.

Braking and handling are greatly affected when operating in hilly

terrain. Improper procedure could cause loss of control or

overturn and result in serious injury or death.

Avoid climbing steep hills (15_ maximum).

Use extreme caution when operating on hills, and follow proper

operating procedures outlined in the owner’s manual.

Never climb hills with excessively slippery or loose surfaces.

Never open the throttle suddenly.

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.

Download from Www.Somanuals.com. All Manuals Search And Download.

OPERATION

Driving Safely

Sidehilling

WARNING

Crossing hillsides or turning on hills can result in loss of control or

vehicle overturn, resulting in severe injury or death. Avoid

crossing the side of a hill when possible. When unavoidable,

exercise extreme caution. Avoid operating on steep hills (15_

maximum).

Driving Downhill

Whenever descending a hill, follow these precautions:

1. Proceed directly downhill.

2. Slow down.

3. Apply the brakes slightly to aid in slowing.

WARNING

Traveling downhill improperly could cause loss of control or

vehicle overturn. Always check the terrain carefully before

descending a hill.

Never descend a hill at high speed. Excessive speed may result

in loss of vehicle control and lead to serious injury or death.

Always operate slowly when traveling downhill.

Avoid descending a hill at an angle, which would cause the

vehicle to lean sharply to one side. Travel straight downhill when

possible.

Download from Www.Somanuals.com. All Manuals Search And Download.

OPERATION

Driving Safely

Driving Through Water

WARNING

The large tires on your RANGER may cause the vehicle to float in

deep or fast-flowing water, which could result in loss of control

and lead to serious injury or death. Never cross deep or

fast-flowing water with your RANGER.

Your Polaris RANGER can

operate through water up

to a maximum

recommended depth equal

to the floorboards (1).

Follow these procedures

when operating through

water:

1. Always determine

water depths and

current before entering.

2. Choose a crossing

where both banks have

gradual inclines.

3. Proceed slowly, avoiding rocks and obstacles.

4. After leaving water, always dry the brakes by applying light

pressure to the lever repeatedly until braking action is normal.

NOTE: After running your vehicle in water, it’s critical that you

perform the services outlined in the Periodic Maintenance

Chart beginning on page 53. Give special attention to engine

oil, transmission oil, front and rear gearcases, and all grease

fittings.

CAUTION

Immersion can result in major damage if the vehicle isn’t serviced

correctly and promptly. After immersion, always take the vehicle

to your dealer service. Do not start the engine!

If it’s impossible to bring the vehicle to your dealer before starting

the engine, perform the service outlined on page 77, and take the

vehicle to your dealer at the first opportunity.

Download from Www.Somanuals.com. All Manuals Search And Download.

OPERATION

Driving Safely

Driving Over Obstacles

Be alert! Look ahead and learn to read the terrain you’re traveling on.

Watch for hazards such as logs, rocks and low hanging branches.

WARNING

Severe injury or death can result if your vehicle suddenly comes

in contact with a hidden obstacle. Not all obstacles are

immediately visible. Reduce speed and travel with caution in

unfamiliar terrain.

Download from Www.Somanuals.com. All Manuals Search And Download.

OPERATION

Driving Safely

Driving in Reverse

Follow these guidelines when operating in reverse:

1. Back slowly.

2. Apply the brakes lightly for stopping.

3. Avoid turning at sharp angles.

4. Always avoid backing downhill.

5. Never open the throttle suddenly while backing.

6. Always inspect left and right fields of vision before backing.

WARNING

Failure to use caution when operating in reverse can result in

serious injury or death. Before shifting into reverse, always check

for obstacles or people behind the vehicle and follow the reverse

operation procedures outlined in this manual. Always back slowly.

Download from Www.Somanuals.com. All Manuals Search And Download.

OPERATION

Driving Safely

Parking on an Incline

Avoid parking on an incline if possible. If it’s unavoidable, follow

these precautions:

1. Place the transmission in gear.

2. Set the parking brake.

3. Block the rear wheels on the downhill side.

WARNING

A rolling vehicle can cause property damage and serious injury.

Always apply the parking brake after stopping the engine. Always

block the downhill side of the wheels if leaving the vehicle on a

hill, or park the vehicle in a sidehill position instead.

Operating the vehicle while the parking brake is engaged could

cause loss of control and result in serious injury or death. Always

disengage the parking brake before operating the vehicle.

Download from Www.Somanuals.com. All Manuals Search And Download.

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:

Always load the cargo box with the load as far forward as

possible.

Always operate the vehicle with extreme care when hauling or

towing loads.

Slow down and drive in the lowest gear available.

The RANGER has been designed to carry or tow specific capacities.

Always read and understand the load distribution warnings listed on

the warning labels. Never exceed the following capacities.

Maximum Capacities

(Level Ground)

Cargo Box

RANGER 4X4

RANGER 2X4

RANGER TM

1500 lbs. (681 kg)

1250 lbs. (567 kg)

1000 lbs. (454 kg)

750 lbs. (340 kg)

WARNING

Driving with passengers in

the cargo box can result in

severe injury or death.

Never allow passengers to

ride in the cargo box.

Passengers must always

ride in the cab with seat

belts fastened securely.

Download from Www.Somanuals.com. All Manuals Search And Download.

OPERATION

Hauling Cargo

Dumping the Cargo Box

WARNING

Operating the vehicle while the cargo box is raised could result in

severe injury. The box could close unexpectedly and cause injury

to the driver or passenger. The rear tires will also catch the rear

of a raised box, damaging the vehicle and creating hazardous

driving conditions.

Never operate this vehicle with the cargo box in the raised

position.

1. Select a level site to

dump the cargo box. Do

not attempt to dump or

unload the vehicle while

parked on an incline.

2. Set the parking brake.

3. Dismount the vehicle.

4. Ensure that the cargo is

positioned evenly or

toward the front of the

cargo box.

5. Release the tailgate by

pulling up on the tailgate latch.

6. Stand clear and pull up on the cargo box release lever (1).

7. Lift the front of the cargo box to dump the cargo.

8. Lower the cargo box and push down securely to latch.

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.

Download from Www.Somanuals.com. All Manuals Search And Download.

OPERATION

Hauling Cargo

Towing Loads

WARNING

Towing improperly can alter vehicle handling and may cause loss

of control or brake instability, which can result in serious injury or

death. Always follow these precautions when towing:

Never load more than 150 lbs. (68.1 kg) tongue weight on the

towing bracket.

Do not operate the vehicle faster than 10 mph (16 km/h) when

towing. Towing a trailer increases braking distance.

Do not tow more than the recommended weight for the vehicle.

See the towing capacity chart below and the specifications charts

beginning on page 102.

Attach a trailer to the trailer hitch bracket only. Do not attach a

trailer to any other location or you may lose control of the vehicle.

Never tow a trailer on a grade steeper than 15°.

Maximum Towing Capacities (Level Ground)

Total Towed

Total Towed Total Hitch Maximum

Load Weight Load Weight

Vertical

Weight

Towing

Speed

(level ground) (15° grade)

RANGER

1000 lbs.

(454 kg)

600 lbs.

(272 kg)

100 lbs.

45.4 kg)

10 mph

(16 kph)

RANGER

1000 lbs.

(454 kg)

600 lbs.

(272 kg)

100 lbs.

45.4 kg)

10 mph

(16 kph)

2X4

RANGER

1500 lbs.

(681 kg)

850 lbs.

(386 kg)

150 lbs.

(68.1 kg)

10 mph

(16 kph)

4X4

Belt Life

To extend belt life, use the lowest gear possible when hauling or

towing heavy cargo.

Download from Www.Somanuals.com. All Manuals Search And Download.

OPERATION

Driving Safely

Parking the RANGER

WARNING

A rolling vehicle can cause property damage and serious injury.

Always apply the parking brake after stopping the engine.

1. Stop the vehicle on a level surface.

2. When the engine has stopped, apply the parking brake.

3. Remove the ignition switch key to prevent unauthorized use.

WARNING

Gasoline is extremely flammable and can be explosive under

certain conditions. 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.

Download from Www.Somanuals.com. All Manuals Search And Download.

OPERATION

Differential Operation Modes

The rear axle is equipped with a lockable differential. On AWD

models, engaging AWD locks the front differential and the rear

differential.

CAUTION

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.

AWD (4X4)

AWD

When in AWD, the rear wheels rotate

at the same speed. The front wheels

also rotate at the same speed. See page

50 for AWD operating instructions.

2WD/Rear Differential Locked

When the rear differential is locked,

both rear wheels rotate at the same

2WD

speed. It’s beneficial to lock the

differential in low traction situations.

To lock the differential on the TM,

push the lock lever up.

To lock the differential on the 2X4 and

4X4, move the AWD/Differential

Switch to the center (2WD) position.

OFF/Differential Unlocked

When the rear differential is unlocked,

AWD

the rear wheels can rotate at different

speeds. Unlock the differential to

make maneuvering easier and

minimize damage to turf.

2WD

To unlock the differential on the TM,

push the lock lever down.

To unlock the differential on the 2X4

and 4X4, move the AWD/Differential

Switch to the lowest (OFF) position.

Download from Www.Somanuals.com. All Manuals Search And Download.

OPERATION

All Wheel Drive (AWD)

When in AWD, the front gearcase will automatically engage anytime

the rear wheels lose traction. When the rear wheels regain traction, the

front gearcase will automatically disengage.

There is no limit to the length of time the vehicle may remain in AWD.

Engaging Front Gearcase

The AWD switch may be turned on or off while the vehicle is moving.

Initially, the vehicle’s electronic system will not enable the AWD until

the engine RPM is below 3100. Once enabled, the AWD remains

enabled until the AWD switch is turned off. If the switch is turned off

while the front gearcase is moving, it will not disengage until the rear

wheels regain traction.

See page 49 for AWD switch operation.

Engage the AWD before getting into conditions where front wheel

drive may be needed. If the rear wheels are spinning, release the

throttle before switching to AWD.

CAUTION

Switching to AWD while the rear wheels are spinning may cause

severe drive shaft and gearcase damage. Always switch to AWD

while the rear wheels have traction or are at rest.

Download from Www.Somanuals.com. All Manuals Search And Download.

EMISSION CONTROL SYSTEMS

Crankcase Emission Control System

This engine is equipped with a closed crankcase system. Blow-by

gases are forced back to the combustion chamber by the intake system.

All exhaust gases exit through the exhaust system.

Exhaust Emission Control System

The emissions from the exhaust of this vehicle are controlled by engine

design, including factory-set fuel delivery and ignition. The engine

and related components must be maintained at Polaris specifications to

achieve optimal performance.

Engine idle speed is the only adjustment Polaris recommends that the

operator perform. Any other adjustments should be performed by an

authorized Polaris dealer.

The RANGER TM emissions label (1) is located on the front of the

engine. Remove the service panel (2) to view the label. The label on

the RANGER 2X4 and 4X4 (3) is located on the recoil cover. Remove

the seat and look through the gap in the aluminum exhaust shield to

view the label.

NOTE: The installation of devices that effectively increase exhaust

emissions beyond their legal limits will void all manufacturer

warranties and may violate laws governing the registration

and operation of this vehicle.

Download from Www.Somanuals.com. All Manuals Search And Download.

EMISSION CONTROL SYSTEMS

Noise Emission Control System

Do not modify the engine, intake or exhaust components, as doing so

may affect compliance with U.S.A. EPA noise control requirements (40

CFR 205) and local noise level requirements.

Operation on Public Lands in the U.S.A.

Your Polaris vehicle has a spark arrestor that was tested and qualified

to be in accordance with the USDA Forest Service Standard 5100-1C.

Federal law requires that this spark arrestor be installed and functional

when the vehicle is operated on public lands.

Operation of off-road vehicles on public lands in the U.S.A. is

regulated by 43 CFR 8343. Violations are subject to monetary

penalties. Federal regulations can be viewed online at

www.gpoaccess.gov/ecfr/.

Electromagnetic Interference

This spark ignition system complies with Canadian ICES-002.

This vehicle complies with European directives 97/24/EC and

89/336/EEC.

Download from Www.Somanuals.com. All Manuals Search And Download.

MAINTENANCE AND LUBRICATION

Periodic Maintenance Chart

Careful periodic maintenance will help keep your vehicle in the safest,

most reliable condition. Inspection, adjustment and lubrication of

important components are explained in the periodic maintenance chart.

Inspect, clean, lubricate, adjust and replace parts as necessary. When

inspection reveals the need for replacement parts, use genuine Polaris

parts available from your Polaris dealer.

Record maintenance and service in the Maintenance Log beginning on

page 120.

NOTE: Service and adjustments are important for proper vehicle

operation. If you’re not familiar with safe service and

adjustment procedures, have a qualified dealer perform

these operations.

Maintenance intervals in the following chart are based upon average

riding conditions and an average vehicle speed of approximately 10

miles per hour. Vehicles subjected to severe use must be inspected and

serviced more frequently.

Severe Use Definition

S Frequent immersion in mud, water or sand

S Racing or race-style high RPM use

S Prolonged low speed, heavy load operation

S Extended idle

S Short trip cold weather operation

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.

Monitor the oil level, and if it continues to rise, discontinue use and

determine the cause or see your dealer.

Download from Www.Somanuals.com. All Manuals Search And Download.

MAINTENANCE AND LUBRICATION

Periodic Maintenance Chart

Maintenance Chart Key

Perform these procedures more frequently for vehicles subjected to

severe use.

Emission-related service (Failure to conduct this maintenance will

not void the emissions warranty but may affect emissions.)

Have an authorized Polaris dealer perform these services.

WARNING

Improperly performing the procedures marked with a J could

result in component failure and lead to serious injury or death.

Have an authorized Polaris dealer perform these services.

Download from Www.Somanuals.com. All Manuals Search And Download.

MAINTENANCE AND LUBRICATION

Periodic Maintenance Chart

Perform all services at whichever maintenance interval is reached first.

Item

Maintenance Interval

(whichever comes first)

Remarks

Hours Calendar

Miles

(Km)

Steering

Pre-Ride

Daily

Make adjustments as need-

ed. See Pre-Ride Checklist

on page 33.

Front suspension

Rear suspension

Tires

Brake fluid level

Brake lever travel

Brake systems

Wheels/fasteners

Frame fasteners

Engine oil level

Air filter, pre-filter

Inspect; clean often; replace

as needed

Air box sediment

tube

Daily

Drain deposits when visible

Coolant

(if applicable)

Check level daily, change

coolant every 2 years

Headlamp/tail

lamp

Daily

Check operation; apply

dielectric grease if replacing

Air filter,

main element

Weekly

Inspect; replace as needed

Recoil housing

Drain water as needed,

check often if operating in

wet conditions

Brake pad wear

Battery

10 H

Monthly

Inspect periodically

20 H

25 H

Monthly

Check terminals; clean; test

Inspect level; change yearly

Front gearcase oil

(if equipped)

Rear gearcase oil

(if equipped)

25 H

Monthly

Inspect level; change yearly

Transmission oil

Perform these procedures more often for vehicles subjected to severe use.

Emission-Related Service

Have an authorized Polaris dealer perform these services.

Download from Www.Somanuals.com. All Manuals Search And Download.

MAINTENANCE AND LUBRICATION

Periodic Maintenance Chart

Item

Maintenance Interval

(whichever comes first)

Remarks

Hours Calendar

Miles

(Km)

Engine breather

filter (if equipped)

25 H

50 H

Monthly

1 M

Inspect; replace if necessary

Engine oil change

(break-in)

Perform a break-in oil

change at one month

General

lubrication

3 M

Lubricate all fittings, pivots,

cables, etc.

Shift Linkage

Steering

50 H

6 M

Inspect, lubricate, adjust

Lubricate

Front suspension

Rear suspension

Lubricate

Carburetor float

bowl

Drain bowl periodically and

prior to storage

Throttle Cable/

ETC Switch

50 H

6 M

Inspect; adjust; lubricate;

replace if necessary

Choke cable

Inspect; adjust; lubricate;

replace if necessary

Carburetor air

intake ducts/

flange

Inspect ducts for proper

sealing/air leaks

Drive belt

50 H

6 M

Inspect; adjust; replace as

needed

Cooling system

(if applicable)

Inspect coolant strength

seasonally; pressure test

system yearly

Engine oil change 100 H

6 M

Perform a break-in oil

change at 25 hours/one

month

Oil filter change

100 H

Oil tank vent hose 100 H

Valve clearance 100 H

6 M

12 M

Replace with oil change

Inspect routing, condition

Inspect; adjust

Perform these procedures more often for vehicles subjected to severe use.

Emission-Related Service

Have an authorized Polaris dealer perform these services.

Download from Www.Somanuals.com. All Manuals Search And Download.

MAINTENANCE AND LUBRICATION

Periodic Maintenance Chart

Item

Maintenance Interval

(whichever comes first)

Remarks

Hours Calendar

Miles

(Km)

Fuel system

Fuel filter

100 H

12 M

Check for leaks at tank cap,

lines, fuel valve, filter, pump,

carburetor; replace lines

every two years

100 H

12 M

Replace yearly

Radiator

(if applicable)

Inspect; clean external

surfaces

Cooling hoses

(if applicable)

Inspect for leaks

Engine mounts

100 H

12 M

Inspect

Exhaust muffler/

pipe

Spark plug

Ignition Timing

Wiring

100 H

12 M

Inspect; replace as needed

Inspect

Inspect for wear, routing,

security; apply dielectric

grease to connectors

subjected to water, mud, etc.

Clutches (drive

and driven)

100 H

12 M

Inspect; clean; replace worn

parts

Front wheel

bearings

Inspect; replace as needed

Brake fluid

200 H

300 H

24 M

36 M

Change every two years

Clean out

Spark arrestor

Idle speed

Adjust as needed

Toe adjustment

Inspect periodically; adjust

when parts are replaced

Auxiliary brake (if

equipped)

Inspect daily; adjust as

needed

Headlight aim

Adjust as needed

Perform these procedures more often for vehicles subjected to severe use.

Emission-Related Service

Have an authorized Polaris dealer perform these services.

Download from Www.Somanuals.com. All Manuals Search And Download.

MAINTENANCE AND LUBRICATION

Lubrication Recommendations

Check and lubricate all components at the intervals outlined in the

Periodic Maintenance Chart beginning on page 53. Items not listed in

the chart should be lubricated at the General Lubrication interval.

Lubrication Chart Key

More often under severe use, such as wet or dusty conditions

L Polaris Premium all Season Grease or grease conforming to NLGI

No. 2, such as Conoco Superlube M or Mobilegrease Special

Use Polaris Premium U-Joint Lube every 500 miles, before long

periods of storage, or after pressure washing or submerging.

Item

Engine Oil

Lube

Method

Polaris Premium 4

Synthetic 0W40

Add to proper level on dipstick.

Brake Fluid

DOT 3 or DOT 4

Maintain level between fill lines. See

page 86.

Main Gearcase Oil

(Transmission)

Premium AGL Syn-

Maintain as recommended on page 69.

Maintain as recommended on page 70.

Maintain as recommended on page 71.

Locate fittings and grease

thetic Gearcase Lube

Front Gearcase Oil

Premium Demand

Drive Hub Fluid

Rear Gearcase Oil

Premium ATV Angle

Drive Fluid

(1) Prop Shaft U-joints FGrease

Front Prop Shaft Yoke FGrease

(4X4)

Locate fittings and grease

(3 pumps maximum)

Ball Joint

Locate fitting (back side of struts),

grease with grease gun.

"LGrease

(2) Swing Arm

Bushings

Locate fittings on swing arm and

grease with grease gun.

LGrease

Download from Www.Somanuals.com. All Manuals Search And Download.

MAINTENANCE AND LUBRICATION

Lubrication Recommendations

(2)

(1)

4X4

Download from Www.Somanuals.com. All Manuals Search And Download.

MAINTENANCE AND LUBRICATION

Engine Oil

Always check and change the engine oil at the intervals outlined in the

Periodic Maintenance Chart beginning on page 53. Always change the

oil filter whenever changing oil.

Premium 4 Synthetic Oil

Polaris Premium 4 All Season Synthetic engine oil has been specially

formulated for use in Polaris 4-cycle engines. It’s a fully synthetic,

high performance, multi-viscosity oil designed to provide the ultimate

in lubrication performance and protection. See page 101 for the part

numbers of Polaris products.

Premium 4 possesses unsurpassed film strength over the widest

possible temperature range. It resists viscosity and frictional

breakdown in ambient temperatures from -40° F. to 120° F. Its

exceptional frictional properties result in more efficient operation, more

power output and lower fuel consumption.

Although Polaris Premium 4 is the only oil recommended for use in

this engine, use of any API certified “SH” oil is allowable as long as

it’s 0W-40. Oil may need to be changed more frequently if Polaris

Premium 4 is not used. Follow the manufacturer’s recommendations

for ambient temperature operation.

CAUTION

Mixing brands or using a non-recommended oil may cause

serious engine damage. We recommend the use of Polaris

Premium 4 All Season synthetic oil or API certified “SH” oil,

0W-40. Never substitute or mix oil brands. Use only 0W-40.

WARNING

Vehicle operation with insufficient, deteriorated, or contaminated

engine oil will cause accelerated wear and may result in engine

seizure, accident, and injury. Always perform the maintenance

procedures as outlined in the Periodic Maintenance Chart.

Download from Www.Somanuals.com. All Manuals Search And Download.

MAINTENANCE AND LUBRICATION

Engine Oil

Always check and change the oil at the intervals outlined in the

Periodic Maintenance Chart beginning on page 53. We recommend the

use of Polaris Premium 4 All Season Synthetic engine oil.

Oil Check (2x4, 4X4)

The oil tank is located under the

seat.

1. Position the vehicle on a

level surface.

2. Start the engine and let it

idle for 20-30 seconds.

3. Stop the engine and remove

the seat (see page 27).

4. Remove the dipstick (1) and

wipe it dry with a clean

cloth.

5. Reinstall the dipstick and

screw it in completely.

NOTE: The dipstick must be

ADD 8 OZ.

NORMAL

FULL

screwed in

completely to keep

the angle and depth

of the stick consistent.

6. Remove the dipstick and check to see that the oil level is between

the full and add marks (2). Add oil if necessary. Do not overfill.

NOTE: A rising oil level between checks in cool weather driving can

indicate moisture collecting in the oil reservoir. If the oil level

is above the full mark, change the oil.

Download from Www.Somanuals.com. All Manuals Search And Download.

MAINTENANCE AND LUBRICATION

Engine Oil

Oil and Filter Change (2x4, 4X4)

CAUTION

Hot oil can cause serious burns. Do not allow hot oil to come into

contact with skin.

1. Run the engine two to three minutes

until warm. Stop the engine.

2. Clean the area around the drain

plug (1) at the bottom of the oil

tank.

3. Place a drain pan beneath the

oil tank and remove the drain

plug. Allow the oil to drain

completely.

4. Install a new sealing

washer (2) on the oil

drain plug.

NOTE: The sealing surfaces

on the drain plug and

oil tank should be clean and

free of burrs, nicks or scratches.

5. Reinstall the drain plug and torque to 14 ft. lbs. (19 Nm).

6. Disconnect the lower oil delivery hose and remove the screen

fitting (3) from the oil tank. Clean the fitting.

NOTE: The fitting threads must be sealed with LOCTITE PST 505 or

PTFE seal tape.

7. Reinstall the screen fitting and rotate the fitting clockwise a

minimum of 2 1/2 turns into the tank threads. Continue to rotate

the fitting until the nipple of the fitting aligns with the mark (4) on

the tank.

NOTE: Do not over-tighten. Maximum torque for the screen fitting is

25 ft. lbs. (34 Nm).

Download from Www.Somanuals.com. All Manuals Search And Download.

MAINTENANCE AND LUBRICATION

Engine Oil

Oil and Filter Change (2x4, 4X4)

8. Reattach the oil line.

9. Place shop towels beneath the

oil filter (5). Using an oil filter

wrench, turn the filter

counterclockwise to remove.

10. Using a clean dry cloth, clean

the filter sealing surface on the

crankcase.

11. Lubricate the gasket on the new

filter with a film of new engine

oil. Check to make sure the

gasket is in good condition.

Also make sure the gasket from

the old filter is not still on the

engine.

12. Install the new filter and turn by hand until the filter gasket

contacts the sealing surface, then turn and additional 1/2 turn.

13. Approximately one cup of engine oil will remain in the crankcase.

To drain, remove the drain plug on the lower right side of the

crankcase.

NOTE: The sealing surfaces on the drain plug and crankcase should

be clean and free of burrs, nicks or scratches.

14. Reinstall the drain plug and torque to 14 ft. lbs. (19 Nm).

15. Remove the dipstick and fill the tank with two quarts (1.9 l) of

Polaris Premium 4 Synthetic Oil.

16. Place the gear selector in neutral and set the parking brake.

17. Prime the oil pump using the procedure on page 64. Then stop

the engine and inspect for leaks.

18. Re-check the oil level on the dipstick and add oil as necessary to

bring the level to the upper mark on the dipstick.

19. Dispose of used filter and oil properly.

Download from Www.Somanuals.com. All Manuals Search And Download.

MAINTENANCE AND LUBRICATION

Engine Oil

Oil Pump Priming (2x4, 4X4)

This priming procedure must be

performed whenever the oil hose

connection between the oil tank

and pump inlet has been

disconnected.

1. Clamp or pinch off the vent

line (1) approximately 2I

from the oil tank (2), between

the end of the oil tank vent

fitting and the vent line’s

pressure relief slit (3).

2. Run the engine for 15-20 seconds.

3. Remove the vent line clamp.

The oil pump will now be

properly primed and ready for

operation.

Download from Www.Somanuals.com. All Manuals Search And Download.

MAINTENANCE AND LUBRICATION

Engine Oil

Oil Check (TM)

1. Position the vehicle on a level

surface.

2. Start the engine and let it idle for

20-30 seconds.

3. Stop the engine and remove the

seat as described on page 27.

Remove the service panel (1) by

pulling upward.

4. Remove the dipstick (2) and wipe

it dry with a clean cloth.

5. Replace the dipstick and seat it

completely.

6. Remove the dipstick and check to see

that the oil level is between the FULL

(3) and ADD (4) marks. Add oil

through the oil filler hole (5) as needed.

Do not overfill.

NOTE: A rising oil level between checks

in cool weather driving can indicate

moisture collecting in the oil reservoir.

If the oil level is over the full mark,

change the oil.

Download from Www.Somanuals.com. All Manuals Search And Download.

MAINTENANCE AND LUBRICATION

Engine Oil

Oil and Filter Change (TM)

1. Position the vehicle on a level surface.

2. Run the engine two to three minutes until

warm, then stop the engine.

3. Clean the area around the drain plug (6) at the bottom of the

engine. The plug is accessible through the access hole in the

bottom of the skid plate.

CAUTION

Hot oil can cause serious burns. Do not allow hot oil to come into

contact with skin.

4. Place a drain pan beneath the engine and remove the drain plug.

Allow the oil to drain completely.

5. Replace the sealing washer on the drain plug.

NOTE: The sealing surfaces on the drain plug and crankcase should

be clean and free of burrs, nicks or scratches.

6. Reinstall the drain plug and torque to 14 ft. lbs. (19 Nm).

Download from Www.Somanuals.com. All Manuals Search And Download.

MAINTENANCE AND LUBRICATION

Engine Oil

Oil and Filter Change (TM)

7. Place shop towels beneath the oil

filter (1). Using an oil filter

wrench (2), turn the filter

counterclockwise to remove.

8. Using a clean dry cloth, clean the

filter sealing surface on the

crankcase.

9. Check to make sure the o-ring (3)

is in good condition. Lubricate the

o-ring on the new filter with a film

of engine oil.

10. Install the new filter and turn by

hand until the filter gasket contacts

the sealing surface, then turn an

additional 3/4 turn.

NOTE: The sealing surfaces on the

drain plug and crankcase

should be clean and free of

burrs, nicks or scratches.

11. Add 1.64 quarts (1550 ml) of the

recommended oil.

12. Start the engine and allow it to run

for two to three minutes.

13. Place the gear selector in neutral and set the parking brake.

14. Stop the engine and check the oil level on the dipstick. Add oil to

the FULL mark if necessary.

15. Dispose of used filter and oil properly.

Download from Www.Somanuals.com. All Manuals Search And Download.

MAINTENANCE AND LUBRICATION

Gearcases

Gearcase Specification Chart

Gearcase

Lubricant

Capacity

Fill Plug

Torque

Drain Plug

Torque

Main Gearcase

(Transmission)

(4X4)

Premium AGL

Synthetic Gearcase

Lube

15.2 oz.

(450 ml)

14 ft. lbs.

(19.4 Nm)

14 ft. lbs.

(19.4 Nm)

Main Gearcase

(Transmission)

(2X4, TM)

Premium AGL

Synthetic Gearcase

Lube

18.2 oz.

(540 ml)

14 ft. lbs.

(19.4 Nm)

14 ft. lbs.

(19.4 Nm)

Front Gearcase

(4X4)

Premium Demand

Drive Hub Fluid

5 oz.

8-10 ft. lbs.

11 ft. lbs.

(15 Nm)

(150 ml) (11-13.6 Nm)

Rear Gearcase

(2X4, 4X4)

Premium ATV Angle

Drive Fluid

18 oz.

(532 ml)

40-50 ft. lbs. 30-45 in. lbs.

(54-68 Nm)

(3-5 Nm)

Rear Gearcase

(TM)

Premium ATV Angle

Drive Fluid

10 oz.

(300 ml)

14 ft. lbs.

(19.4 Nm)

14 ft. lbs.

(19.4 Nm)

Download from Www.Somanuals.com. All Manuals Search And Download.

MAINTENANCE AND LUBRICATION

Gearcases

Transmission (Main Gearcase)

Always check and change the transmission oil at the intervals outlined

in the Periodic Maintenance Chart beginning on page 53. Maintain the

oil level even with the bottom of the fill plug hole. We recommend the

use of Premium AGL Synthetic Gearcase Lubricant. See page 101 for

the part numbers of Polaris products.

Oil Check

1. Position the vehicle on a level

surface.

2. Remove the fill plug (1), which is

located on the rear of the vehicle.

3. Check the oil level and add as

needed.

4. Reinstall the fill plug. Torque to

specification. See page 68.

Oil Change

The drain plug (2) is located on the

bottom of the transmission. Access the

drain plug through the drain hole in the

skid plate.

1. Remove the fill plug.

2. Remove the drain plug and drain the

oil into a drain pan. Dispose of used

oil properly.

3. Wipe the magnetic end of the drain

plug clean to remove accumulated

metallic filings.

4. After the oil has drained completely, install a

new sealing washer and reinstall the drain plug.

Torque to specification. See page 68.

NOTE: Refer to the Gearcase Specifications Chart on page 68.

5. Add the recommended oil as needed. Do not overfill.

6. Reinstall the fill plug. Torque to specification.

7. Check for leaks.

Download from Www.Somanuals.com. All Manuals Search And Download.

MAINTENANCE AND LUBRICATION

Gearcases

Front Gearcase (4X4)

Always check and change the front gearcase oil at the intervals

outlined in the Periodic Maintenance Chart beginning on page 53.

Maintain the oil level even with the bottom thread of the fill plug hole.

We recommend the use of Polaris Premium Demand Drive Hub Fluid.

See page 101 for the part numbers of Polaris products.

The front gearcase fill plug (1) is located on the right side of the front

gearcase.

Oil Check

1. Position the vehicle on a level

surface.

2. Remove the fill plug and check

the oil level.

3. Add the recommended hub fluid

as needed.

4. Reinstall the fill plug. Torque to

specification. See page 68.

Oil Change

1. Support the vehicle securely

with a jackstand.

2. Remove the front tire on the

driver’s side.

3. Remove the fill plug.

4. Remove the gearcase drain plug (2) located on the bottom

right-hand side and drain the oil into a drain pan. Discard used oil

properly.

5. Clean and reinstall the drain plug. Torque to specification. See

page 68.

6. Add 5 oz. (150 ml) of the recommended hub fluid. Refer to the

Gearcase Specifications Chart on page 68.

7. Reinstall the fill plug. Torque to specification. See page 68.

8. Check for leaks.

Download from Www.Somanuals.com. All Manuals Search And Download.

MAINTENANCE AND LUBRICATION

Gearcases

Rear Gearcase

Always check and change the rear gearcase oil at the intervals outlined

in the Periodic Maintenance Chart beginning on page 53. Maintain the

oil level even with the bottom thread of the fill plug hole. We

recommend the use of Polaris ATV Angle Drive Fluid. See page 101

for the part numbers of Polaris products.

The rear gearcase fill plug (1) is on the driver’s side of the rear

gearcase.

Oil Check

1. Position the vehicle on a level

surface.

2. Remove the fill plug and

check the oil level.

3. Add the recommended

fluid as needed.

4. Reinstall the fill plug. Torque

to specification. See page 68.

Oil Change

1. Remove the fill plug.

2. Remove the drain plug (2)

from the bottom of the

gearcase and drain the oil

into a drain pan. Discard

used oil properly.

2X4

4X4

3. Clean and reinstall the drain

plug. Torque to specification.

See page 68.

4. Add the recommended fluid.

Refer to the Gearcase

Specifications Chart on page

68.

5. Reinstall the fill plug. Torque

to specification. See page 68.

6. Check for leaks.

Download from Www.Somanuals.com. All Manuals Search And Download.

MAINTENANCE AND LUBRICATION

Cooling System (2X4, 4X4)

Operation

The engine coolant level is controlled or maintained by the recovery

system. The recovery system components are the overflow bottle,

radiator filler neck, radiator pressure cap and connecting hose.

As coolant operating temperature increases, the expanding (heated)

excess coolant is forced out of the radiator, past the pressure cap, and

into the overflow bottle. As engine coolant temperature decreases, the

contracting (cooled) coolant is drawn back up from the tank, past the

pressure cap, and into the radiator.

NOTE: Some coolant level drop on new vehicles is normal as the

system is purging itself of trapped air. Observe coolant

levels and maintain as recommended by adding coolant to

the overflow bottle.

Adding or Changing Coolant

To ensure that the coolant maintains its ability to protect the engine, we

recommend that the system be completely drained every two years and

a fresh mixture of antifreeze and water added. Polaris recommends the

use of Polaris Premium 60/40 anti-freeze/coolant or a 50/50 mixture of

high quality aluminum compatible anti-freeze/coolant and distilled

water. Polaris Premium 60/40 is already premixed and ready to use.

Do not dilute with water. See page 101 for the part numbers of Polaris

products.

NOTE: Always follow the manufacturer’s mixing recommendations

for the freeze protection required in your area.

Any time the cooling system has been drained for maintenance or

repair, replace the coolant. If the recovery bottle has run dry, the level

in the radiator should be inspected. Add coolant as needed.

Download from Www.Somanuals.com. All Manuals Search And Download.

MAINTENANCE AND LUBRICATION

Cooling System (2X4, 4X4)

Radiator and Cooling Fan

Always check and clean the screen and radiator fins at the intervals

outlined in the Periodic Maintenance Chart beginning on page 53. Do

not obstruct or deflect air flow through the radiator by installing

unauthorized accessories in front of the radiator or behind the cooling

fan. Interference with the radiator air flow can lead to overheating and

consequent engine damage.

CAUTION

Washing the vehicle with a high-pressure hose could damage the

radiator fins and impair the radiator’s effectiveness. Exercise

caution if a high-pressure system is used for washing the vehicle.

Coolant Level

Always check and change the coolant at

the intervals outlined in the Periodic

Maintenance Chart beginning on page 53.

Maintain the coolant level between the

minimum and maximum marks on the

bottle (when the fluid is cool). The

overflow bottle (1) is located in front of

the right front wheel.

1. Position the vehicle on level ground.

2. View the coolant level in the overflow bottle.

3. If the coolant level is below the safe operating range, lift the hood

and locate the overflow bottle lid. Remove the lid and use a funnel

to add coolant through the filler opening. Reinstall the cap.

NOTE: If coolant must be added often, or if the overflow bottle runs

completely dry, there may be a leak in the system. Have the

cooling system inspected by your Polaris dealer.

Download from Www.Somanuals.com. All Manuals Search And Download.

MAINTENANCE AND LUBRICATION

Cooling System (2X4, 4X4)

Radiator Coolant Level

Always check and change the coolant at the intervals outlined in the

Periodic Maintenance Chart beginning on page 53.

WARNING

Escaping steam can cause severe burns. Never remove the

pressure cap while the engine is warm or hot. Always allow the

engine to cool before removing the pressure cap.

1. Lift the hood and slowly

remove the radiator cap (1).

2. View the coolant level through

the opening.

3. Use a funnel and slowly add

coolant as needed.

NOTE: This procedure is

required only if the

cooling system has been

drained for maintenance

and/or repair. But if the

overflow bottle has run

dry, the level in the

radiator should also be

inspected.

NOTE: Use of a non-standard pressure cap will not allow the

recovery system to function properly. See your dealer for

the correct replacement part.

Download from Www.Somanuals.com. All Manuals Search And Download.

MAINTENANCE AND LUBRICATION

Spark Plugs

CAUTION

Using non-recommended spark plugs can result in serious engine

damage. Always use Polaris-recommended spark plugs. Refer

to the specifications section beginning on page 102.

Spark Plug Gap/Torque

Model

Electrode Gap

New Plug Torque Used Plug Torque

RANGER

2X4, 4X4

9-11 ft. lbs.

(12-15 Nm)

9-11 ft. lbs.

(12-15 Nm)

.025″ (.06 cm)

RANGER

8.7-10.8 ft. lbs.

(11.8-14.6 Nm)

16.6-19.5 ft. lbs.

(22.5-26.4 Nm)

.025″ (.06 cm)

Spark plug condition is indicative of engine operation. The spark plug

firing end condition should be read after the engine is warmed up and

the vehicle is driven at higher speeds. Immediately check the spark

plug for correct color.

WARNING

A hot exhaust system and engine can cause serious burns. Wear

protective gloves when removing a spark plug for inspection.

1. Normal

The normal insulator tip is gray, tan or light brown. There will be few

combustion deposits. The electrodes are not burned or eroded. This

indicates the proper type and heat range for the engine and the service.

NOTE: The tip should not be white. A white insulator tip indicates

overheating, caused by use of an improper spark plug or

incorrect carburetion adjustments.

2. Wet Fouled

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 injection oil, improper use of the choke, or

incorrect carburetion adjustments.

Spark Plug Removal and Replacement

1. Remove the seat to access the engine compartment.

2. Remove the spark plug cap. Using the spark plug wrench provided

in the tool kit, remove the plug by rotating it counterclockwise.

3. Reverse the procedure for spark plug installation. Torque to

specification.

Download from Www.Somanuals.com. All Manuals Search And Download.

MAINTENANCE AND LUBRICATION

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.

The PVT system rotates at high speeds, creating large amounts

of force on clutch components. Extensive engineering and

testing has been conducted to ensure the safety of this product.

However, as the owner, you have the following responsibilities to

make sure this system remains safe:

Always follow all recommended maintenance procedures. See

your dealer as outlined in the owner’s manual.

This PVT system is intended for use on Polaris products only. Do

not install it in any other product.

Always make sure the PVT housing is securely in place during

operation.

PVT Drying

There may be some instances when water is accidently ingested into

the PVT system. Use the following instructions to dry it out before

operating.

1. Shift the transmission into neutral and apply full throttle for no

longer than 10 seconds and repeat as necessary. This will expel the

moisture and air dry the belt and clutches.

2. Allow the engine RPM to settle to idle speed, then shift the

transmission to the lowest available range.

3. Test for belt slippage. If the belt slips, repeat the process.

4. Take the vehicle to your dealer for service as soon as possible.

Download from Www.Somanuals.com. All Manuals Search And Download.

MAINTENANCE AND LUBRICATION

Vehicle Immersion

CAUTION

If your vehicle becomes immersed, major engine damage can

result if the vehicle is not thoroughly inspected. Take the vehicle

to your dealer before starting the engine.

If it’s impossible to take your RANGER to a dealer before starting it,

follow the steps outlined below.

1. Move the vehicle to dry land, or at the very least, to a water level

below the floor.

2. Disconnect the fuel pump wires.

3. Remove the spark plug.

4. Place a clean container under the engine and loosen the carburetor

drain screw (1) two turns.

RANGER 2X4, 4X4

RANGER TM

5. Turn the engine over several times with electric start. Inspect the

drained fuel for water or sediment.

6. Dry the spark plug and reinstall, or install a new plug.

7. Tighten the carburetor drain screw.

8. Reconnect the fuel pump wires.

9. Attempt to start the engine. If necessary, repeat the drying

procedure.

10. Take the vehicle to your dealer for service as soon as possible

whether you succeed in starting it or not.

NOTE: If water has been ingested into the PVT follow the procedure

on page 76 for drying.

Download from Www.Somanuals.com. All Manuals Search And Download.

MAINTENANCE AND LUBRICATION

Filter Systems (2X4, 4X4)

Air Filter

Always change the air filter at the intervals outlined in the Periodic

Maintenance Chart beginning on page 53.

1. Lift the cargo box to access the

air box.

2. Remove the air box cover and

inspect the gasket. It should

adhere tightly to the cover and

seal all the way around.

3. Remove the air filter (1).

4. Do not attempt to clean the main

element. Install a new air filter.

NOTE: Apply a small amount of

general purpose grease to

the sealing edges of the

filter before installing.

5. Inspect the air box for oil or water deposits. If present, drain them

into a suitable container.

NOTE: Service the air filter more frequently if the vehicle is operated

in wet conditions or at high throttle openings for extended

periods.

Download from Www.Somanuals.com. All Manuals Search And Download.

MAINTENANCE AND LUBRICATION

Filter Systems (2X4, 4X4)

Breather Filter and Hoses

1. Lift the cargo box and locate the

air box.

2. Follow the right-hand breather

line (1) out the side of the air

box and locate the filter (2).

3. Remove and inspect the filter

for debris. Blow gently through

the filter in the direction of the

arrow to check for clogging.

Replace as needed.

4. Check hoses for cracks,

deterioration, abrasion, or leaks.

Replace as needed.

5. Reinstall the filter with the

arrow pointing toward the

engine and secure the clamps.

CAUTION

Operation of the vehicle without a breather filter can cause engine

damage. Always reinstall the breather filter after removing it for

service.

Fuel Filter

Your Polaris vehicle is equipped with an in-line fuel filter. Have your

dealer replace it after every 100 hours of operation. Do not attempt to

clean the fuel filter.

Download from Www.Somanuals.com. All Manuals Search And Download.

MAINTENANCE AND LUBRICATION

Filter Systems (TM)

Air Filter

Always check and change the air

filter at the intervals outlined in the

Periodic Maintenance Chart

beginning on page 53.

1. Remove the seat to access the air

cleaner.

2. Remove the breather hose (1) from

the cylinder.

3. Remove the wing nut (2) and remove

the air cleaner cover (3).

4. Remove the primary filter (4) and the

secondary filter (5).

NOTE: Do not attempt to clean the

primary filter. Install new.

5. Wash the secondary (foam) filter with

hot soapy water. Rinse and dry

thoroughly.

6. Inspect the filter for tears or damage.

Replace with a new filter if needed.

7. Apply foam filter oil or clean engine oil

and squeeze the filter until excess oil is

removed.

8. Reassemble all components.

Download from Www.Somanuals.com. All Manuals Search And Download.

MAINTENANCE AND LUBRICATION

Carburetor/Engine Idle RPM Adjustment

The idle speed adjustment should be performed as outlined in the

Periodic Maintenance Chart, or whenever the idle speed is changed.

Recommended engine idle RPM for the RANGER 2X4 and 4X4 is

1200 +/- 200. Recommended engine idle RPM for the RANGER TM is

1000 +/- 100.

If the engine idle speed is not satisfactory,

and all other conditions are favorable, the

carburetor can be adjusted with the

following procedure.

2X4

4X4

1. Engage the parking brake and place

the gear shift lever in the neutral

position.

2. Warm up the engine by running the

vehicle approximately five minutes.

3. Remove the the seat and locate the

idle adjust screw (1).

4. Place the transmission in gear (with

park brake engaged).

5. Turn the carburetor idle adjust screw

in or out until the desired idle RPM is

reached. Turn the screw in (clockwise)

to raise RPM. Turn the screw out

(counterclockwise) to lower RPM.

Download from Www.Somanuals.com. All Manuals Search And Download.

MAINTENANCE AND LUBRICATION

Spark Arrestor

WARNING

Failure to heed the following warnings while servicing the spark

arrestor could result in serious injury or death.

Do not perform service on the spark arrestor while the system is

hot. Exhaust system temperatures can reach 1000° F. Allow

components to cool sufficiently before proceeding.

Remove any combustible materials from the area.

Wear eye protection and gloves.

Do not stand behind or in front of the vehicle while purging.

Never run the engine in an enclosed area. Exhaust contains

poisonous carbon monoxide gas that can cause loss of

consciousness or death in a very short time.

Never go under the vehicle while it’s inclined.

Download from Www.Somanuals.com. All Manuals Search And Download.

MAINTENANCE AND LUBRICATION

Spark Arrestor

Use the following procedure to periodically purge accumulated carbon

from the exhaust pipe.

1. Remove the arrestor

clean-out plugs (1) located

on the bottom of the

muffler.

2. Place the transmission in

neutral and start the engine.

3. Purge accumulated carbon

from the system by

momentarily revving the

engine several times.

4. If carbon is expelled, cover or plug the exhaust outlet (2) and rap

on the pipe around the clean-out plugs while revving the engine

several more times.

5. If particles are still suspected to be in the muffler, elevate the rear

of the vehicle one foot higher than the front. Set the parking brake

and block the wheels. Make sure the vehicle is in neutral and

repeat steps 2 and 4.

6. If particles are still suspected to be in the muffler, drive the vehicle

onto the incline so the front of the vehicle is one foot higher than

the rear. Set the parking brake and block the wheels. Make sure

the vehicle is in neutral and repeat steps 3 and 4 until no more

particles are expelled when the engine is revved.

7. Stop the engine and allow the arrestor to cool.

8. Reinstall the arrestor plugs and remove the outlet cover or plug.

Download from Www.Somanuals.com. All Manuals Search And Download.

MAINTENANCE AND LUBRICATION

Throttle System

WARNING

Failure to check or maintain proper operation of the throttle

system can result in an accident and lead to serious injury or

death if the throttle pedal sticks during operation.

Never start or operate this vehicle if it has a sticking or improperly

operating throttle pedal.

Immediately contact your dealer for service if throttle problems

arise.

Always check the pedal for free movement and return before

starting the engine and occasionally during operation.

Throttle Freeplay

If the throttle pedal (1) has excessive play

due to cable stretch or misadjustment, it

will cause a delay in throttle response,

especially at low engine speed. The throttle

may also not open fully. If the throttle

pedal has no freeplay, the throttle may be

hard to control, and the idle speed may be

erratic.

Check the throttle pedal freeplay at the

intervals outlined in the Periodic

Maintenance Chart beginning on page 53.

Adjust the freeplay if necessary.

Download from Www.Somanuals.com. All Manuals Search And Download.

MAINTENANCE AND LUBRICATION

Throttle System

Throttle Freeplay Inspection

1. Apply the parking brake (2) and shift the transmission to neutral.

2. Start the engine and warm it up thoroughly.

3. Measure the distance the throttle pedal moves before the engine

begins to pick up speed. Freeplay should be 1/16 to 1/8 inches.

Throttle Freeplay Adjustment

1. Slide the boots (1) off the inline cable adjuster sleeve (2). Loosen

the adjuster locknut (3).

2. Turn the adjuster until 1/16 to 1/8 inch freeplay is achieved.

NOTE: While adjusting, flip the throttle lever back and forth.

3. Tighten the locknut and slide the boots over the cable adjuster until

they touch at the midpoint of adjuster.

Throttle Cable Adjustment (TM)

If the proper freeplay cannot be obtained with the throttle block

adjuster, adjust the cable at the carburetor using the following

procedure.

1. Remove the seat and loosen the

clamp screw (1) and the throttle

cable adjustment screw (2).

2. Adjust the cable as needed.

3. Tighten both screws and

reinstall the seat.

4. Check for proper throttle

operation and correct freeplay

in all steering wheel positions.

Download from Www.Somanuals.com. All Manuals Search And Download.

MAINTENANCE AND LUBRICATION

Brakes

The front and rear brakes are hydraulic disc type brakes. Press down on

the brake pedal to engage the brakes. See page 31.

Brake Fluid

Routine inspections are recommended to keep the brake system in

good operating condition. Inspect the level of the brake fluid before

each operation.

Change the brake fluid at the intervals outlined in the Periodic

Maintenance Chart beginning on page 53. The brake fluid should also

be changed if it becomes contaminated, if the fluid level is below the

minimum, or if the type and brand of the fluid in the reservoir are

unknown.

1. Position the vehicle on a level

surface.

2. View the brake fluid level at the

reservoir (1) under the hood.

Maintain the fluid level between

the upper (MAX) and lower (MIN)

marks on the reservoir.

3. If the fluid level is lower than the

lower level line, add brake fluid to

the upper (MAX) line.

4. Apply the brake forcefully for a

few seconds and check for fluid

leakage around the fittings.

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.

Download from Www.Somanuals.com. All Manuals Search And Download.

MAINTENANCE AND LUBRICATION

Brakes

Brake Inspection

1. Check the brake system for fluid

leaks.

2. Check the brake pedal for excessive

travel or a spongy feel.

3. Check the friction pads for wear,

damage and looseness.

4. Inspect the brake disc spline and

pad wear surface for excessive

wear.

5. Change pads when worn to 3/64″

3/64″ (.1 cm)

(.1 cm).

Parking Brake Inspection

1. Slowly push the parking brake

down with your foot.

2. After 8 to 12 clicks of lever

travel, check the vehicle for

movement. The vehicle should

not roll while parked. If the

vehicle moves, adjustment is

necessary

Parking Brake Adjustment

1. Position the vehicle on a level surface.

2. Place the transmission in neutral.

3. Loosen or tighten the nuts on each

end of the parking brake cable as

needed.

Download from Www.Somanuals.com. All Manuals Search And Download.

MAINTENANCE AND LUBRICATION

Steering Wheel Inspection

Check the steering wheel for specified freeplay and smooth operation

at the intervals outlined in the Periodic Maintenance Chart beginning

on page 53.

1. Position the vehicle on level ground.

2. Lightly turn the steering wheel left and right.

3. There should be 0.8 - 1.0 in (20 - 25 mm) of free play.

4. If there is excessive freeplay or strange noises, or the steering feels

rough or “catchy,” have the steering system inspected by an

authorized Polaris dealer.

Cylinder Head/Cylinder Base Fastener Torque

Have your dealer check the RANGER cylinder head and cylinder base

fasteners for proper torque at the first service or after 25 hours.

Rear Spring Adjustment

The rear shock absorber springs are adjusted by rotating

the adjustment cam (1) either clockwise or

counterclockwise to increase or decrease spring tension.

Suspension Adjustment (2x4, 4X4)

The rear suspension of the RANGER 2X4 and 4X4

may be adjusted to provide a stiffer suspension if

necessary. The shocks are mounted to the inside

mounting holes (A) at the factory, but they may be

relocated to the outside mounting holes (B).

1. Remove the shock mounting bolts.

2. Reposition the shocks to the outside mounting holes.

3. Reinstall the shock mounting bolts. Torque to 30 ft. lbs. (40 Nm).

Download from Www.Somanuals.com. All Manuals Search And Download.

MAINTENANCE AND LUBRICATION

Seat Belts

Inspect all three seat belts for proper operation before each use of the

vehicle.

1. Push the latch plate into the buckle until it clicks. The latch plate

must slide smoothly into the buckle. A click indicates that it’s

securely latched.

2. Push the red button in the middle of the buckle to make sure it

releases freely.

3. Check the belt webbing for wear, cuts or damage. If any

irregularities are found, have the seat belt system checked and/or

replaced by an authorized Polaris dealer.

The RANGER seat belt is adjustable and

should be adjusted for both the operator

and passenger before driving. Although

having the belt at 30° is typical for many

people, it will not accommodate all body

sizes and shapes. Make sure the seat belt

is adjusted to the lowest possible lap

position before riding.

1. To adjust, loosen the bolts (1).

2. Reposition both the buckle and

retractor. Tighten the bolts.

NOTE: The center belt does not self

adjust. Before riding, pull on the

strap to secure the belt on the lap

of the center passenger.

WARNING

Failure to follow the age recommendations for this vehicle could

result in serious injury or death. No one under the age of 16 may

operate this vehicle. No one under the age of 5 may ride as a

passenger in this vehicle.

Download from Www.Somanuals.com. All Manuals Search And Download.

MAINTENANCE AND LUBRICATION

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 cm) 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. When replacing tires, always use original equipment

size and type.

Tire Tread Depth

1/8I (.3 cm)

Always replace tires when tread depth

is worn to 1/8″ (.3 cm) or less.

Axle and Wheel Nut Torque Specifications

Inspect the following items occasionally for tightness, and if they’ve

been loosened for maintenance service.

Location

Specification

35 ft. lbs. (47 Nm)

70 ft. lbs. (95 Nm)

110 ft. lbs. (150 Nm)

Front Wheel Nuts

Rear Wheel Nuts

Front Spindle Nut

Center and Rear Hub

Retaining Nuts

Download from Www.Somanuals.com. All Manuals Search And Download.

MAINTENANCE AND LUBRICATION

Tires

WARNING

Improperly installed wheels can adversely affect tire wear and

vehicle handling, which can result in serious injury or death.

Always ensure that all nuts are torqued to specification. Do not

service axle nuts that have a cotter pin installed. See your

Polaris dealer.

Wheel Removal

1. Stop the engine, place the transmission in gear and lock the

parking brake.

2. Loosen the wheel nuts slightly.

3. Elevate the side of the vehicle by placing a suitable stand under the

frame.

4. Remove the wheel nuts and washers. Remove the wheel.

Wheel Installation

1. With the transmission

in gear and the parking

brake locked, place the

wheel in the correct

position on the wheel

hub. Be sure the valve

stem is toward the

outside and rotation

arrows on the tire point

toward forward

rotation.

2. Attach the wheel nuts

and washers and finger

tighten.

3. Carefully lower the vehicle to the ground.

4. Torque the wheel nuts according to the specifications on page 90.

Download from Www.Somanuals.com. All Manuals Search And Download.

MAINTENANCE AND LUBRICATION

Lights

When servicing a halogen lamp, don’t touch the lamp with bare

fingers. Oil from your skin leaves a residue, causing a hot spot that

will shorten the life of the lamp.

WARNING

Poor lighting while driving can result in severe injury or death.

Headlight and taillight lenses become dirty during normal

operation. Wash the headlights frequently to maintain lighting

quality.

Hot components can cause serious burns to skin. Do not service

the headlamps until they’ve cooled sufficiently.

Headlight Lamp Replacement

1. Open the hood.

2. Unplug the headlamp from the

wiring harness (1). Be sure to pull

on the connector, not on the wiring.

3. Turn the lamp counterclockwise to

remove it.

4. Install the new lamp.

NOTE: Make sure the tab on the

lamp locates properly in the

housing.

5. Reinstall the harness assembly into

the headlight assembly.

Download from Www.Somanuals.com. All Manuals Search And Download.

MAINTENANCE AND LUBRICATION

Lights

Headlight Beam Adjustment

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. Start the engine and switch on the headlight.

4. Observe the headlight aim.

The most intense part of the

headlight beam should be

aimed 8″ (20.3 cm) below

the mark placed on the wall

in step 2.

NOTE: Include the weight of a rider on

the seat while performing this step.

5. Adjust the beam to the desired position by turning the adjustment

screw (1).

Brake Lights

When the brake pedal is depressed, the console brake light comes on.

Check the brake light before each ride.

1. Turn the ignition switch to the ON position.

2. Depress the brake pedal. The brake light should come on after

about 10mm (0.4 in.) of pedal travel. If the light doesn’t come on,

check the bulb.

Download from Www.Somanuals.com. All Manuals Search And Download.

MAINTENANCE AND LUBRICATION

Lights

Indicator Lamp Replacement

1. Lift the hood.

2. Reach in behind the console

panel and lift the release (1) to

unplug the light from the

harness.

3. Using a flathead screwdriver,

press on the tab (2) on the top

of the light to remove the

indicator light assembly from

the console panel.

4. Using a screwdriver, turn the

light that needs to be replaced

1/4 turn counterclockwise.

5. Grip the light with a needle nose plier and remove the light from

the assembly.

6. Install the new light and use a small flat head screwdriver to seat it

into place, 1/4 turn clockwise.

7. Snap the assembly back into the console panel and reconnect the

harness.

8. Close the hood.

Tool Kit

To help you perform routine maintenance, a tool kit is provided with

your vehicle. Keep the tool kit with your vehicle at all times.

S A screwdriver

S An open-end wrench (8-10 mm)

S An open-end wrench (12-14 mm)

S A tire pressure gauge

S A spark plug wrench and handle

S A spanner wrench (for shock adjustment)

NOTE: Additional tools will be necessary to perform routine

maintenance.

Download from Www.Somanuals.com. All Manuals Search And Download.

MAINTENANCE AND LUBRICATION

Cleaning Your RANGER

Keeping your vehicle clean will not only improve its appearance but it

can also extend the life of various components. With a few

precautions, your vehicle can be cleaned much like an automobile.

The best and safest way to clean your vehicle is with a garden hose and

a pail of mild soap and water. Use a professional type washing mitten,

cleaning the upper body first and the lower parts last. Rinse with water

frequently and dry with a chamois to prevent water spots.

NOTE: If warning labels are damaged, contact your Polaris dealer

for free replacement.

If a high pressure type car wash system is used, extreme care must be

taken to avoid water damage to the wheel bearings, transmission seals,

body panels, brakes, headlights and warning labels. Many expensive

repair bills can result from using high pressure detergent systems.

NOTE: If a high pressure car wash is used, grease all zerk fittings

immediately after washing. Also run the vehicle to evaporate

any water that may have entered the engine or exhaust

system.

Download from Www.Somanuals.com. All Manuals Search And Download.

MAINTENANCE AND LUBRICATION

Storage

If your vehicle is to be placed in extended or off season storage, the

following steps should be taken to preserve its condition.

1. Perform all necessary repairs and thoroughly clean the vehicle.

2. Remove the spark plug and pour approximately one ounce of

Premium 4 oil into the cylinder. Operate the starter for a few

seconds and reinstall the spark plug.

3. Remove the battery. Store it in a cool, dry place out of the sun.

4. Lubricate suspension pivot points, lower steering post and rear axle

fittings.

5. Drain the engine side cover (4X4).

6. Block the vehicle so all tires are suspended off the ground.

7. Spray oil on all unpainted metal surfaces to prevent rusting. Avoid

getting oil on rubber parts or in the brakes.

8. Lubricate all cables.

9. Tie a plastic bag over the exhaust pipe and air cleaner inlet to

prevent moisture or small animals from entering.

10. Cover the vehicle with a canvas cover. Do not use plastic or coated

materials since they do not allow ventilation for the vehicle.

Download from Www.Somanuals.com. All Manuals Search And Download.

MAINTENANCE AND LUBRICATION

Removal from Storage

1. Check the battery electrolyte level and charge the battery if

necessary. Install it in the vehicle. Make sure the battery vent hose

is routed properly and that it’s not pinched or restricted in any way.

2. Make sure the spark plug is tight.

3. Fill the fuel tank with fuel.

4. Check all the points listed in the Daily Pre-Ride Inspection section

on page 33.

NOTE: Tightness of the bolts, nuts and other fasteners should be

checked by an authorized Polaris dealer.

5. Lubricate at the intervals outlined in the Periodic Maintenance

Chart beginning on page 53.

WARNING

Engine exhaust contains poisonous carbon monoxide and can

cause loss of consciousness or death. Never run an engine in an

enclosed area.

Download from Www.Somanuals.com. All Manuals Search And Download.

MAINTENANCE AND LUBRICATION

Battery

Keep the battery terminals and connections free of corrosion. If

cleaning is necessary, remove the corrosion with a stiff wire brush.

Wash with a solution of one tablespoon baking soda and one cup water.

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 the 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. Ventilate when charging or using in an

enclosed space. Always shield eyes when working near

batteries. KEEP OUT OF REACH OF CHILDREN.

Download from Www.Somanuals.com. All Manuals Search And Download.

MAINTENANCE AND LUBRICATION

Battery

Replenishing Battery Fluid (Conventional Battery)

A poorly maintained battery will deteriorate

rapidly. Check the battery fluid level often.

The fluid level should be kept between the

upper and lower level marks (1).

To refill use only distilled water. Tap water

contains minerals that are harmful to a battery.

WARNING

Improperly connecting or disconnecting battery cables can result

in an explosion and cause serious injury or death. When

removing the battery, always disconnect the negative (black)

cable first. When reinstalling the battery, always connect the

negative (black) cable last.

Battery Removal

1. Open the hood.

2. Remove the battery vent

tube from the battery.

3. Disconnect the black

(negative) battery cable first.

4. Disconnect the red (positive)

battery cable next.

5. Lift the battery out of the

vehicle, being careful not to

tip it sideways and spill any

electrolyte.

CAUTION

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.

Download from Www.Somanuals.com. All Manuals Search And Download.

MAINTENANCE AND LUBRICATION

Battery

Battery Installation

1. Set the battery in its holder.

2. Install the battery vent tube. It must be free from obstructions and

securely installed. If not, battery gases could accumulate and cause

an explosion. The tube should be routed away from the frame and

body to prevent corrosion. Avoid skin contact with electrolyte as

severe burns could result.

3. First connect and tighten the red (positive) cable.

4. Second connect and tighten the black (negative) cable.

5. Verify that cables are properly routed.

NOTE: When installing a new battery, make sure it’s fully charged

prior to its initial use. 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.

Battery Storage

When the vehicle is placed in storage for three months or more, the

battery should be removed, stored out of the sun in a cool, dry place

and tested monthly. Before reusing, take the battery to your dealer for

testing and recharging.

100

Download from Www.Somanuals.com. All Manuals Search And Download.

POLARIS PRODUCTS

Part No.

Description

Engine Lubricant

2870791

2871281

2871844

Fogging Oil (12 oz. Aerosol)

Premium 4 Synthetic 0W-40 (4-Cycle) Engine Oil (qt.)

Premium 4 Synthetic 0W-40 (4-Cycle) Engine Oil (gal.)

Gearcase / Transmission Lubricants

Premium AGL Synthetic Gearcase Lube (qt.)

Premium AGL Synthetic Gearcase Lube (gal.)

Premium ATV Angle Drive Fluid (8 oz.)

Premium ATV Angle Drive Fluid (2.5 gal.)

Pump for Gallon Jug

2873602

2873603

2871653

2872276

2870465

2871654

2872277

Premium Demand Drive Hub Fluid (8 oz.)

Premium Demand Drive Hub Fluid (2.5 gal.)

Grease / Specialized Lubricants

Premium All Season Grease (3 oz. cartridge)

Premium All Season Grease (14 oz. cartridge)

Starter Drive Grease

Premium U-Joint Lube (3 oz.)

Premium U-Joint Lube (14 oz.)

Grease Gun Kit

Dielectric Grease (Nyogelt)

Chain Lube (6.25 oz. aerosol)

Chain Lube (16 oz. aerosol)

2871322

2871423

2871460

2871515

2871551

2871312

2871329

2872073

2872348

Coolant

2871323

2871534

60/40 Coolant (gal.)

60/40 Coolant (qt.)

Additives / Miscellaneous

Brake and Clutch Cleaner

Carbon Clean Plus (12 oz.)

Fuel Stabilizer (16 oz.)

DOT3 Brake Fluid

2872889

2871326

2870652

2870990

2872893

2871956

Engine Degreaser

LOCTITE 565 Thread Sealant

101

Download from Www.Somanuals.com. All Manuals Search And Download.

SPECIFICATIONS

RANGER TM

Gross Vehicle Weight

Fuel Capacity

2400 lbs. (1089 kg)

8.5 gal. (32.2 l)

Towing Capacity

Max. Cargo Box Load

Overall Length

1000 lbs. (454 kg)

750 lbs. (340 kg)

113 in. (282 cm)

60 in. (152.4 cm)

58 in. (147.3 cm)

51 in. (129.5 cm)

76 in. (193 cm)

Overall Width (box)

Overall Width (tires)

Overall Height

Wheelbase

Ground Clearance

Dry Weight

7.2 in. (183 mm)

1050 lbs. (476 kg)

Cargo Box (L x W x H)

58 x 42 x 10 in.

(147 x 106.7 x 25.4 cm)

Min. Turning Radius

Engine Oil Capacity

Coolant Capacity

Engine

132 in. (335.3 cm)

1.64 qts. (1.55 l)

2 valve 4 stroke twin cylinder

Displacement

Bore x Stroke

Pilot Jet

653 cc

2-80 x 65

Main Jet

140

Needle Jet

Jet Needle

Air Screw

2.0

Alternator Output

Compression Ratio

Starting System

Carburetor

360 W

8.3

Electric

27 mm Nikki

Magneto

26_ @ 3600 rpm

BPR4EY

Ignition System

Ignition Timing

Spark Plug

102

Download from Www.Somanuals.com. All Manuals Search And Download.

SPECIFICATIONS

RANGER TM

Lubrication System

Engine Oil

Full Pressure

0W/40

Driving System Type

Shift Type

PVT

Single Lever (console)

Gear Reduction - Low

Gear Reduction - Reverse

Gear Reduction - High

Drive Ratio - Front

Drive Ratio - Final

Tire Size - Front

6.84:1

4.71:1

3.70:1

25 x 10 - 12

25 x 11 - 12

10 psi

Tire Size - Rear

Tire Pressure - Front

Tire Pressure - Rear

Brakes, Front/Rear

10 psi

Foot Activated,

4 wheel hydraulic disc

Brake, Parking

Hood Headlight

Taillights

Foot activated, mechanical

2 dual beam, 35W, quartz/halogen

2 single beam, 5W

Brake Light

2 single beam, 5W

Indicator Light

1.0 W

NOTE: See your Polaris dealer for jetting and clutching specifications.

103

Download from Www.Somanuals.com. All Manuals Search And Download.

SPECIFICATIONS

RANGER 2x4

Gross Vehicle Weight

Fuel Capacity

2500 lbs. (1135 kg)

8.5 gal. (32.2 l)

Towing Capacity

Max. Cargo Box Load

Overall Length

1400 lbs. (636 kg)

850 lbs. (386 kg)

113 in. (282 cm)

60 in. (152.4 cm)

58 in. (147.3 cm)

75 in. (190.5 cm)

76 in. (193 cm)

Overall Width (box)

Overall Width (tires)

Overall Height

Wheelbase

Ground Clearance

Dry Weight

11.5 in. (29.2 cm)

1105 lbs. (501 kg)

Cargo Box (L x W x H)

58 x 42 x 10 in.

(147 x 106.7 x 25.4 cm)

Min. Turning Radius

Engine Oil Capacity

Coolant Capacity

Engine

132 in. (335.3 cm)

2 qts. (2.1 l)

2.25 qts. (2.4 l)

4 valve 4 stroke single cylinder

with counter balance

Displacement

Bore x Stroke

Pilot Jet

499 cc

92 x 75

42.5

Main Jet

135

Needle Jet

P-6 (829)

4MB32-3

2.5

Jet Needle

Air Screw

Alternator Output

Compression Ratio

Starting System

Carburetor

250 W

10.2:1

Electric

34 mm CV Mikuni

CDI

Ignition System

Ignition Timing

Spark Plug

30_ @ 5000 rpm

NGK BKR5E

104

Download from Www.Somanuals.com. All Manuals Search And Download.

SPECIFICATIONS

RANGER 2x4

Lubrication System

Engine Oil

Dry Sump

0W/40

Driving System Type

Shift Type

PVT

Single Lever (console)

8.71:1

Gear Reduction - Low

Gear Reduction - Reverse

Gear Reduction - High

Drive Ratio - Front

Drive Ratio - Final

Tire Size - Front

5.9:1

3.83:1

3.70:1

25 x 10 - 12

25 x 11 - 12

8-12 psi

Tire Size - Rear

Tire Pressure - Front

Tire Pressure - Rear

Brakes, Front/Rear

Foot activated,

4 wheel hydraulic disc

Brake, Parking

Foot activated, mechanical

Hood Headlight

Taillights/Brake Light

Indicator Light

2 dual beam, 35W, quartz/halogen

1.0 W

NOTE: See your Polaris dealer for jetting and clutching specifications.

105

Download from Www.Somanuals.com. All Manuals Search And Download.

SPECIFICATIONS

RANGER 4X4

Gross Vehicle Weight

Fuel Capacity

2700 lbs. (1226 kg)

8.5 gal. (32.2 l)

Towing Capacity

Max. Cargo Box Load

Overall Length

1500 lbs. (681 kg)

1000 lbs. (454 kg)

113 in. (282 cm)

60 in. (152.4 cm)

58 in. (147.3 cm)

75 in. (190.5 cm)

76 in. (193 cm)

Overall Width (box)

Overall Width (tires)

Overall Height

Wheelbase

Ground Clearance

Dry Weight

11.5 in. (29.2 cm)

1185 lbs. (537 kg)

Cargo Box

(L x W x H)

58 x 42 x 10 in.

(147 x 106.7 x 25.4 cm)

Min. Turning Radius

Engine Oil Capacity

Coolant Capacity

Engine

132 in. (335.3 cm)

2 qts. (2.1 l)

2.25 qts. (2.4 l)

4 valve 4 stroke single cylinder

with counter balance

Displacement

Bore x Stroke

Pilot Jet

499 cc

92 x 75

42.5

Main Jet

135

Needle Jet

P-6 (829)

4MB32-3

2 1/2

Jet Needle

Air Screw

Alternator Output

Compression Ratio

Starting System

Carburetor

250 W

10.2:1

Electric

34 mm CV Mikuni

CDI

Ignition System

Ignition Timing

Spark Plug

30_ @ 5000 rpm

NGK BKR5E

106

Download from Www.Somanuals.com. All Manuals Search And Download.

SPECIFICATIONS

RANGER 4X4

Lubrication System

Engine Oil

Dry Sump

0W/40

Driving System Type

Shift Type

PVT

Single Lever (console)

8.71:1

Gear Reduction - Low

Gear Reduction - Reverse

Gear Reduction - High

Drive Ratio - Front:

Drive Ratio - Final

Tire Size - Front

5.9:1

3.83:1

3.70:1

25 x 10 - 12

25 x 11 - 12

8-12 psi

Tire Size - Rear

Tire Pressure - Front

Tire Pressure - Rear

Brakes, Front/Rear

Foot Activated,

4 wheel hydraulic disc

Brake, Parking

Hood Headlight

Taillights

Foot activated, mechanical

2 dual beam, 35W, quartz/halogen

2 single beam, 5W

Brake Light

2 single beam, 5W

Indicator Light

1.0 W

NOTE: See your Polaris dealer for jetting and clutching specifications.

107

Download from Www.Somanuals.com. All Manuals Search And Download.

TROUBLESHOOTING

Contact your Polaris dealer for service if you’re unable to identify

solutions using the following charts.

Engine Doesn’t Turn Over

Possible Cause

Solution

Tripped circuit breaker

Low battery voltage

Reset the breaker

Recharge battery to 12.5 VDC

Check all connections and tighten

Loose battery connections

Loose solenoid connections

Engine Turns Over, Fails to Start

Possible Cause

Solution

Out of fuel

Refuel

Clogged fuel filter

Inspect and clean or replace

Drain the fuel system and refuel

Replace with new fuel

Water is present in fuel

Old or non-recommended fuel

Fouled or defective spark plug(s)

No spark to spark plug

Crankcase filled with water or fuel

Overuse of choke

Inspect plug(s), replace if necessary

Immediately see your Polaris dealer

Inspect, clean and/or replace spark plugs

Replace the filter

Clogged fuel filter

Low battery voltage

Mechanical failure

Recharge battery to 12.5 VDC

See your Polaris dealer

Engine Pings or Knocks

Possible Cause

Solution

Poor quality or low octane fuel

Incorrect ignition timing

Replace with recommended fuel

See your Polaris dealer

Set gap to specs or replace plugs

Incorrect spark plug gap or heat range

108

Download from Www.Somanuals.com. All Manuals Search And Download.

TROUBLESHOOTING

Engine Backfires

Possible Cause

Solution

Weak spark from spark plugs

Incorrect spark plug gap or heat range

Old or non-recommended fuel

Incorrectly installed spark plug wires

Incorrect ignition timing

Inspect, clean and/or replace spark plugs

Set gap to specs or replace plugs

Replace with new fuel

See your Polaris dealer

Mechanical failure

Engine Runs Irregularly, Stalls or Misfires

Possible Weak Spark Cause

Fouled or defective spark plugs

Worn or defective spark plug wires

Incorrect spark plug gap or heat range

Loose ignition connections

Water present in fuel

Solution

Inspect, clean and/or replace spark plugs

See your Polaris dealer

Set gap to specs or replace plugs

Check all connections and tighten

Replace with new fuel

Low battery voltage

Recharge battery to 12.5 VDC

Inspect and replace

Kinked or plugged fuel vent line

Incorrect fuel

Replace with recommended fuel

Inspect and clean or replace

See your Polaris dealer

Clogged air filter

Other mechanical failure

Possible Lean Fuel Mixture Cause Solution

Low or contaminated fuel

Low octane fuel

Add or change fuel, clean the fuel system

Replace with recommended fuel

Replace filter

Clogged fuel filter

Incorrect jetting

See your Polaris dealer

Possible Rich Fuel Mixture Cause Solution

Overuse of choke

Fuel is very high octane

Incorrect jetting

Inspect, clean and/or replace spark plugs

Replace with lower octane fuel

See your Polaris dealer

109

Download from Www.Somanuals.com. All Manuals Search And Download.

TROUBLESHOOTING

Engine Stops or Loses Power

Possible Cause

Solution

Out of fuel

Refuel

Kinked or plugged fuel vent line

Water present in fuel

Inspect and replace

Replace with new fuel

Overuse of choke

Inspect, clean and/or replace spark plugs

See your Polaris dealer

Fouled or defective spark plugs

Worn or defective spark plug wires

Incorrect spark plug gap or heat range

Loose ignition connections

Low battery voltage

Set gap to specs or replace plugs

Check all connections and tighten

Recharge battery to 12.5 VDC

Replace with recommended fuel

Inspect and clean or replace

See your Polaris dealer

Incorrect fuel

Clogged air filter

Other mechanical failure

Overheated engine

Clean radiator screen and core if equipped

Clean engine exterior

See your Polaris dealer

110

Download from Www.Somanuals.com. All Manuals Search And Download.

WARRANTY

LIMITED WARRANTY

Polaris Sales Inc., 2100 Highway 55, Medina, MN 55340, gives a SIX MONTH LIM-

ITED WARRANTY on all components of the Polaris RANGER against defects in mate-

rial or workmanship. This warranty covers the parts and labor charges for repair or

replacement of defective parts which are covered by this warranty. This warranty begins

on the date of purchase. This warranty is transferrable to another consumer during the

warranty period through a Polaris dealer.

REGISTRATION

At the time of sale, the Warranty Registration Form must be completed by your dealer

and submitted to Polaris within ten days. Upon receipt of this registration, Polaris will

record the registration for warranty. No verification of registration will be sent to the

purchaser as the copy of the Warranty Registration Form will be the warranty entitle-

ment. If you have not signed the original registration and received the customer copy,

please contact your dealer immediately. NO WARRANTY COVERAGE WILL BE

ALLOWED UNLESS YOUR VEHICLE IS REGISTERED WITH POLARIS.

Initial dealer preparation and set-up of your vehicle is very important in

ensuring trouble-free operation. Purchasing a machine in the crate or without

proper dealer set-up will void your warranty coverage.

WARRANTY COVERAGE AND EXCLUSIONS:

LIMITATIONS OF WARRANTIES AND REMEDIES

The Polaris limited warranty excludes any failures that are not caused by a defect in ma-

terial or workmanship. This warranty does not cover accidental damage, normal wear

and tear, abuse or improper handling. This warranty also does not cover any vehicle that

has been altered structurally, neglected, improperly maintained, used for racing, or used

for purposes other than for which it was manufactured, or for any damages which occur

during trailer transit or as a result of unauthorized service or the use of unauthorized

parts. In addition, this warranty does not cover physical damage to paint or finish, stress

cracks, tearing or puncturing of upholstery material, corrosion, or defects in parts, com-

ponents or the vehicle caused by fire, explosions or any other cause beyond Polaris’ con-

trol.

This warranty does not cover the use of unauthorized lubricants, chemicals, or fuels that

are not compatible with the vehicle. The exclusive remedy for breach of this warranty

shall be, at Polaris’ exclusive option, repair or replacement of any defective materials, or

components or products. THE REMEDIES SET FORTH IN THIS WARRANTY ARE

THE ONLY REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF THIS

WARRANTY. POLARIS SHALL HAVE NO LIABILITY TO ANY PERSON FOR

INCIDENTAL, CONSEQUENTIAL OR SPECIAL DAMAGES OF ANY DE-

SCRIPTION, WHETHER ARISING OUT OF EXPRESS OR IMPLIED WARRANTY

OR ANY OTHER CONTRACT, NEGLIGENCE, OR OTHER TORT OR OTHER-

WISE. Some states do not permit the exclusion or limitation of incidental or consequen-

tial damages or implied warranties, so the above limitations or exclusions may not apply

to you if inconsistent with controlling state law.

111

Download from Www.Somanuals.com. All Manuals Search And Download.

WARRANTY

LIMITATIONS OF WARRANTIES AND REMEDIES

ALL IMPLIED WARRANTIES (INCLUDING BUT NOT LIMITED TO THE IM-

PLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICU-

LAR PURPOSE) ARE LIMITED IN DURATION TO THE ABOVE SIX MONTH

WARRANTY PERIOD. POLARIS FURTHER DISCLAIMS ALL EXPRESS WAR-

RANTIES NOT STATED IN THIS WARRANTY. Some states do not allow limitations

on how long an implied warranty lasts, so the above limitation may not apply to you if

inconsistent with controlling state law.

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 Registra-

tion 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.

Please work with your dealer to resolve any warranty issues. Should your dealer require

any additional assistance they will contact the appropriate person at Polaris.

This warranty gives you specific legal rights, and you may also have other rights which

vary from state to state.

If any of the above terms are void because of state or federal law, all other warranty terms

will remain in effect.

Lubricants

1. Mixing oil brands or using non-recommended oil may cause engine damage. We

recommend the use of Polaris engine oil.

2. Damage resulting from the use of non-recommended lubricants may not be covered

by warranty.

SPARK ARRESTOR

Polaris warrants that the spark arrestor in this vehicle will meet the efficiency requirements

of 43 CFR 8340.1(c) for at least 1000 hours whensubjected tonormal useand whenmainte-

nance and installation are in accordance with Polaris recommendations.

112

Download from Www.Somanuals.com. All Manuals Search And Download.

WARRANTY

Exported Vehicles

EXCEPT WHERE SPECIFICALLY REQUIRED BY LAW, THERE IS NO

WARRANTY OR SERVICE BULLETIN COVERAGE ON THIS VEHICLE IF IT IS

SOLD OUTSIDE THE COUNTRY OF THE SELLING DEALER’S AUTHORIZED

LOCATION.

This policy does not apply to vehicles that have received authorization for export from

Polaris Industries. Dealers may not give authorization for export. You should consult an

authorized dealer to determine this vehicle’s warranty or service bulletin coverage if you

have any questions.

This policy does not apply to vehicles registered to government officials or military per-

sonnel on assignment outside the country of the selling dealer’s authorized location.

This policy does not apply to Safety Recalls.

How to Get Service

In the Country where your vehicle was purchased:

Warranty or Service Bulletin repairs must be done by an authorized Polaris dealer. If you

move or are traveling within the country where your vehicle was purchased, Warranty or

Service Bulletin repairs may be requested from any authorized Polaris dealer who sells

the same line as your vehicle.

Outside the Country where your vehicle was purchased:

If you are traveling temporarily outside the country where your vehicle was purchased,

you should take your vehicle to an authorized Polaris dealer. You must show the dealer

photo identification from the country of the selling dealer’s authorized location as proof

of residence. Upon residence verification, the servicing dealer will be authorized to per-

form the warranty repair.

If You Move:

If you move to another country, be sure to contact Polaris Customer Assistance and the

customs department of the destination country before you move. Vehicles importation

rules vary considerably from country to country. You may be required to present docu-

mentation of your move to Polaris Industries in order to continue your warranty cover-

age. You may also be required to obtain documentation from Polaris Industries in order

to register your vehicle in your new country.

How to Get Service

If Purchased From A Private Party:

If you purchase a Polaris product from a private citizen outside of the country in which

the vehicle was originally purchased, all warranty coverage will be denied.

Notice

If your vehicle is registered outside of the country where it was purchased, and you have

not followed the procedure set out above, your vehicle will no longer be eligible for war-

ranty or service bulletin coverage of any kind. (Vehicles registered to Government

officials or military personnel on assignment outside of the country where the vehicle

was purchased will continue to be covered by the basic warranty.)

For questions call Polaris Customer Assistance:

United States: 1-763-417-8650

Canada: 1-204-925-7100

113

Download from Www.Somanuals.com. All Manuals Search And Download.

WARRANTY

California Emission Control Warranty Statement

Your Warranty Rights and Obligations

The California Air Resources Board and Polaris Industries Inc., 2100 Highway 55,

Medina, Minnesota 55340 (herein “POLARIS”) are pleased to explain the emission

control system warranty on your 2005 and later Large Spark Ignition Engine (herein

“LSI engine”). “The California Air Resources Board has designated this engine for this

vehicle as an LSI engine which produces 25 and greater horsepower and the vehicle has

a six (6) or four (4)-wheel drive and/or a round steering wheel.” In California, this LSI

engine must be designed, built and equipped to meet the state’s stringent anti-smog stan-

dards. Polaris must warrant the emission control system on your LSI engine for the peri-

od of time described below, provided there has been no abuse, neglect or improper

maintenance of your LSI engine.

Your emission control system includes parts such as the carburetor and the ignition sys-

tem. Also included may be hoses, connectors and other emission-related assemblies.

Where a warrantable condition exists, POLARIS will repair your LSI engine at no cost to

you, including diagnosis, parts and labor.

Manufacturer’s Warranty Coverage:

The 2005 and later LSI engines are warranted for two (2) years. If any emission related

part on your LSI engine is defective, the part will be repaired or replaced by POLARIS.

Owner’s Warranty Responsibilities:

As the LSI engine owner, you are responsible for the performance of the required

maintenance listed in your Owner’s Safety and Maintenance Manual (herein “Own-

er’s Manual”). POLARIS recommends that you retain all receipts covering mainten-

ance on your LSI engine, but POLARIS cannot deny warranty solely for the lack of

receipts or for your failure to ensure the performance of all scheduled maintenance.

As the LSI engine owner, you should, however, be aware that POLARIS may deny

you warranty coverage if your LSI engine or a part has failed due to abuse, neglect,

improper maintenance or unapproved modifications.

You are responsible for presenting your LSI engine to a dealer authorized by

POLARIS as soon as a problem exists. The warranty repairs should be completed in a

reasonable amount of time, not to exceed 30 days.

If you have any questions regarding your warranty rights and responsibilities, you

should contact the Polaris Warranty Department at 1-763-417-8650.

Limited Warranty

California Only

POLARIS warrants to the owner of 2005 and later LSI engines that the LSI engine (1)

has been designed, built, and equipped at the time of manufacture so as to conform with

the applicable regulations of the California Air Resources Board and, (2) is free from

defects in materials and workmanship which may cause it to fail to conform with those

regulations as applicable according to the terms and conditions stated below.

114

Download from Www.Somanuals.com. All Manuals Search And Download.

WARRANTY

California Emission Control Warranty Statement

Warranty Period

This warranty period begins on the date, which the LSI engine is delivered, to the origi-

nal retail purchaser and ends two years after that date. During this two year period

POLARIS warrants to the original retail purchaser and each subsequent purchaser that

the LSI engine is free from defect in material and workmanship that can cause the failure

of a warranted emission-related part.

What is Covered Under This Warranty

Repair and/or replacement of any warranted emission-related part will be performed at

no charge provided the work is performed at an authorized dealer. There will also be no

charge for any diagnostic labor performed at an authorized dealer, which leads to the

determination that a warranted emission-related part is defective.

Any warranted part which is not scheduled for replacement as required maintenance, or

which is scheduled only for regular inspection to the effect of “repair or replace as

necessary” shall be warranted for the warranty period. Any warranted part which is

scheduled for replacement as required maintenance shall be warranted for the period of

time up to the first scheduled replacement of that part. This warranty shall apply only

towards the repair, replacement, and/or adjustment of the component parts listed below.

Emission-Related Parts Covered Under This Warranty

(1) Fuel Metering System

(i) Carburetor and internal parts (and/or pressure regulator or fuel injection system).

(ii) Air/fuel ratio feedback and control system, if applicable.

(iii) Cold start enrichment system, if applicable.

(iv) Regulator assy (gaseous fuel, if applicable)

(2) Air Induction System

(i) Intake manifold, if applicable

(ii) Air filter

(3) Ignition System

(i) Spark plugs.

(ii) Magneto or electronic ignition system.

(iii) Spark advance/retard system, if applicable.

(4) Exhaust manifold, if applicable

(5) Miscellaneous Items Used in Above Systems

(i) Electronic controls, if applicable

(ii) Hoses, belts, connectors, and assemblies.

(iii) Filter lock assy (gaseous fuel, if applicable)

If an authorized dealer determines that other LSI engine components have been damaged

due to the failure of a warranted emission-related part during the warranty period,

POLARIS will repair and/or replace the necessary components.

115

Download from Www.Somanuals.com. All Manuals Search And Download.

WARRANTY

California Emission Control Warranty Statement

What is Not Covered Under This Warranty

This warranty does not cover any emission-related part, which malfunctions, fails, or is

damaged due to alterations and/or modifications such as changing, adding, or removing

parts.

When the LSI engine is being serviced under warranty, POLARIS and any of its

authorized dealers shall not be liable for any loss of use of the LSI engine, for any

damage to goods, or loss of time or inconvenience. This limited warranty also does not

apply to any emission-related part which malfunctions, fails, or is damaged due to failure

to follow the maintenance and operating instructions specified in the 2005 and later

Owner’s Manual including:

(a) Improper or inadequate maintenance of any warranted emission-related part

(b) Improper installation, adjustment, or repair of the LSI engine or any warranted

emission-related part unless performed by an authorized dealer

(d) Repairs and diagnosis performed outside of an authorized dealer

(e) Use of parts which are not authorized by POLARIS

Maintenance Schedule

The LSI engine owner is responsible for having all scheduled inspection and

maintenance services performed at the intervals specified in the 2005 and later Owner’s

Manual and to retain records of these services as having been performed. These records

should be transferred to each subsequent owner of the LSI engine. POLARIS cannot

deny a claim solely because there are no records of scheduled maintenance, however, a

warranty claim may be denied if the failure to perform the scheduled maintenance and

inspection resulted in the failure of a warranted emission-related part. As a minimum, the

LSI engine owner is responsible for the scheduled inspection and maintenance described

below which are based on the procedures described in the Owner’s Manual.

NOTE:

Perform these procedures more often for vehicles subjected to severe use.

Emission Control System Service (California)

Have an authorized Polaris dealer perform these services.

116

Download from Www.Somanuals.com. All Manuals Search And Download.

WARRANTY

California Emission Control Warranty Statement

Maintenance Schedule

Item

Maintenance Interval

(whichever comes first)

Remarks

Hours Calendar

Miles

(Km)

Engine oil level

Pre-Ride

Make adjustments as need-

ed. See Pre-Ride Checklist

on page 33.

Air filter, pre-filter

Daily

Weekly

Monthly

1 M

Inspect; clean often

Air box sediment

tube

Drain deposits when visible

Inspect; replace as needed

Inspect; replace if necessary

Air filter,

main element

Engine breather

filter (if equipped)

25 H

50 H

Engine oil change

(break-in)

Perform a break-in oil

change at one month

Throttle Cable/

ETC Switch

6 M

Inspect; adjust; lubricate;

replace if necessary

Choke cable

6 M

Inspect; adjust; lubricate;

replace if necessary

Carburetor air

intake ducts/

flange

6 M

Inspect ducts for proper

sealing/air leaks

Engine oil change 100 H

6 M

Perform a break-in oil

change at 25 hours/one

month

Oil filter change

100 H

6 M

Replace with oil change

Inspect routing, condition

Inspect; adjust

Oil tank vent hose 100 H

12 M

Valve clearance

Fuel system

100 H

Check for leaks at tank cap,

lines, fuel valve, filter, pump,

carburetor; replace lines

every two years

Fuel filter

100 H

12 M

Replace yearly

Spark plug

Ignition Timing

Inspect; replace as needed

Inspect

117

Download from Www.Somanuals.com. All Manuals Search And Download.

WARRANTY

California Emission Control Warranty Statement

Repair and Replacement of Emission-Related Parts

It is recommended that only LSI engine replacement parts, which have been authorized

and approved by POLARIS, should be used in the performance of any warranty

maintenance or repairs of emission-related parts. These replacement parts will be

provided at no charge if the part is still under warranty.

How to File a Warranty Claim/Where to Get Warranty Service

All repairs qualifying under this Limited Warranty must be performed by a dealer who

sold you the LSI engine or a dealer authorized by POLARIS. In the event that any

emission-related part is found to be defective during the warranty period, you must

notify the Polaris Warranty Department at 1-763-417-8650 and you will be advised of

the appropriate dealer where the warranty repair is to be performed.

118

Download from Www.Somanuals.com. All Manuals Search And Download.

WARRANTY

U.S.A. EPA Emissions Limited Warranty

This All Terrain Vehicle (ATV) or Off Road Utility Vehicle (ORUV) emissions limited

warranty is in addition to the Polaris standard limited warranty for this vehicle.

Polaris warrants that this vehicle is; (1) designed, built, and equipped to conform at the

time of initial sale with the requirements of 40 CFR 1051 and, (2) free from defects in

materials and workmanship that may keep it from meeting these requirements.

The emissions warranty period for this vehicle begins on the date the vehicle is delivered

to the original retail purchaser and ends 30 months (2.5 years) after that date, or after

5000 km (3100 miles), whichever comes first.

This emission-related warranty covers components whose failure would increase an en-

gine’s emissions, including electronic controls, fuel injection, exhaust-gas recirculation,

aftertreatment, or any other system utilized in this vehicle to control emissions. Replac-

ing or repairing other components not covered by this emissions warranty or the standard

warranty is the responsibility of the owner; including the parts, labor and other costs

associated with recommended maintenance.

The exclusive remedy for breach of this limited warranty shall be, at the exclusive option

of Polaris, repair or replacement of any defective materials, components or products.

THE REMEDIES SET FORTH IN THIS LIMITED WARRANTY ARE THE ONLY

REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF THIS WARRANTY.

POLARIS SHALL HAVE NO LIABILITY TO ANY PERSON FOR INCIDENTAL,

CONSEQUENTIAL OR SPECIAL DAMAGES OF ANY DESCRIPTION,WHETHER

ARISING OUT OF EXPRESS OR IMPLIED WARRANTY OR ANY OTHER CON-

TRACT, NEGLIGENCE OR OTHER TORT OR OTHERWISE.

ALL IMPLIED WARRANTIES (INCLUDING BUT NOT LIMITED TO ANY IM-

PLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICU-

LAR PURPOSE) ARE LIMITED IN DURATION TO THE WARRANTY PERIOD

DESCRIBED HEREIN. POLARIS DISCLAIMS ALL EXPRESS WARRANTIES

NOT STATED IN THIS WARRANTY. Some states do not allow limitations on how

long an implied warranty lasts, so the above limitation may not apply if it is inconsistent

with the controlling state law.

This limited warranty excludes failures not caused by a defect in material or workman-

ship. This limited warranty does not cover damage due to accidents, abuse or improper

handling, maintenance or use. This limited warranty also does not cover any engine that

has been structurally altered, or any engine that has been used in racing competition. This

limited warranty also does not cover physical damage, corrosion or defects caused by

fire, explosions or other similar causes beyond the control of Polaris.

If you have any questions regarding your warranty rights and responsibilities, you

should contact the Polaris Warranty Department at 1-763-417-8650.

119

Download from Www.Somanuals.com. All Manuals Search And Download.

MAINTENANCE LOG

Periodic Maintenance Record

Use the following chart to record periodic maintenance.

DATE

MILES (KM)

TECHNICIAN

SERVICE PERFORMED / COMMENTS

120

Download from Www.Somanuals.com. All Manuals Search And Download.

MAINTENANCE LOG

DATE

MILES (KM)

TECHNICIAN

SERVICE PERFORMED / COMMENTS

121

Download from Www.Somanuals.com. All Manuals Search And Download.

INDEX

Age Restrictions . . . . . . . . . . . . . . . . .

Driving Through Water . . . . . . . . . . . 41

Driving Uphill . . . . . . . . . . . . . . . . . 39

Dumping the Cargo Box . . . . . . . . . . 46

Air Filter (2x4, 4X4) . . . . . . . . . . . . . 78

Air Filter (TM) . . . . . . . . . . . . . . . . . 80

All Wheel Drive (AWD) . . . . . . . . 49-50

Auxiliary Outlet . . . . . . . . . . . . . . . . 26

AWD Switch (4X4) . . . . . . . . . . . . . 30

Electromagnetic Interference . . . . . . . 52

Emission Control Systems . . . . . . 51-52

Engaging Front Gearcase . . . . . . . . . 50

Engine Idle RPM Adjustment . . . . . . 81

Engine Oil . . . . . . . . . . . . . . . . . . . 60-67

Equipment Modifications . . . . . . . . . 10

Exhaust Emission Control System . . 51

Battery . . . . . . . . . . . . . . . . . . . . 98-100

Battery Fluid . . . . . . . . . . . . . . . . . . . 99

Battery Installation . . . . . . . . . . . . . 100

Battery Removal . . . . . . . . . . . . . . . . 99

Battery Storage . . . . . . . . . . . . . . . . 100

Brake Fluid . . . . . . . . . . . . . . . . . . . . 86

Brake Inspection . . . . . . . . . . . . . . . . 87

Brake Lights . . . . . . . . . . . . . . . . . . . 93

Brake Pedal . . . . . . . . . . . . . . . . . . . . 31

Brakes . . . . . . . . . . . . . . . . . . . . . . 86-87

Braking . . . . . . . . . . . . . . . . . . . . . . . 36

Breather Filter and Hoses . . . . . . . . . 79

Filter Systems (TM) . . . . . . . . . . . . . 80

Filter Systems (2x4, 4X4) . . . . . . . 78-79

Front Gearcase (4X4) . . . . . . . . . . . . 70

Fuel Cap . . . . . . . . . . . . . . . . . . . . . . 26

Fuel Filter . . . . . . . . . . . . . . . . . . . . . 79

Fuel Gauge . . . . . . . . . . . . . . . . . . . . 26

Fuel Safety . . . . . . . . . . . . . . . . . . . . 22

Carburetor Adjustment . . . . . . . . . . . 81

Cleaning Your RANGER . . . . . . . . . . 95

Component Locations . . . . . . . . . . 23-25

Console . . . . . . . . . . . . . . . . . . . . . . . 28

Coolant . . . . . . . . . . . . . . . . . . . . . . . 72

Coolant Level . . . . . . . . . . . . . . . . . . 73

Cooling System (2x4, 4X4) . . . . . 72-74

Cooling System Operation . . . . . . . . 72

Crankcase Emission Control System . 51

Cylinder Head Torque . . . . . . . . . . . . 88

Gear Selector . . . . . . . . . . . . . . . . . . . 29

Gearcase Specification Chart . . . . . . . 68

Gearcases . . . . . . . . . . . . . . . . . . . 68-71

Hauling Cargo . . . . . . . . . . . . . . . . 45-47

Headlight Beam Adjustment . . . . . . . 93

Ignition Switch . . . . . . . . . . . . . . . . . 30

Indicator Lamp Replacement . . . . . . 94

Indicator Lights . . . . . . . . . . . . . . . . . 26

Decals and Locations . . . . . . . . . . 18-21

Differential Operation Modes . . . . . . 49

Differential Lock Operation . . . . . . . 49

Differential Lock Switch (4X4) . . . . . 30

Disengaging AWD . . . . . . . . . . . . . . 50

Driving Downhill . . . . . . . . . . . . . . . 40

Driving in Reverse . . . . . . . . . . . . . . 43

Driving On Slippery Surfaces . . . . . . 38

Driving Over Obstacles . . . . . . . . . . . 42

Driving Procedures . . . . . . . . . . . . . . 37

Driving Safely . . . . . . . . . . . . . . . . 37-48

Light Switch . . . . . . . . . . . . . . . . . . . 30

Lights . . . . . . . . . . . . . . . . . . . . . . 92-94

Lubrication Recommendations . . . 58-59

Main Gearcase . . . . . . . . . . . . . . . . . 69

Maintenance . . . . . . . . . . . . . . . . 53-100

Maintenance Log . . . . . . . . . . . 120-121

122

Download from Www.Somanuals.com. All Manuals Search And Download.

INDEX

Noise Emission Control System . . . . 52

Spark Arrestor . . . . . . . . . . . . . . . . 82-83

Spark Plugs . . . . . . . . . . . . . . . . . . . . 75

Specifications . . . . . . . . . . . . . . 102-107

Starting a Cold Engine . . . . . . . . . . . 34

Starting a Warm Engine . . . . . . . . . . 35

Starting the Engine . . . . . . . . . . . . 34-35

Steering Wheel Inspection . . . . . . . . 88

Stopping the Engine . . . . . . . . . . . . . 35

Storage . . . . . . . . . . . . . . . . . . . . . . . 96

Suspension Adjustment (2X4, 4X4) . 88

Switches . . . . . . . . . . . . . . . . . . . . . . 30

Oil and Filter Change (2x4, 4X4) . 62-63

Oil and Filter Change (TM) . . . . . 66-67

Oil Check (2x4, 4X4) . . . . . . . . . . . . 61

Oil Check (TM) . . . . . . . . . . . . . . . . 65

Oil Pump Priming (2x4, 4X4) . . . . . . 64

Operator Safety . . . . . . . . . . . . . . . . 5-17

Parking Brake Adjustment . . . . . . . . 87

Parking Brake Inspection . . . . . . . . . 87

Parking Brake Lever . . . . . . . . . . . . . 31

Parking Brake Release . . . . . . . . . . . 31

Parking on an Incline . . . . . . . . . . . . 44

Parking the RANGER . . . . . . . . . . . . 48

Periodic Maintenance Chart . . . . . 53-57

Polaris Products . . . . . . . . . . . . . . . 101

Pre Ride Inspection . . . . . . . . . . . . . . 33

Premium 4 Synthetic Oil . . . . . . . . . . 60

PVT Drying . . . . . . . . . . . . . . . . . . . 76

PVT System . . . . . . . . . . . . . . . . . . . 76

Throttle Cable Adjustment (TM) . . . . 85

Throttle Freeplay . . . . . . . . . . . . . . . . 84

Throttle Pedal . . . . . . . . . . . . . . . . . . 31

Throttle System . . . . . . . . . . . . . . . 84-85

Tire Tread Depth . . . . . . . . . . . . . . . . 90

Tires . . . . . . . . . . . . . . . . . . . . . . . 90-91

Tool Kit . . . . . . . . . . . . . . . . . . . . . . . 94

Torque Specifications . . . . . . . . . . . . 90

Towing Capacities . . . . . . . . . . . . . . . 47

Towing Loads . . . . . . . . . . . . . . . . . . 47

Trailer Hitch Bracket . . . . . . . . . . . . . 26

Transmission . . . . . . . . . . . . . . . . . . . 69

Troubleshooting . . . . . . . . . . . . 108-110

Radiator and Cooling Fan . . . . . . . . . 73

Radiator Coolant Level . . . . . . . . . . . 74

Rear Gearcase . . . . . . . . . . . . . . . . . . 71

Rear Spring Adjustment . . . . . . . . . . 88

Removal from Storage . . . . . . . . . . . 97

Vehicle Break-In Period . . . . . . . . . . 32

Vehicle Identification Numbers . . . . . .

Vehicle Immersion . . . . . . . . . . . . . . 77

Safety . . . . . . . . . . . . . . . . . . . . . . . 5-22

Seat Belts . . . . . . . . . . . . . . . . . . 27, 89

Seat Removal . . . . . . . . . . . . . . . . . . 27

Sidehilling . . . . . . . . . . . . . . . . . . . . 40

Warranty . . . . . . . . . . . . . . . . . . 111-118

Wheel Installation . . . . . . . . . . . . . . . 91

Wheel Removal . . . . . . . . . . . . . . . . 91

123

Download from Www.Somanuals.com. All Manuals Search And Download.

Pelco Stereo System RM2196 User Manual
Perreaux Stereo Amplifier Silhouette SXP2 User Manual
Philips Battery Charger R20 P2 User Manual
Philips Network Cables SWV3434S User Manual
Philips Recording Equipment AJ3050 User Manual
Philips Switch SDW5058 17 User Manual
Pioneer Stereo Receiver VSX D909S User Manual
Planet Technology Switch GSW 2416SF User Manual
Polk Audio Home Theater System 500 ls User Manual
Polycom Webcam EDOC2501b User Manual