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1. secure connections Item Remarks Page Brake system pedal travel Ensure proper operation Brake fluid Ensure proper level 63 Front suspension Inspect lubricate if necessary 58 Rear suspension Inspect lubricate if necessary 58 Steering Ensure free operation 65 Tires Inspect condition and pressure RE Wheels fasteners Inspect ensure fastener tightness 66 Frame nuts bolts fasteners Inspect ensure tightness Accelerator Ensure proper operation 35 Indicator lights switches Ensure operation 30 Headlamp Check operation apply POLARIS 68 dielectric grease when lamp is replaced Brake light tail lamp Check operation apply POLARIS 70 dielectric grease when lamp is replaced Seat belts Check length of belt for damage 37 check latches for proper operation Latches hood tailgate seat Ensure all latches are secure Batteries Ensure full charges proper water 71 74 levels clean terminals Battery cables Inspect for proper cable routing and 73 38 OPERATION Driving Procedure Qs ceto OON 1 NN Disconnect the charging cable if connected Wear a helmet and eye protection Sit in the driver s seat and fasten the seat belt Apply the brakes Place the direction selector in neutral N Turn the key to the ON position Wait about a second for the contac tor to close before continuing Move the direction selector to forward or re
2. below Color Indication Code Definition Green Solid Charge is complete charger is in mainte nance mode Green Fast Flash Less than 8096 of charge is completed Green Slow Flash More than 80 of charge is completed Amber Flashing Power mode is reduced low AC voltage or high internal charger temperature exists open hood to improve air flow Red Flashing Charger error exists reset charger power and refer to Troubleshooting Guide on page 31 Key Switch Move the direction selector switch to neu tral then turn the key to the ON position to activate the electrical circuits Tip The accelerator will not start the motor if the direction selector switch is in forward or reverse when the key is turned on Switch to neutral then choose forward or reverse Turn the key to the OFF position to disable all electrical circuits The key can be removed from the switch when it is in the OFF position 27 FEATURES AND CONTROLS Console Drive Mode Switch CAUTION Changing the drive mode switch position while driving could result in an automatic increase or decrease in speed without a change to accelerator pedal pressure Press the top of the switch to select high mode Use high mode for most trail riding conditions The vehicle will oper ate at speeds up to 25 MPH 40 km h Press the bottom of the switch to select low mode Low mode is recom mended for short term operation in extreme load conditions U
3. 75 16 Weight 51 Wheel Installation 67 Wheel Nut Torque 66 Wheel 67
4. 83 Warrdnly ede 84 Maintenance Log 90 kw e 92 INTRODUCTION The RANGER is an off road vehicle Familiarize yourself with all laws and regulations concerning the operation of this vehicle in your area The following signal words and symbols appear throughout this manual and on your vehicle Your safety is involved when these words and sym bols are used Become familiar with their meanings before reading the manual A The safety alert symbol indicates a potential personal injury hazard WARNING A WARNING indicates a hazardous situation which if not avoided may result in death or serious injury CAUTION A CAUTION indicates a hazardous situation which if not avoided may result in minor or moderate injury NOTICE A NOTICE indicates a situation that may result in property damage The Prohibition Safety Sign indicates an action NOT to take in order to avoid a hazard The Mandatory Action Sign indicates an action that NEEDS to be taken to avoid a hazard INTRODUCTION 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 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 preca
5. 36 S Safety Labels 7 11 Safety 4 Seat Belt Inspection 37 Seat Belts ass eiii eri 37 Seat 36 Severe Use Definition 56 Shock Spring Adjustment 65 93 INDEX S Signal 4 Specifications Gearcase 59 Speed Towing 51 Steering Wheel Inspection 65 Nye ro pq 75 78 Storage 78 Storage Removal 79 Storing the Vehicle 79 Switches AWD Switch 29 Direction Selector 29 Drive Mode Switch 28 Headlight Switch 29 Key Switch 27 T Tire Pressure 7 Tires Nut 66 Tread 66 Wheel Installation 67 Wheel Removal 67 Towing 51 Towing 51 Towing Vehicle 52 Trailer Hitch Bracket 23 59 60 Transporting the RANGER 53 Troubleshooting Vehicle Will Not Operate 83 Charge Status Indicator 31 Malfunction Indicator 3l 94 V Vehicle Identification Numbers 6 Vehicle 33 Vehicle Will Not Operate 83 Warning Symbols 4 Washing the Vehicle
6. 5 419 RANGER EV Owner s Manual for Maintenance and Safety E A WARNING Read understand and follow all of the instructions and safety precautions in this manual and on all product labels Failure to follow the safety precautions could result in serious injury or death 100 RECYCLED The text is printed on 10096 recycled with 4096 post consumer waste PCW PMS 419 AWARNING Improper vehicle use can result in SEVERE INJURY or DEATH NEVER Operate At speeds too fast for your skills or the conditions After or while using Alcohol or Drugs e On hills steeper than 15 degrees 15 On public roads A collision can occur with another vehicle With more than ONE passenger or with passengers under age twelve or who cannot comfortably reach the floor and hand holds e On paved surfaces pavement may seriously affect handling and control e With non Polaris approved accessories they may seriously affect stability ALWAYS e Wear your seat belt Vehicle rollover could cause severe injury or death e Wear a helmet and eye protection and keep hands and feet in vehicle at all times e Reduce speed and use extra caution when carrying a passenger Avoid sharp turns or turns while applying heavy throttle e Operate slowly in reverse avoid sharp turns or sudden braking e Make sure passenger reads and understands all safety labels Watch for branches or
7. 30 Indicator Charge Status 27 K Key 27 Key Periodic Maintenance Chart 56 L Lamp Replacement Indicator Lights 70 Lights Brake Lights 70 Headlight Beam Adjustment 69 Headlight Lamp Replacement 68 Indicator Lamp Replacement 70 Indicator Lights 30 Lubrication Recommendations 58 M Main Gearcase 59 60 Main Power Connector 34 Maintenance Precautions 21 Maintenance Periodic 56 57 Malfunction Indicator 31 Modifications 15 1 8 sas aie eta 45 Oil Change Front Gearcase 62 Main Gearcase 60 60 Oil Level Front Gearcase 61 Main Gearcase 59 59 Operation 33 Operator 12 21 Park Brake Lever 26 Parking on an Incline 47 Parking the Vehicle 52 Periodic Maintenance Chart 56 57 POLARIS 82 Polishing the Vehicle 76 Pre Ride Inspection 38 Pressure Tire 7 R Range of Operation 33 Removing the Vehicle from Storage 79 Reverse 46 Roll Over Protection System 36 ROPS Cab
8. SPECIFICATIONS RANGER EV Brake System Brakes 4 Wheel hydraulic disc w dual bore front calipers Park Brake Dash mounted lever activated mechanical park Front suspension brake Independent Macpherson struts w 8 in 20 3 cm travel Rear suspension Dual A Arm w 9 in 22 9 cm travel Tires 25x9 12 Carlisle All Trail Tire pressure Cup holders 20 psi 137 9 kPa Dual cup holders Indicator panel Indicates directional selection park brake and motor or controller malfunction Charge indicator Digital indicates battery discharge Hour meter Auxiliary power Digital indicates cumulative hours of vehicle move ment 12 volt accessory outlet Rider restraints Automotive style 3 point seat belts Multi mode switch L M H Low Max Range High Headlights taillights brake Dual 50 watt lights Storage Glove box POLARIS PRODUCTS Part Number Description Gearcase Lubricants 2871653 Premium ATV Angle Drive Fluid 8 02 237 ml 2872276 Premium ATV Angle Drive Fluid 2 5 gal 9 5 1 2877922 Demand Drive Plus Fluid qt 95 1 2877923 Demand Drive Plus Fluid 2 5 gal 9 5 Grease Specialized Lubricants 2871312 Grease Gun Kit Premium All Season 2871322 Premium All Season Grease 3 02 89 ml cartridge 2871423 Premium All Season Grease 14 0z 414 ml cartridge 2871515 Premium U Joint Lube 3 0z 89 ml c
9. Poor lighting can result in reduced visibility when driving Headlight and taillight lenses become dirty during normal operation Clean lights frequently and replace burned out lamps promptly Always make sure lights are adjusted properly for best visibility 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 Headlight Lamp Replacement 1 Open the hood CAUTION Hot components can cause burns to skin Allow lamps to cool before servicing 2 Unplug the headlamp from the wiring harness Be sure to pull on the connector not on the wiring Wiring Harness 3 Turn the lamp counter clockwise to remove it 4 Install the new lamp Tip Make sure the tab on the lamp locates properly in the housing 5 Reinstall the harness assembly into the headlight assembly 68 Lights Headlight Beam Adjustment Place the vehicle on a level surface with the headlight approxi mately 25 ft 7 6 m from a wall Measure the distance from the floor to the center of the headlight and make a mark on the wall at the same height Apply the brakes Turn the key on Turn the headlights on Observe the headlight aim The most intense part of the headlight beam should be aimed 8 20 cm below the mark placed on the wall Include the weight of a rider on the seat while performing this step
10. 54 55 Disengaging AWD 55 Locking the Differential 54 Auxiliary 12 Volt Terminal Board 25 Auxiliary 25 AWD 54 55 AWD 29 Axle Nut Torque 66 B Batteries 73 Charge Status Indicator 27 31 Charger Operation 33 Charging 72 Charging 26 33 73 Conditioning 33 Discharge Indicator 25 Ehud elem 74 Handling Precautions 32 Inspections 73 Main Power Connector 34 Operation Range 33 Replacement 73 Temperature Implications 33 Brake Lever Park 26 Brake Lights 70 Brake Pedal 35 Brak 63 64 Brake Fluid 63 Brake Inspection 64 Cab Frame ROPS 36 Cal BO s e 48 49 Cargo Box Dumping 50 Charge Status Indicator 27 31 Charging Batteries 72 Charging 26 72 Chrome Wheel Care 77 Cleaning and Storage 75 78 Component Locations 22 23 Cors 2 eet ates 24 30 Corrosion Removal Chrome TI 92 D Differential Locking 54 Direction Selector 29 Discharge Indicator 25 Disen
11. Set the park brake 4 Place the direction selector in neu tral 5 Turn the key off Rel 6 Dismount the vehicle Be Col 7 Ensure that the cargo is positioned evenly or toward the front of the cargo box 8 Release the tailgate latches 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 9 Stand clear and pull up on the cargo box release lever 10 Lift the front of the cargo box to dump the cargo 11 Lower the cargo box and push down securely to latch 12 Close the tailgate and secure both tailgate latches 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 50 Towing Loads Towing improperly can alter vehicle handling and may cause loss of control or brake instability Always follow these precautions when tow ing OPERATION 1 Never load more than 150 Ibs 68 1 kg tongue weight on the tow ing bracket 2 Do not operate the vehicle faste
12. surface imperfections caused by external stress heat cold or contamination operator error or abuse improper component alignment tension adjustment or altitude compensation failure due to snow water dirt or other foreign substance ingestion contamination improper maintenance modified components use of aftermarket components resulting in failure unauthorized repairs repairs made after the warranty period expires or by an unauthorized repair center use of the product in competition or for commercial purposes Warranty will not apply to any product which has been damaged by abuse accident fire or any other casualty not determined a defect of materials or workmanship The POLARIS limited warranty excludes any battery failures that are not caused by a defect in material or workmanship Warranty claims for battery replacements require specific testing as outlined by the POLARIS Warranty Department and the battery man ufacturer U S Battery prior to replacement If the POLARIS Warranty Department in conjunction with U S Battery determines that the failure of the battery is caused by a defect in material or workmanship POLARIS will assist with the processing of the war ranty claim through U S Battery for a replacement battery This warranty does not cover the time required to test and or diagnose issues with the battery Consequential damage caused by defective batteries are excluded from this warranty Use of any charger not recommended
13. Axle and Wheel Nut Torque Specifications Inspect the following items occasionally for tightness and if they ve been loosened for maintenance service Do not lubricate the stud or the lug nut Nut Type Location Nut Torque Lug Nut Front and Rear 90 ft Ibs 122 Nm Ri ee Flange Front and Rear 35 ft lbs 47 Nm u Spindle Nut Front 70 ft Ibs 95 Nm Hub Retaining Nuts Center and Rear 110 ft Ibs 150 Nm 66 Tires Wheel Removal 1 Apply the brakes 2 Setthe park brake 3 Turn the key off 4 Loosen the wheel nuts slightly 5 Elevate the side of the vehicle by placing a suitable stand under the frame 6 Remove the wheel nuts and washers Remove the wheel Wheel Installation 1 Setthe park brake 2 Place the wheel in the correct position on the WARNING Improperly installed wheels can adversely affect tire wear and wheel hub Be sure the valve stem is toward the outside and rotation arrows on the tire point toward forward rota tion 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 3 4 5 Attach the wheel nuts and washers and finger tighten Carefully lower the vehicle to the ground Torque the wheel nuts to specification See page 66 67 MAINTENANCE Lights
14. Drain Plug 10 Discard used oil properly 62 MAINTENANCE Brakes The front and rear brakes are hydraulic disc type brakes Press down on the brake pedal to engage the brakes See page 35 Brake Fluid Inspect the brake system routinely Inspect the level of the brake fluid before each operation 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 Change the brake fluid every two years and any time the fluid becomes contaminated the fluid level is below the minimum or if the type and brand of the fluid in the reservoir are unknown See page 58 for fluid recommendations 1 Position the vehicle on a level Maximum surface 2 View the brake fluid level at the reservoir in the driver s side wheel well The level should be between the upper MAX and lower MIN level lines 3 Ifthe fluid level is lower than the upper 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 Minimum 63 MAINTENANCE Brakes Brake Inspection 1 2 64 Check the brake system for fluid leaks Check the brake pedal for excessive travel
15. If a headlight needs adjustment access the adjustment screw under the hood or through the wheel well Loosen the screw adjust the headlight and tighten the screw Repeat steps 4 6 until the lamp is properly adjusted 69 MAINTENANCE Lights Brake Lights When the brake pedal is depressed the console brake light comes on Check the brake light before each ride 1 Turn the key 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 Indicator Lamp Replacement 1 Liftthe hood Release 2 Reachin behind the console Tab panel and lift the release to unplug the light from the harness 3 Using a flathead screwdriver press on the tab on the top of the light to remove the indi cator light assembly from the console panel 4 Locate the expired lamp Using a screwdriver rotate the lamp 1 4 turn counter clockwise 5 Grip the lamp with a needle nose pliers and remove it from the assembly 6 Install the new lamp Using a screwdriver rotate the lamp 1 4 turn clockwise to seat it 7 Snap the assembly back into the console panel Reconnect the har ness 8 Close the hood 70 MAINTENANCE Batteries AWARNING Battery posts terminals and related components contain lead and lead compounds chemicals known to cause cancer and reproductive harm Always wash your hands after touching or handling the
16. If the plates are exposed add water to about 1 8 inch 3 mm above the plates then charge Check the fluid level again after charging Maintain the fluid level 1 4 inch 6 mm below the bottom of the fill well in the cell cover Do not overfill V Cell Covers Plates 74 MAINTENANCE Cleaning and Storage Washing the Vehicle Keeping your POLARIS vehicle clean will not only improve its appear ance but it can also extend the life of various components NOTICE High water pressure may damage components POLARIS recommends washing the vehicle by hand or with a garden hose using mild soap NOTICE Certain products including insect repellents and chemicals will damage plastic surfaces Do not allow these types of products to contact the vehicle The best and safest way to clean your POLARIS vehicle is with a gar den hose and a pail of mild soap and water 1 Usea professional type washing cloth cleaning the upper body first and the lower parts last 2 Rinse with clean water frequently 3 Dry surfaces with a chamois to prevent water spots Washing Tips Avoid the use of harsh cleaners which can scratch the finish Do not use a power washer to clean the vehicle Do not use medium to heavy duty compounds on the finish Always use clean cloths and pads for cleaning and polishing Old or reused cloths and pads may contain dirt particles that will scratch the finish Avoid directing water toward electrical compo
17. No person under the age of 12 may ride as a passenger in this vehicle Any passenger must be able to comfortably reach the floor and hand holds The driver and any passenger must wear helmet eye protection and seat belt at all times Always keep arms and legs inside the cab frame while the vehicle is in motion Always keep both hands on the steering wheel and both feet on the floorboards of the vehicle during operation Never permit a guest to operate this vehicle unless the guest has read this manual and all product labels To reduce tipover risk be especially careful when encountering obstacles and slopes and when braking on hills or during turns This vehicle is for off road use only Never operate on public roads Always avoid paved surfaces Never consume alcohol or drugs before or while operating this vehicle Never operate at excessive speeds Always travel at a speed proper for the terrain visibility and operating conditions and your experience Never attempt jumps or other stunts 12 SAFETY Operator Safety Always inspect your vehicle each time you use it to make sure it s in safe operating condition Always follow the inspection and maintenance procedures and schedules described in this manual Always travel slowly and use extra caution when operating on unfamiliar terrain Be alert to changing terrain Never operate on excessively rough slippery or loose terrain Always follow prop
18. and understand the Owner s Manual and all warning and instruction labels before operating the vehicle Seat Belts Riding in this vehicle without wearing the seat belt increases the risk of serious injury in the event of an accident or sudden stop Riders must wear seat belts at all times Always make sure the seat belts are secured for both the operator and passenger before riding Protective Apparel Riding in this vehicle without wearing an approved helmet and protective eyewear increases the risk of a serious injuries in the event of an accident Operator and passenger must always wear an approved helmet that fits properly and eye protection goggles or face shield 16 SAFETY Operator Safety Ventilation When Charging Batteries Failure to provide adequate ventilation while charging batteries can result in an explosion Volatile hydrogen gas is emitted during charging and may accumulate in pockets at the ceiling Always ensure a minimum of 5 air changes per hour in the charging area Always remove any storage covers from the vehicle and open any cab doors if equipped before charging Failure to Inspect Before Operating Failure to inspect and verify that the vehicle is in safe operating condition before operating increases the risk of an accident Always inspect your RANGER before each use to make sure it s in safe operating condition Always follow all inspection and maintenance procedures and schedules described in
19. by POLARIS and or modifications to the vehicle will void any stated or implied warranty on the battery Battery warranty exclusions include damage caused by abuse or neglect such as improper fluid levels loose wiring or rusted or corroded hard ware lack of proper maintenance improper installation of the battery neglect break age freezing fire explosion or wreckage the addition of any chemical operation of the battery in an overcharged condition operation of the battery in an uncharged condition below half charge 1 200 specific gravity and use of a battery charged by systems other than those supplied or recommended by POLARIS 86 WARRANTY LIMITATIONS OF WARRANTIES AND REMEDIES 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 materi als 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 DESCRIPTION WHETHER ARISING OUT OF EXPRESS OR IMPLIED WAR RANTY OR ANY OTHER CONTRACT NEGLIGENCE OR OTHER TORT OR OTHERWISE THIS EXCLUSION OF CONSEQUENTIAL INCIDENTAL AND SPECIAL DAMAGES IS INDEPENDENT FROM AND SHALL SURVIVE ANY FINDING THAT THE E
20. form 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 Mixing lubricant brands or using non recommended lubricants may cause component damage We recommend the use of POLARIS lubricants for this vehicle Damage result ing from the use of non recommended lubricants may not be covered by warranty Exported Vehicles EXCEPT WHERE SPECIFICALLY REQUIRED BY LAW THERE IS NO WAR RANTY OR SERVICE BULLETIN COVERAGE ON THIS VEHICLE IF IT IS SOLD OUTSIDE THE COUNTRY OF THE SELLING DEALER S AUTHORIZED LOCA TION 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 Bulletins 88 WARRANTY How to Get Service In the Country wh
21. in reverse and slowly allow the vehicle to roll straight downhill while applying light brake pressure to control speed OPERATION Driving on a Sidehill Sidehilling Driving on a sidehill is not recommended Improper procedure could cause loss of control or overturn Avoid crossing the side of any hill unless absolutely necessary If crossing a sidehill is unavoidable follow these precautions 1 Slow down 2 Exercise extreme caution 3 Avoid crossing the side of a steep hill 15 maximum Driving Downhill When driving downhill follow these precautions 1 Avoid steep hills 15 maximum 2 Always descend a hill with the direction selector switch on for ward Never descend a hill with the switch on neutral 3 Drive straight down hill Avoid descending a hill at an angle which would cause the vehicle to lean sharply to one side Travel straight downhill when possible 15 maximum 4 Slow down 5 Apply the brakes slightly to aid in slowing 43 OPERATION Driving Through Water Your POLARIS vehicle can operate through water up to a maximum recommended depth equal to the floorboards NOTICE Serious damage can occur to the electrical system and batteries if the vehicle is operated in water deeper than the floorboards Follow these procedures when operating through water 1 Determine water depths and current before entering water 2 Choose a crossing where both banks have gradual incline
22. operate faster than 10 MPH 16 km h Do not tow on public streets Do not allow passengers in the towed vehicle Avoid abrupt starts and stops Avoid sharp turns and abrupt steering maneuvers Avoid towing on a hill OPERATION Transporting the RANGER When transporting the RANGER for a long distance or on public streets always use a trailer with an approved load rating greater than the RANGER 5 curb vehicle weight of 1700 165 771 kg plus any installed accessories or cargo Follow these guidelines when transporting the RANGER 1 Place the direction selector in neutral Set the park brake Remove the key to prevent loss Secure the seat hood and tailgate latches Always tie the frame of the RANGER to the transporting unit securely with suitable straps pn cm DOM If using an open trailer remove the windshield 1f equipped Mo Never allow passengers on a trailer or in a trailered vehicle 8 Reduce speed and drive with caution 53 OPERATION Wheel Drive AWD Press the top of the rocker switch to engage All Wheel Drive AWD Once enabled the AWD remains enabled until the switch is turned off The AWD switch may be turned on or off while the vehicle is moving When the AWD switch is on the front gearcase will automatically engage any time the rear wheels lose traction When the rear wheels regain traction the front gearcase will automatically disengage Tip AWD will not engage initially
23. or a spongy feel Check the friction pads for wear damage and looseness Inspect the brake disc spline and pad wear surface for excessive wear Change pads when worn to 3 64 1 mm MAINTENANCE Steering Wheel Inspection Check the steering wheel for specified freeplay and smooth operation at the intervals outlined in the Periodic Maintenance Chart beginning on page 56 1 Position the vehicle on a level surface 2 Lightly turn the steering wheel left and right There should be 0 8 1 0 20 25 mm of freeplay at the outer rim of the steering wheel 3 Ifthere is excessive freeplay or strange noises or the steering feels rough or catchy have the steering system inspected by an autho rized POLARIS dealer Spring Adjustment Adjust the rear shock absorber springs by rotating the adjustment cams either clockwise or counter clockwise to increase or decrease spring tension 65 MAINTENANCE Tires AWARNING Operating your vehicle with worn tires improperly inflated tires non standard tires or improperly installed tires will affect vehicle handling and could cause an accident resulting in serious injury or death Always follow all tire maintenance procedures as outlined in this manual and on the labels on the vehicle Always use original equipment size and type when replacing tires Tire Tread Depth i Always replace tires 1 8 3 mm when tread depth is worn to 1 8 3 mm or less 22 WS
24. the owner s manual Using Alcohol or Drugs Operating the vehicle after consuming alcohol or drugs could adversely affect operator judgment reaction time balance and perception Never drink alcohol or use drugs or medications before or while operating this vehicle 17 SAFETY Operator Safety Operating a Damaged Vehicle Operating a damaged vehicle can result in an accident After any overturn or accident have a qualified service dealer inspect the entire machine for possible damage including but not limited to brakes accelerator steering system and electrical system Operating at Excessive Speeds Operating this vehicle at excessive speeds increases the operator s risk of losing control Always operate at a speed that s appropriate for the terrain the visibility and operating conditions your skills and your passengers skills Operating on Pavement This vehicle s tires are designed for off road use only not for use on pavement Operating this vehicle on paved surfaces including sidewalks paths parking lots and driveways may adversely affect the handling of the vehicle and could result in loss of control and accident or overturn Avoid operating the vehicle on pavement If it s unavoidable travel slowly and avoid sudden turns or stops Operating on Public Roads Operating this vehicle on public streets roads or highways could result in a collision with another vehicle Never operate this vehicle on any publi
25. OLARIS dealer to purchase a replacement Replacement safety labels are pro vided by POLARIS at no charge The part number is printed on the label Container Passenger Tire Pressure Warning WARNING Passengers can be thrown off This can cause serious injury or death Never carry passengers in cargo box Maximum Box Load 500 Ibs 227 kg IMPROPER TIRE PRESSURE OR OVERLOADING can cause loss of control resulting in SEVERE INJURY OR DEATH TIRE PRESSURE IN PSI KPa FRONT TIRE INFLATE TO 20 psi 137 9 kPa REAR TIRE INFLATE TO 20 psi 137 9 kPa gt MAXIMUM WEIGHT CAPACITY ER WEIGHT OF OPERATOR PASSENGE CARGO AND ACCESSORIES 1000 LBS 455 kg 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 7176305 SAFETY Safety Labels and Locations Battery Compartment Warning WARNING SULFURIC ACID in batteries will burn skin eyes and clothing Do not tip batteries Keep vent caps tight and level In event of injury flush with water and call physi cian immediately HIGH VOLTAGE CABLES and terminals are contained within this compartment Improp
26. ON Hauling Cargo AWARNING Hauling cargo improperly can alter vehicle handling and may cause loss of control or brake instability which can result in serious injury or death Always follow these precautions when hauling cargo Never exceed the maximum weight capacity of the vehicle When determining the weight you are adding to the vehicle include the weight of the operator passenger accessories loads in the rack or box and the load on the trailer tongue The combined weight of these items must not exceed the maximum weight capacity REDUCE SPEED AND ALLOW GREATER DISTANCES FOR BRAKING WHEN HAULING CARGO Always load the cargo box with the load as far forward and as low as possible When operating over rough or hilly terrain reduce speed and cargo to maintain stable driving conditions Always operate the vehicle with extreme care when hauling or towing loads Slow down and drive in the lowest gear available SECURE ALL LOADS BEFORE OPERATING Unsecured loads can create unstable operating conditions which could result in loss of control of the vehicle OPERATE ONLY WITH STABLE AND SAFELY ARRANGED LOADS When handling off centered loads that cannot be centered securely fasten the load and operate with extra caution Always attach the tow load to the hitch point designated for your vehicle HEAVY LOADS CAN CAUSE BRAKING AND CONTROL PROBLEMS Use extreme caution when applying brakes with a loaded vehicle Avoid terrain or situatio
27. XCLUSIVE REMEDY FAILED OF ITS ESSENTIAL PUR POSE 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 U S Battery s liability shall be to replace the defective battery Replacement shall mean furnishing a new battery or used battery with sufficient life to complete the warranty term which is incidental or reasonably equivalent to the warranted product at no cost to the purchaser during the replacement period ALL IMPLIED WARRANTIES INCLUDING BUT NOT LIMITED TO THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PAR TICULAR PURPOSE ARE LIMITED IN DURATION TO THE ABOVE SIX MONTH WARRANTY PERIOD POLARIS FURTHER DISCLAIMS ALL EXPRESS WARRANTIES NOT STATED IN THIS WARRANTY Some states do not allow limi tations on how long an implied warranty lasts so the above limitation may not apply to you if inconsistent with controlling state law 87 WARRANTY HOW TO OBTAIN WARRANTY SERVICE If your vehicle requires warranty service you must take it to a POLARIS Servicing Dealer When requesting warranty service you must present your copy of the Warranty Registration form to the dealer THE COST OF TRANSPORTATION TO AND FROM THE DEALER IS YOUR RESPONSIBILITY POLARIS suggests that you use your original selling dealer however you may use any POLARIS Servicing Dealer to per
28. and after the warranty period We also take great pride in our complete line of apparel parts and acces sories available through our online store at www purepolaris com Have your accessories and clothing delivered right to your door POLARIS The Way Out POLARIS THE WAY OUT and RANGER are registered trademarks of POLARIS Industries Inc Copyright 2010 POLARIS Sales Inc All information contained within this publication is based on the latest product information at the time of publication Due to constant improvements in the design and quality of production components some minor discrep ancies may result between the actual vehicle and the information presented in this publi cation 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 2011 RANGER EV Owner s Manual P N 9923128 2 TABLE OF CONTENTS 4 Salety osi ea Sheed cee 7 Features and Controls 22 ties dete EX 38 Maintenance 56 80 POLARIS Products 82 Troubleshooting
29. arcase fluid Brake fluid change every two years and any time the fluid looks dark or contaminated 78 MAINTENANCE Storing the Vehicle Any time the vehicle will be parked for more than a few hours follow the recommended storage procedures l 2199 cd uU decani Make any necessary repairs and clean the vehicle See page 75 Clean the batteries See page 73 Store the vehicle out of the sun in a cool dry place Be sure the storage area is well ventilated Turn the key off Do not set the park brake Verify that tire pressure is at specification Block the wheels to prevent rolling Fully charge the batteries Leave the charger connected to maintain a full charge during the storage period or check battery voltage each month during storage and recharge as needed to maintain a full charge If the charger remains connected check it monthly to verify proper operation Tip Do not use plastic or coated materials They do not allow enough ventilation to prevent condensation and may promote corrosion and oxidation WARNING Do not cover the vehicle while the charger is connected Dangerous levels of hydrogen gas could accumulate Removal from Storage Qi Acc Inspect all battery connections Verify that batteries are fully charged Verify that tire pressure is at specification Perform the pre ride inspection See page 38 Inspect and verify the tightness of the bolts nuts and other fasteners Lu
30. artridge 2871551 Premium U Joint Lube 14 0z 414 ml cartridge 2871329 Dielectric Grease Nyogel Additives Miscellaneous 2872189 DOT 4 Brake Fluid 82 TROUBLESHOOTING Vehicle Will Not Operate Possible Cause Solution Low battery voltage Recharge the battery overnight Loose battery connections Check all connections and tighten Loose contactor connections Check all connections and tighten Loose electronic control box connections Inspect clean reinstall connectors Required torque exceeds motor capability In neutral cycle key off and on select low range then select direction 83 WARRANTY LIMITED WARRANTY POLARIS Sales Inc 2100 Highway 55 Medina MN 55340 gives a SIX MONTH LIMITED WARRANTY on all components of the POLARIS RANGER against defects in material or workmanship POLARIS also supports a one year limited supplier war ranty covering defects in material or workmanship on the factory installed 12 volt bat teries in the 48 volt system 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 transferable 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 thi
31. astal areas are more susceptible to corrosion if not properly cleaned Clean chrome wheels more often if they re exposed to salt or other corrosive elements 1 Wash chrome wheels frequently Use mild detergent Never use abrasive cleaners on plated or painted surfaces 2 Rinse well with clear water Soap detergents salt dirt mud and other elements can cause corrosion 3 Polish the clean chrome wheels periodically Use an automotive grade chrome polish 4 Routinely and liberally apply a weather resistant wax to each pol ished chrome wheel Choose a product suitable for chrome finishes Read and follow the product labels and instructions Removing Corrosion If light rust is found on the chrome finish use steel wool 0000 OTT grade to remove it Gently rub the affected areas with the steel wool until the corrosion has been removed Clean and polish the wheel as out lined above 77 MAINTENANCE Cleaning and Storage Storage Tips Clean the Exterior Make any necessary repairs and clean the vehicle as recommended See page 75 Inspect and Lubricate Inspect all cables and lubricate all areas of the vehicle as recommended in the Periodic Maintenance Chart beginning on page 56 Battery Maintenance See pages 71 74 for procedures Fluid Levels Inspect the fluid levels Add or change fluids as recommended in the Periodic Maintenance Chart beginning on page 56 Front and rear gearcase fluid 1f equipped Main ge
32. aximum life charge your vehicle at every opportunity Use only the charger supplied with the vehicle Inspect bat tery connections regularly Failure to properly maintain your batteries will void warranty coverage 7176414 SAFETY Safety Labels and Locations Battery Caution CAUTION Do not drive through water above Discretionary Warning the floor of the vehicle Battery damage will occur Batteries require regular mainte nance Failure to maintain batteries in accordance with the owners man ual can result in battery damage vehicle malfunction fire and or severe injury or death Max towing speed 10 MPH 16 km h drivetrain damage will occur if towed faster than 10 MPH 16 km h Batt Set parking brake before leaving attery vehicle Caution Wig Turn Power On key to Off posi tion and remove when not in use When towing vehicle turn Power On key to Off position 7176204 Age 16 Warning Operating this vehicle if you are under the age of 16 increases your chance of severe injury or death NEVER operate this vehicle if you are under age 16 and NEVER operate this vehicle without a valid driver s license 7175566 10 SAFETY Safety Labels and Locations Discretionary Warning WARNING Improper vehicle use can result in Severe Injury or Death NEVER Operate At speeds too fast for your skills or the conditions After or while using Alcohol or Drugs e On hills steeper than 15 degre
33. batteries A WARNING Charging a damaged battery can result in serious injury Never attempt to charge a frozen or bulging battery Discard the battery appropriately and install a new battery A WARNING Improperly connecting or disconnecting battery cables can result in an explosion and cause serious injury or death A 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 71 MAINTENANCE Batteries Battery Charging When not in use park the vehicle and connect the bat tery charger The vehicle s charging cord is located inside the charge plug holder on the console WARNING Failure to provide adequate ventilation while charging batteries can result in an explosion Hydrogen gas is emitted during charging and will rise and accumulate at the ceiling Always ensure a minimum of five 5 air changes Charging Cord per hour in the charging area Never charge the batteries in an area
34. bricate at the intervals outlined in the Periodic Maintenance Chart beginning on page 56 79 SPECIFICATIONS Dry Weight RANGER EV 1750 Ibs 793 8 kg Ground Clearance 10 in 25 4 cm Length 108 in 274 3 cm Width 56 5 in 143 5 cm Height 73 in 185 4 cm Wheelbase 72 in 183 cm Turning Radius Box Dimensions Inside 150 in 381 cm Load Capacity 32 x 42 x 11 5 in 81 x 107 x 29 cm Box Capacity 500 Ibs 227 kg Payload Capacity 1000 Ibs 455 kg Hitch Towing Capacity 1250 Ibs 567 kg Motor configuration Cargo System Lock amp Ride Seating 2 Skid Plate Plastic Performance Single 48 volt high efficiency AC induction motor Motor peak 30 HP Controller 650 Amp Sevcon Gen IV controller with multi mode driving and regenerative braking Battery pack 11 7 kw battery pack at 48V DC with 8 12 volt US12VXC batteries in series parallel configuration Maximum speed 25 MPH 40 2 km h Range in Max Range mode on flat ground 50 miles 80 5 km may vary with driving condi tions Throttle Redundant non contact inductive sensing pedal On board charger Delta Q 120 volt AC input 48 volt DC output Charge time Main gearcase transaxle 8 hours dependent on depth of discharge Drivetrain Direct drive motor to transaxle with low noise gears Drive On demand AWD 2WD turf mode
35. c street road or highway including dirt and gravel roads In some areas it s unlawful to operate this vehicle on public streets roads and highways 18 SAFETY Operator Safety Turning Improperly Turning improperly could cause loss of traction loss of control accident or overturn Always follow proper procedures for turning Never turn abruptly or at sharp angles Never turn at high speeds Practice turning at slow speeds before attempting to turn at faster speeds Jumps and Stunts Attempting wheelies jumps and other stunts increases the risk of an accident or overturn Never attempt wheelies jumps or other stunts Avoid exhibition driving Operating in Unfamiliar Terrain Failure to use extra caution when operating on unfamiliar terrain could result in an accident or overturn Unfamiliar terrain may contain hidden rocks bumps or holes that could cause loss of control or overturn Travel slowly and use extra caution when operating on unfamiliar terrain Always be alert to changing terrain conditions Operating on Slippery Terrain Failure to use extra caution when operating on excessively rough slippery or loose terrain could cause loss of traction loss of control accident or overturn Do not operate on excessively slippery surfaces Always reduce speed and use additional caution when operating on slippery surfaces 19 SAFETY Operator Safety Stalling While Climbing a Hill Stalling or rolling backwards while cli
36. d such as being rated for protection from oil in a garage or workshop environment 2 Usethe proper cord wire gauges for the cord length used Length lt 25 ft 7 5 m 50 ft 15 m 100 ft 30 m Gauge 16AWG 1 5 2 14AWG 2 5mm2 10AWG 6 0mm2 Battery Operation Range Range is significantly affected by tire pressure alignment terrain and driving style Always maintain proper tire pressure as specified on safety labels 33 FEATURES AND CONTROLS Main Power Connector NOTICE Damage to electrical connections and components will occur if they are unplugged before the main power connector is disconnected Always disconnect the main power connector before servicing or unplugging any electrical components When disconnected the Main Power Connector main power connector dis connects the battery pack from all electrical compo nents with the exception of the contactor After servic ing the vehicle the main power connector should be the last connection to be made The main power connector is located under the seat on NN Battery Installation the driver s side of the con E and Wire Lead troller tray adjacent to the Connection main line contactor To dis connect unplug the connec tor To disconnect the battery pack from the vehicle com pletely disconnect the main power connector then remove the wire from the battery terminal WARNING Insulate any tools used with
37. dy Power delivery terminated to protect against overheating If either occurs stop the vehicle and turn the key off Allow the motor and controller to cool adequately before operating Malfunction Park Brake Neutral Gear X Y CHOIR NT 8 Motor Controller Reverse Forward High Temperature Gear Gear If 30 FEATURES AND CONTROLS Malfunction Indicator Troubleshooting Guide The malfunction codes will blink on the controller The code definitions provided here are for informational purposes only Tip If the indicator illuminates due to a minor issue such as a low voltage condi tion or a sequence fault reversing direction without releasing the accelera tor turning the key on while in forward or reverse select neutral and turn the key off and on to clear the error If the error does not clear please see your POLARIS dealer for diagnosis and repair of Blinks Steady Code Definition Key was turned on in forward or reverse switch to neutral then to forward or reverse Data or configuration error Sequence fault Power fault Contactor issue Throttle input error Voltage protection Ni A 05 N Controller or motor out of temperature range E Soft
38. e servicing or unplugging any electrical components See page 34 Always follow all safety instructions in the maintenance portion of this owner s manual as well as the following Make sure the vehicle is properly immobilized before beginning any mainte nance Always block the chassis securely before working under the vehicle Turn the key off and remove it from the vehicle Insulate any tools used within the battery area to prevent sparks or battery explosion caused by shorting the battery terminals or wiring Remove the bat teries or cover the exposed terminals with an insulating material FOR MORE INFORMATION ABOUT SAFETY call POLARIS at 1 800 342 3764 21 FEATURES AND CONTROLS Component Locations ROPS Cab Frame Headlights JASS Ho ss Front Bumper Brush Guard 22 FEATURES AND CONTROLS Component Locations Tailgate Latch Releases Tailgate 7 CV Boot Rear Caliper Trailer Hitch Bracket This vehicle is equipped with a receiver hitch bracket for a trailer hitch Trailer towing equipment is not supplied with this vehicle To avoid injury and property damage always heed the warnings and towing capacities outlined on pages 48 51 23 FEATURES AND CONTROLS Console Park Brake Lever Headlight Switch Charge Status Indicator AWD Switch Battery Discharge Indicator Hour Meter Charge Plug Holder 12V Auxilia
39. er con tact between battery terminals can result in electrical shorts ELECTRICAL SHORTS can result in burns Do not use high pressure water to wash the battery compart ment Damage to the vented batteries will result Tampering with or unauthorized modification of this unit could result in serious personal injury will void the warranty and can result in permanent damage to the vehicle Refer to your Owner s Manual or contact your local POLARIS dealer with any questions 7176206 Battery Compartment Warning SAFETY Safety Labels and Locations Battery Charging Warning WARNING Explosive gases are released when batteries Battery Charging Warning are charged Keep sparks flames and ciga rettes away Shield eyes when working near batteries Do not charge batteries in a non ventilated enclosed area or near flammable materials Do not attempt to charge frozen leaking or damaged batteries Connect battery charger to properly rated electrical receptacle with GFCI Do not charge with storage or weather cover on vehicle or with the cab enclosure doors closed as fire and explosion are possible Refer to Owner s Manual or contact your local POLARIS dealer with any questions TO MAXIMIZE BATTERY LIFE Always check and maintain water level monthly Use only distilled water Water level should be kept 1 4 6 mm below fill well Do not overfill the battery Always keep batteries fully charged For m
40. er procedures for turning Practice turning at slow speeds before attempting to turn at faster speeds Never turn at exces sive speeds Always have this vehicle checked by an authorized POLARIS dealer if it has been involved in an accident Never operate this vehicle on hills too steep for the vehicle or for your abilities Practice on smaller hills before attempting larger hills Always follow proper procedures for climbing hills as described in this manual Check the terrain carefully before attempting to climb a hill Never climb hills with excessively slippery or loose surfaces Never go over the top of a hill at high speed Always follow the proper procedures outlined in this manual for trav eling downhill and for braking on hills Check the terrain carefully before descending a hill Never travel downhill at high speed Avoid going downhill at an angle which would cause the vehicle to lean sharply to one side Travel straight down the hill where possible Always check for obstacles before operating in a new area Never attempt to operate over large obstacles such as rocks or fallen trees Always follow the proper procedures outlined in this manual when operating over obstacles Always be careful of skidding or sliding On slippery surfaces such as ice travel slowly and exercise caution to reduce the chance of skid ding or sliding out of control 13 S AFETY Operator Safety 14 Never operate your vehicle in fast flow
41. ere 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 War ranty 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 perform 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 importa tion rules vary considerably from country to country You may be required to present documentation of your move to POLARIS Industries in order to continue your warranty coverage You may also be required to obtain documentation from POLARIS Industries in order to register your vehicle in your new country You should warranty register your vehicle at a local POLARIS dealer in your new country immediately after you move to continue your warranty coverage and to ensure that you receive safety information and notices regardi
42. es 15 On public roads a collision can occur with a another vehicle With more than one passenger or a passenger under age twelve or who can not comfortably reach the floor and hand holds On paved surfaces pavement may seriously affect handling and control With non POLARIS approved accessories they may seriously affect stability ALWAYS Wear your seat belt Vehicle rollover could cause severe injury or death Wear a helmet and eye protection and keep hands and feet in vehicle at all times Reduce speed and use extra caution when carrying a passenger Avoid sharp turns or turns while applying heavy throttle Operate slowly in reverse avoid sharp turns or sudden braking Make sure passenger reads and understands all safety labels Watch for branches or other hazards that could enter vehicle LOCATE AND READ OWNER S MANUAL FOLLOW ALL INSTRUCTIONS AND WARNINGS 7176169 11 SAFETY Operator Safety AWARNING Serious injury or death can result if you do not follow these instructions and procedures which are outlined in further detail within your owner s manual Read this manual and all labels carefully Follow the operating procedures described Never allow anyone under age 16 to operate this vehicle and never allow anyone without a valid driver s license to operate this vehicle Do not carry a passenger until you have at least two hours of driving experience with this vehicle
43. ezing weather follow these precautions 1 Do not operate on excessively rough slippery or loose terrain 2 Slow down before entering slippery areas 3 Maintain a high level of alertness reading the trail and avoiding quick sharp turns which can cause skids 4 Engage all wheel drive before wheels begin to lose traction NOTICE 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 5 Correct a skid by turning the steering wheel in the direction of the skid Never apply the brakes during a skid Sideways Turn in skid d direction of a DLA ra lt M C Coec S BS TEC d 41 OPERATION Driving Uphill Whenever traveling uphill follow these precautions 1 42 Always travel straight uphill Avoid steep hills 15 maximum Keep both feet on the floor Always check the terrain carefully before ascending any hill Never climb hills with excessively 15 maximum slippery or loose surfaces Proceed at a steady rate of speed 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 If the vehicle stalls while climbing a hill apply the brakes Place the direction selector in neutral turn the key off and on then select low range Place the direction selector switch
44. filings 5 Reinstall the drain plug Torque to specification 6 Add the recommended oil as needed Do not overfill Drain Plug 7 Reinstall the fill plug Torque to specification 8 Check for leaks 9 Dispose of used oil properly 60 MAINTENANCE Gearcases Front Gearcase Always check and change the front gearcase oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 56 Maintain the oil level even with the bottom thread of the fill plug hole Refer to the Gearcase Specifications Chart on page 59 for recommended lubricants capacities and torque specifications See page 82 for the part numbers of POLARIS products Oil Check The front gearcase fill plug is located on the left side of the front gearcase 1 Position the vehicle on a level surface 2 Remove the fill plug Check the oil level E 3 Add the recommended oil as needed 4 Reinstall the fill plug Torque to specification 61 MAINTENANCE Gearcases Front Gearcase Oil Change 1 2 9 Support the vehicle securely with a jackstand Remove the front tire on the driver s side Remove the fill plug Place a drain pan under the drain plug Remove the drain plug Allow the oil to drain completely Fill Plug Clean the drain plug Reinstall the l drain plug Torque to specification Add the recommended oil Reinstall the fill plug Torque to specification Check for leaks
45. gaging AWD 55 Drive Mode Switch 28 Driving Downhill 43 Driving in 46 Driving on a Sidehill 43 Driving on Slippery Surfaces 41 Driving Over Obstacles 45 Driving Procedure 39 40 Driving Through Water 44 Driving 42 Dumping the Cargo Box 50 E Equipment Modifications 15 F Fluid Change Front 62 Main Gearcase 60 60 Fluid Level Front Gearcase 61 Main Gearcase 59 59 Fluid Levels During Storage 78 Fluid Recommendation 59 Fluid 74 Fluid 63 Front 61 62 Fuel Stabilizer 78 G Gearcase Specification Chart 59 Gearcase Front 61 62 Gearcase Main 59 60 59 62 Hauling 48 49 Headlight Beam Adjustment 69 Headlight Lamp Replacement 68 Headlight Switch 29 Hitch Bracket 23 Hitch 51 25 l Indicator Light Replacement 70 Indicator Lights
46. he battery compartment to avoid causing a short circuit to the electrical system Battery Inspections Inspect battery terminal connections monthly Clean batteries as recom mended Using an insulated wrench torque bolts to 8 ft lbs 11 Nm Battery Cleaning Always keep battery terminals and connections free of corrosion To clean remove corrosion with a stiff wire brush Wash with a solution of one tablespoon baking soda and one cup water Rinse well with tap water and dry off with clean shop towels Coat battery terminals with dielectric grease or petroleum jelly NOTICE Do not allow cleaning solution or tap water to enter the batteries Battery Replacement With proper care and maintenance as outlined in this owner s manual battery life could be extended up to four years or longer depending on the amount of use When battery replacement is necessary please see your authorized POLARIS dealer WARNING Handling batteries and electrical components improperly can result in serious injury or death Do not attempt to remove batteries or battery cables Always see your dealer for battery related service 73 MAINTENANCE Batteries Battery Fluid A poorly maintained battery will deteriorate rapidly Check the battery fluid level often Add only distilled water Tap water contains minerals that are harmful to a battery Unless the plates are exposed before charging distilled water should be added to a battery after charging
47. in the battery area to prevent sparks or battery explosion caused by shorting as oe the battery terminals or wiring Front of vehicle Remove the batteries or cover the exposed terminals with an insulating material to controller to contactor B wire 34 FEATURES AND CONTROLS Brake Pedal Push the brake pedal toward the floor to slow or stop the vehicle Apply the brakes before turning the key on Accelerator Pedal The accelerator pedal will function only when the key is ON and the Accelerator direction selector switch is set to Pedal either forward or reverse To begin moving or to increase vehicle speed gradually push the accelerator pedal toward the floor Holding the accel erator pedal down continuously will accelerate the vehicle to the maxi mum speed To slow the vehicle release the accelerator pedal Electric motor braking provides braking when the pedal is released For additional speed control or to stop the vehicle apply the service brakes 35 FEATURES AND CONTROLS Roll Over Protection System ROPS The Rollover Protective Structure ROPS on this ROPS Cab vehicle meets OSHA 1928 53 Fame rollover performance En requirements Always have your authorized POLARIS dealer thoroughly inspect the ROPS if it ever becomes damaged in any way F V No device can assure occu pant protection in the event of rollover Alwa
48. ing water or in water deeper than that specified in this manual Wet brakes may have reduced stop ping ability Test your brakes after leaving water If necessary apply them lightly several times to let friction dry out the pads 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 Always use the proper size and type of tires specified in this manual Always maintain proper tire pressure as specified on safety labels Never modify this vehicle through improper installation or use of accessories Never exceed the stated load capacity for this vehicle Cargo should be properly distributed and securely attached Reduce speed and fol low the instructions in this manual for hauling cargo or pulling a trailer Allow a greater distance for braking Always set the park brake and remove the key when leaving the vehi cle unattended SAFETY Operator Safety Equipment Modifications Never install any accessory that grounds to the vehicle chassis The chassis is a floating ground to protect against electrical short circuits and hazards 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 pur poses Any modifications to the original equipment of the vehicle create a subs
49. latch plate into the buckle until it clicks 3 Release the strap it will self tighten 4 Torelease the seat belt press the square red button in the buckle s center Seat Belt Inspection Inspect all seat belts for proper operation before each use of the vehicle 1 Push the latch plate into the buckle until it clicks The latch plate must slide smoothly into the buckle A click indicates that it s securely latched Push the red release latch in the middle of the buckle to make sure it releases freely Pull each seat belt completely out and inspect the full length for any damage including cuts wear fraying or stiffness If any damage is found or if the seat belt does not operate properly have the seat belt system checked and or replaced by an authorized POLARIS dealer To clean dirt or debris from the seat belts sponge the straps with mild soap and water Do not use bleach dye or household deter gents 37 OPERATION Failure to operate the vehicle properly can result in a collision loss of control accident or overturn which may result in serious injury or death Read and understand all safety warnings outlined in the safety section of this owner s manual Pre Ride Inspection Failure to inspect and verify that the vehicle is in safe operating condi tion before operating increases the risk of an accident Always inspect the vehicle before each use to make sure it s in safe operating condition
50. liary Outlets The 12 volt receptacle can be used to power accessories but is limited to 10 amps the terminal board and 12 volt outlet are fused together at 10 amps 25 FEATURES AND CONTROLS Console Park Brake Lever To help prevent the vehicle from rolling set the park brake when park ing the vehicle When the park brake is set and the park brake indicator is illuminated motor speed is limited If the accelerator is applied this limiting feature prevents operation which protects the park brake pads from excessive wear Tip This feature will not operate properly if the park brake connector or switch under the hood malfunctions or becomes disconnected or if the switch has moved Check for disconnection then see your dealer promptly if this feature fails to operate properly Always apply the service brakes before engaging or releasing the park brake 1 Apply the brakes 2 Pull the park brake lever downward as far as possible 3 Torelease the park brake apply the brakes Press the park brake release inward and move the lever upward as far as possible Charging Cord The charging cord is located inside the charge plug holder on the console See page 72 for charging instructions Charging Cord 26 Console FEATURES AND CONTROLS Charge Status Indicator When charging the batteries the charge status indicator light flashes and changes color to indicate the status of the charge Refer to the table
51. may notice increased steering effort and some vehicle speed restriction Perform the following proce dure to unlock the front gearcase 1 2 Stop the vehicle Move the direction selector to reverse Operate in reverse for at least 10 feet 3 m Stop completely Move the direction selector to forward and drive forward If the front gearcase remains locked after following these instruc tions return the vehicle to your dealer for service 55 MAINTENANCE Periodic Maintenance Chart Careful periodic maintenance will help keep your vehicle in the safest most reliable condition Inspection adjustment and lubrication of important components are explained in the periodic maintenance chart Inspect clean lubricate adjust and replace parts as necessary When inspection reveals the need for replacement parts use genuine POLARIS parts available from your POLARIS dealer Record maintenance and service in the Maintenance Log beginning on page 90 Tip 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 ten 10 miles per hour Vehicles subjected to severe use must be inspected and serviced more frequently Severe Use Definition Frequent immersion in mud water
52. mbing a hill could cause an overturn Always maintain a steady speed when climbing a hill If all forward speed is lost Apply the brakes Switch to reverse and slowly allow the vehicle to roll straight downhill while applying light brake pressure to control speed If you begin rolling downhill Never press the accelerator Apply the brakes gradually until the vehicle is fully stopped Switch to reverse and slowly allow the vehicle to roll straight downhill while applying light brake pressure to control speed Improper Hill Climbing Climbing hills improperly can cause loss of control or vehicle overturn Always follow proper procedures for climbing hills as described in the owner s manual See page 42 Descending Hills Improperly Improperly descending a hill could cause loss of control or overturn Always follow proper procedures for traveling down hills as described in the owner s manual Use the brake pedal to control speed when descending a hill Never travel down a hill at high speed Always descend a hill with the direction selector on FORWARD Never descend a hill in neutral Always check the terrain carefully before descending a hill Avoid traveling down a hill at an angle which would cause the vehicle to lean sharply to one side Travel straight downhill 20 SAFETY Operator Safety Improper Tire Maintenance Operating this vehicle with improper tires or with improper or uneven tire pressure c
53. nents including batter ies wiring and switches 75 MAINTENANCE Cleaning and Storage Washing the Vehicle If a high pressure water system is used for cleaning not recommended exercise extreme caution The water may damage components and could remove paint and labels Avoid directing the water stream at the follow ing items Wheel bearings Main gearcase seals Brakes Cab and body panels Labels and decals Switches and controls Electrical components and wiring If an informational or graphic label becomes illegible or comes off con tact your POLARIS dealer to purchase a replacement Replacement safety labels are provided by POLARIS at no charge Grease all zerk fittings immediately after washing Polishing the Vehicle POLARIS recommends the use of common household aerosol furniture polish for polishing the finish on your POLARIS vehicle Follow the instructions on the container Polishing Tips Avoid the use of automotive products some of which can scratch the finish of your vehicle Always use clean cloths and pads for cleaning and polishing Old or reused cloths and pads may contain dirt particles that will scratch the finish 76 MAINTENANCE Cleaning and Storage Chrome Wheel Care if equipped Proper maintenance will protect chrome wheels from corrosion pre serve wheel life and ensure a like new appearance for many years Chrome wheels exposed to road salt or salt in the air in co
54. ng your vehicle If Purchased From A Private Party If you purchase a POLARIS product from a private citizen to be kept and used outside of the country in which the vehicle was originally purchased all warranty coverage will be denied You must nonetheless warranty register your vehicle under your name and address with a local POLARIS dealer in your country to ensure that you receive safety information and notices regarding your vehicle 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 other than safety bulletins Vehicles reg istered 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 war ranty For questions call POLARIS Customer Assistance United States 1 888 704 5290 Canada 1 204 925 7100 89 MAINTENANCE LOG Use the following chart to record periodic maintenance DATE MILES KM OR HOURS TECHNICIAN SERVICE PERFORMED COMMENTS 90 MAINTENANCE LOG DATE MILES KM OR HOURS TECHNICIAN SERVICE PERFORMED COMMENTS 91 INDEX A Accelerator 35 All Wheel Drive
55. ns that may require backing downhill USE EXTREME CAUTION when operating with loads that extend over the rack sides Stability and maneuverability may be adversely affected causing the vehicle to overturn DO NOT TRAVEL FASTER THAN THE RECOMMENDED SPEEDS Vehicle should never exceed 10 MPH 16 km h while towing a load on a level grass surface Vehicle speed should never exceed 5 MPH 8 km h when towing loads in rough terrain while cornering or while ascending or descending a hill 48 OPERATION Hauling Cargo The RANGER has been designed to carry or tow specific capacities Always read and understand the load distribution warnings listed on the warning labels Move the drive mode switch to low mode if needed See page 28 The total load operator passenger accessories cargo and weight on hitch must not exceed the maximum weight capacity of the vehicle Never exceed the following capacities Model Maximum Capacities Cargo Box Level Ground RANGER EV 1000 Ibs 455 kg 500 Ibs 227 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 A passengers must always ride in the cab with seat belt fastened securely 49 OPERATION Dumping the Cargo Box 1 Select a level site to dump the gt cargo box Do not attempt to t dump or unload the vehicle while Zs parked on an incline 5 2 Apply the brakes 3
56. or pedal before coming to a complete stop AWD Switch The AWD switch has three posi tions Wheel Drive AWD Dif ferential Lock Two Wheel Drive 2WD and Off 1WD Turf Mode Press the top of the switch to engage All Wheel Drive AWD See page 54 for operating instructions Move the switch to the center posi TWD TURF tion to lock the differential and operate in two wheel drive 2WD Press the bottom of the switch to unlock the differential and allow the rear drive wheels to operate independently 1WD This mode of opera tion is well suited to turf driving or when active traction is not needed See page 54 for Differential Lock operating instructions Headlight Switch Press the top of the switch to turn the head On lights on Press the bottom of the switch to turn the headlights off Off 29 FEATURES AND CONTROLS Console Indicator Panel Lights The indicator lights activate Indicator Panel when the key is in the ON position Indicator Status Indicates Malfunction Electrical malfunction flash sequence on controller indicates type see troubleshooting Steady guide on page 31 Key was turned on in forward or reverse switch to neutral then to forward or reverse Park Brake Steady Engaged park brake Gear Position Steady Selected gear forward neutral reverse Motor Controller Flashing Reduced performance due to elevated High temperature Temperature Stea
57. or sand Racing or race style high RPM use Prolonged low speed heavy load operation Maintenance Chart Key gt Perform these operations more often for vehicles subjected to severe use n Have an authorized POLARIS dealer perform these services WARNING Improperly performing the procedures marked with a n could result in component failure and lead to serious injury or death Have an authorized POLARIS dealer perform these services 56 Periodic Maintenance Chart Perform all services at whichever maintenance interval is reached first MAINTENANCE Item Maintenance Interval Remarks whichever comes first Hours Calendar Miles Km n Steering Pre Ride gt Front suspension Pre Ride gt Rear suspension Pre Ride Tires z Pre Ride 3 Inspect and make gt Brake fluid level Pre Ride cere ete 3 needed ee Pre Ride Checklist on gt Brake pedal travel page 38 Brake system Pre Ride Wheels fasteners Pre Ride Frame fasteners Pre Ride Batteries Pre Ride Headlamp tail Daily Check operation apply lamp dielectric grease if replacing gt Brake pad wear 10H Monthly Inspect periodically n Battery terminals 25H Monthly Inspect and clean page 73 Battery fluid levels 25H Monthly Add as needed page 74 Battery terminals 25H Monthly Inspect torque to specification gt Front gearcase oil 25H Monthly Inspect le
58. or termi nal board See page 25 Never connect jumper cables to any of the batteries of this vehicle Use only insulated tools when working in the battery compartment 32 FEATURES AND CONTROLS Batteries Battery Conditioning New batteries cannot initially hold all of their capacity The approxi mate capacity of the battery pack increases as the number of charge cycles increases of Charge Cycles New 15 30 45 Percent of Full Capacity 8096 9096 9596 10096 Ambient Temperature Implications on Batteries 1 Battery range decreases as ambient temperature decreases This can affect the range by up to 30 2 Batteries discharge when left uncharged They can discharge up to 13 per month higher rates in warmer climates with the key off and much faster if the key is left on 3 Batteries can freeze if left uncharged at low ambient temperatures Percent Charged 10096 5096 0 Approximate Freezing Point 60 F 25 51_ 18_ 4_ Charger Operation Open the hood and any door enclosures or zippers This will decrease charger temperature which allows it to operate more efficiently and shorten charge times See pages 71 72 for charging procedures 1 Always use extension cords with the appropriate ratings for the country in which it is used In North America this is a UL rating The cords must also be rated for the conditions in which they are use
59. other hazards that could enter vehicle READ OWNER S MANUAL FOLLOW ALL INSTRUCTIONS AND WARNINGS For your nearest Polaris dealer PELARIS 1 800 5 The Way Out or visit www polarisindustries com Polaris Sales Inc 2100 Hwy 55 Medina MN 55340 Phone 1 888 704 5290 Part No 9923128 Rev 01 Printed in USA WELCOME Thank you for purchasing a POLARIS vehicle and welcome to our world wide family of POLARIS owners We proudly produce an excit ing line of utility and recreational products Snowmobiles All terrain vehicles ATVs e RANGER utility vehicles e Victory Motorcycles Low Emission Vehicles LEVs 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 pro duced 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 ser vice needs during
60. ould cause loss of control or accident Always use the size and type of tires specified for your vehicle Always maintain proper tire pressure as described in the owner s manual and on safety labels Operating on Frozen Bodies of Water Severe injury or death can result if the vehicle and or the operator fall through the ice Never operate the vehicle on a frozen body of water unless you have first verified that the ice is sufficiently thick to support the weight and moving force of the vehicle you and your passengers and your cargo together with any other vehicles in your party Always check with local authorities and residents to confirm ice conditions and thickness over your entire route Vehicle operators assume all risk associated with ice conditions on frozen bodies of water Unauthorized Use of the Vehicle Leaving the keys in the vehicle can lead to unauthorized use of the vehicle which could result in an accident or overturn Always remove the key when the vehicle is not in use Hot Drive Systems The motor and controller are very hot during and after use of the vehicle Hot components can cause burns and fire Do not touch hot drive system components Always keep combustible materials away from the drive system Precautions During Maintenance WARNING Do not work in or near the battery compartment or on any other electrical component of the vehicle while charging the batteries Always disconnect the main power connector befor
61. r than 10 MPH 16 km h when tow ing See page 48 Towing a trailer increases braking distance 3 Do not tow more than the recommended weight for the vehicle See the towing capacity chart below and the specifications charts begin ning on page 80 4 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 5 Never tow a trailer on a grade steeper than 15 Model Total Towed Total Towed Total Hitch Maximum Load Weight Load Weight Vertical Towin Level Ground 15 grade Weight Spee RANGER EV 1250 lbs 850 Ibs 150 Ibs 10 MPH 567 kg 386 kg 68 1 kg 16 kph 51 OPERATION Parking the Vehicle l 2 3 4 5 Apply the brakes Stop the vehicle on a level surface 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 Place the direction selector in neutral Set the park brake Turn the key off Remove the key to prevent unauthorized use Towing the Vehicle NOTICE When towing the vehicle the key MUST be in the OFF position or severe motor damage will occur Follow these procedures when towing the vehicle 1 2 3 52 Place the direction selector in neutral Turn the key off Always follow these precautions when towing this vehicle Do not
62. ries are grounded directly to the negative post on the terminal board Never use the chassis or body as a ground connection Always keep battery terminals and connections clean and free of cor rosion at all times See page 73 Always maintain a full charge on the batteries For best battery life avoid discharging the batteries more than 80 See page 25 Make sure new batteries are fully charged before using New deep cycle batteries need to be cycled several times before reaching full capacity 50 125 cycles depending on type Capacity will be limited during this time Make sure vent caps are installed properly and securely during vehi cle operation and battery charging Recharge batteries fully at the end of each day the vehicle is operated allowing adequate time for the charger to complete its charge cycle The batteries in this vehicle do not have a memory effect Frequent charging will extend their life Avoid charging at temperatures above 120 F 49 C ambient air temperature Closed unvented storage buildings often exceed this temperature when exposed to direct sunlight Never connect an auxiliary battery to the factory installed DC to DC converter If more than 10 amps are needed for accessories always install the POLARIS approved auxiliary accessory battery kit Never connect a 12 volt accessory directly to the batteries Always connect any powered accessory to a 12 volt auxiliary outlet
63. ry Outlet Drive Mode Switch 10 Direction Selector 12 11 Key Switch 12 Indicator Lights 9 00 Soy Oro ms 24 FEATURES AND CONTROLS Console Battery Discharge Indicator The battery discharge indicator displays the amount of charge d 100 Remains Full Charge D removed used from fully charged batteries When the batteries are fully charged the right most bar illuminates indi cating 0 has been used The S 30 70 Discharged charge status indicator will be solid green see page 27 As the batteries discharge the bar Recharge the batteries moves leftward Tip If batteries are not allowed to recharge fully solid green light the battery discharge indicator may be inaccurate When the second bar from the left flashes battery discharge is at 70 The batteries should be recharged as soon as possible Avoid discharging the batteries more than 80 NOTICE If the two left most bars begin to flash battery damage may occur with continued operation Stop the vehicle and recharge the batteries C 50 Remains 50 Discharged Hour Meter The hour meter records and displays the hours of actual vehicle move ment since manufacture Auxiliary 12 Volt Terminal Board The 12 volt terminal board is located under the hood It contains con stant 12 volt switched 12 volt and ground terminals that can be used to power auxiliary lights and accessories The terminals are limited to 10 amps Auxi
64. s 3 Proceed slowly avoiding rocks and obstacles 4 Avoid operating through deep or fast flowing water 5 After leaving water always dry the brakes by applying light pressure to the pedal repeatedly until braking action is normal Floorboard 44 OPERATION Driving Over Obstacles Follow these precautions when operating over obstacles 1 Always check for obstacles before operating in a new area 2 Look ahead and learn to read the terrain Be constantly alert for haz ards such as logs rocks and low hanging branches 3 Travel slowly and use extra caution when operating on unfamiliar terrain Not all obstacles are immediately visible 4 Move the drive mode switch to low mode if needed See page 28 45 OPERATION Driving in Reverse Follow these precautions when operating in reverse 1 Always check for obstacles or people behind the vehicle Always inspect left and right fields of vision before backing Always avoid backing downhill Back slowly Apply the brakes lightly for stopping Avoid turning at sharp angles Quot SERIO S Never accelerate suddenly 46 OPERATION Parking on an Incline 15 maximum Avoid parking on an incline if possible If it s unavoidable follow these precautions 1 Apply the brakes 2 Setthe park brake 3 Place the direction selector in neutral 4 Turn the key off 5 Block the rear wheels on the downhill side 47 OPERATI
65. s 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 trou ble free operation Purchasing a machine in the crate or without proper dealer set up will void your warranty coverage 84 WARRANTY WARRANTY COVERAGE AND EXCLUSIONS LIMITATIONS OF WARRANTIES AND REMEDIES The POLARIS limited warranty excludes any failures that are not caused by a defect in material 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 modified neglected improperly maintained used for rac ing 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 components or the vehicle due to fire explo
66. se low mode when towing hauling loads or maneuvering over obstacles Speed will be limited to a maximum of 10 MPH 16 km h and regenerative braking increases to improve control in aggressive terrain Return the mode switch to high mode for normal operation Move the switch to the center position to select the maximum range mode Use this mode to operate the vehicle a greater distance or for a longer time period This mode limits both speed and torque to obtain the maximum driving range High Maximum Range Low Mode Maximum Torque Deceleration Application Speed percent of regenerative maximum braking torque High 25 MPH 70 Trail riding 40 km h Max 15 MPH 5096 Minimum Whenever possible to maximum Range 24 km h driving range of battery pack Low 10 MPH 100 Maximum Towing hauling loads driving on 16 km h steep hills or aggressive terrain 28 FEATURES AND CONTROLS Console Direction Selector Switch When the direction selector is in the center position the vehicle is in neutral The vehicle will not move if the accel erator is depressed Place the switch in neutral before turning the key on Push the top of the switch to choose for ward operation Push the bottom of the switch to choose reverse operation Always come to a complete stop before reversing direction Tip The malfunction light will illuminate after reversing direction if you press the accelerat
67. sions or any other cause beyond POLARIS control Warranty does not apply to parts exposed to friction surfaces stresses environmental conditions and or contamination for which they were not designed or not intended including but not limited to the following items Wheels and tires Finished and unfinished surfaces Suspension components Carburetor Throttle body components Brake components Engine components Seat components Drive belts Clutches and components Hydraulic components Steering components Circuit breakers Fuses Batteries Electronic components Light bulbs Sealed beam lamps 85 WARRANTY LIMITATIONS OF WARRANTIES AND REMEDIES Warranty applies to the product only and does not allow for coverage of personal loss Some items are considered consumable meaning they are considered part of normal maintenance or part of completing an effective repair The following items are excluded from warranty coverage in the event of a warranty claim Filters Lubricants such as oil grease etc Sealants Cosmetic damage repair Hotel fees Meals Towing charges Shipping handling fees Mileage Product pick up delivery Rentals Loss of product use Loss of vacation personal time Batteries unless deemed defective by the POLARIS Warranty Department and the battery supplier This warranty also excludes failures resulting from improper lubrication improper engine timing improper fuel
68. subject to a flame or spark including areas containing gas or propane water heaters and furnaces Do not smoke in the charging area Always follow these precautions when charging the batteries Position the vehicle on a level surface Make sure the charging area is well ventilated Make sure the key is off Open the hood and any door enclosures or zippers Always use a extension cord with a minimum rating of 20 amps Dyes Inspect the charging cord and extension cord for cracks loose con nections and frayed wiring Replace any damaged components promptly 7 Always connect the vehicle charger to the extension cord first then plug the cord into a wall receptacle 8 Make sure the charger uses a dedicated circuit to prevent overload ing If charging multiple vehicles each vehicle should use a dedi cated circuit Tip After the batteries have fully recharged the battery charger will automati cally cycle in and out of the trickle charge mode to maintain the charge 9 When disconnecting the charger always disconnect the extension cord from the wall receptacle first then disconnect the cord from the vehicle s charging cord 72 MAINTENANCE Batteries Battery Access To access the batteries remove the seat See page 36 Remove the stor age tray if equipped NOTICE Before removing the seat to access the batteries make sure any wire or metal items including seat belt latches remain clear of t
69. tantial safety hazard and increase the risk of bodily injury The warranty on your POLARIS RANGER is terminated if any equip ment has been added to the vehicle or if any modifications have been made to the vehicle that increase its speed or power The addition of certain accessories including but not limited to mow ers blades tires sprayers or large racks may change the handling char acteristics of the vehicle Use only POLARIS approved accessories and familiarize yourself with their function and effect on the vehicle 15 SAFETY Operator Safety AWARNING Failure to operate the RANGER properly can result in a collision loss of control accident or overturn which may result in serious injury or death Heed all safety warnings outlined in this section of the owner s manual See the OPERATION section of the owner s manual for proper operating procedures Age Restrictions This vehicle is an ADULT VEHICLE ONLY NEVER operate this vehicle if you are under age 16 and NEVER operate without a valid driver s license No person under the age of 12 may ride asa passenger in this vehicle Any passenger must be able to comfortably reach the floor and hand holds Operating Without Instruction Operating this vehicle without proper instruction increases the risk of an accident The operator must understand how to operate the vehicle properly in different situations and on different types of terrain All operators must read
70. ug Drain Plug Torque Torque Main Gearcase Premium ATV Angle 20 3 oz 14 ft Ibs 14 ft Ibs Transaxle Drive Fluid 600 ml 19 4 Nm 19 4 Nm Front Gearcase Demand Drive Plus 5 1 oz 8 10 ft Ibs 11 ft Ibs Fluid 150 ml 11 13 6 Nm 15 Nm Main Gearcase Transaxle Always check and change the main gearcase oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 56 Maintain the oil level even with the bottom thread of the fill plug hole Refer to the Gearcase Specifications Chart for recommended lubricants capacities and torque specifications See page 82 for the part numbers of POLARIS products Oil Check The fill plug is located at the right rear of the vehicle Position the vehicle on a level surface 2 Remove the fill plug 3 Check the oil level 4 Add the recommended oil as needed 5 Reinstall the fill plug Torque to specification Fill Plug 59 MAINTENANCE Gearcases Main Gearcase Transaxle Oil Change The drain plug is located on the lower right side of the main gearcase near the fill plug Refer to the Gearcase Specifications Chart on page 59 for recommended lubricants capacities and torque specifications 1 Remove the fill plug 2 Placea drain pan under the drain plug 3 Remove the drain plug Allow the oil to drain completely 4 Wipe the magnetic end of the drain plug clean to remove accu mulated metallic
71. until speed is less than 5 MPH 8 km h Engage the AWD before getting into conditions where front wheel drive may be needed If the rear wheels are T spinning release the accelerator before switching to AWD 4 NOTICE Switching to AWD while the rear wheels are spinning may cause severe drive train damage Always switch to AWD while the rear wheels have traction or are at rest Locking the Differential NOTICE Damage to the differential 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 4 gt Locking the differential in slippery or _ low traction conditions helps improve traction Move the rocker switch to the center position 2WD to lock the differential and operate in rear wheel drive Press the bottom of the switch to unlock the differential and allow the rear drive wheels to operate independently This mode of operation is well suited to turf driving or whenever aggressive traction is not required 54 OPERATION Wheel Drive AWD Disengaging AWD Move the AWD switch to the center or bottom position to disengage AWD If the switch is turned off while the front gearcase is moving it will not disengage until the rear wheels regain traction In some situations the front gearcase may remain locked after turning the AWD switch off If this occurs you
72. utions Read this owner s manual Understand all safety warnings precautions and operating procedures before operating the vehicle Keep this manual with the vehicle This vehicle is an ADULT VEHICLE ONLY NEVER operate this vehicle if you are under age 16 and NEVER operate without a valid driver s license No person under the age of 12 may ride as a passenger in this vehicle Any passenger must be able to comfortably reach the floor and hand holds Never permit a guest to operate this vehicle unless the guest has read this manual and all product labels INTRODUCTION Vehicle Identification Numbers Record your vehicle s identification numbers and key number in the spaces provided Remove the spare key and store it in a safe place A key can be duplicated only by ordering a key blank using your key number and mating it with one of your existing keys The key switch must be replaced if all keys are lost Key 4 Number Frame VIN Vehicle Model Number Frame VIN Motor Serial Number on side of motor Key Number SAFETY Safety Labels and Locations Warning labels have been placed on the vehicle for your protection Read and follow the instructions of the labels on the vehicle carefully If any of the labels depicted in this manual differ from the labels on your vehicle always read and follow the instructions of the labels on the vehicle If any label becomes illegible or comes off contact your P
73. vel change yearly if equipped gt Rear gearcase oil 25H Monthly Inspect level change yearly if equipped gt General 50 H 3M Lubricate all fittings pivots lubrication cables etc n Steering 50H 6M Lubricate gt Front Suspension 50H 6M Lubricate gt Rear Suspension 50 H 6M Lubricate gt Wiring 100 H 12M Inspect for wear routing security apply dielectric grease to connectors Subjected to water mud etc n Front wheel 100 H 12M Inspect replace as needed bearings n Brake fluid 200 H 24M Change every two years Toe adjustment Inspect periodically adjust when parts are replaced Headlight aim Adjust as needed gt Perform these procedures more often for vehicles subjected to severe use Have an authorized POLARIS dealer perform these services n 57 MAINTENANCE Lubrication Recommendations Check and lubricate all components at the intervals outlined in the Peri odic Maintenance Chart beginning on page 56 or more often under severe use such as wet or dusty conditions Items not listed in the chart should be lubricated at the general lubrication interval Item Lube Method Brake Fluid DOT 4 See page 63 Main Gearcase Oil Premium ATV Angle Drive See page 59 Transaxle Fluid Front Gearcase Oil Demand Drive Plus Fluid See page 61 58 MAINTENANCE Gearcases Gearcase Specification Chart Gearcase Lubricant Capacity Fill Pl
74. verse Move the drive mode switch to the desired setting See page 28 Release the park brake Check your surroundings and determine your path of travel 39 OPERATION Driving Procedure 10 Keeping both hands on the steering wheel release the brake pedal and gradually push the accelerator toward the floor to begin driving 11 Drive slowly Practice maneuvering and using the accelerator and brakes on level surfaces 12 Do not carry a passenger until you have at least two hours of driving experience with this vehicle Never carry more than one passenger in this vehicle Never allow a passenger to ride in the cargo box 13 To stop the vehicle release the accelerator pedal completely and brake to a complete stop Tip Always come to a complete stop before reversing direction 14 Set the park brake 15 Place the direction selector in neutral 16 Turn the key off WARNING A rolling vehicle can cause serious injury Always set the park brake when leaving the vehicle unattended 40 OPERATION Driving On Slippery Surfaces AWARNING Skidding or sliding can cause loss of control or overturn if tires regain traction unexpectedly When operating on slippery surfaces such as ice or loose gravel reduce speed and use extra caution to reduce the chance of skidding or sliding out of control Do not operate on excessively slippery surfaces Whenever riding on slippery surfaces such as wet trails or loose gravel or during fre
75. ware fault Charge Status Indicator Troubleshooting Guide The code definitions provided are for informational purposes only Please see your POLARIS dealer for diagnosis and repair Code Definition Solution Blinks 1 Battery high voltage Check battery size and condition 2 Battery low voltage reset charger interrupt AC power for 15 seconds 3 Charge time out battery pack Check connections operate not reaching required voltage charger at lower ambient charger output reduced due to temperature high temperatures 4 Battery could not be trickle Check battery for shorted or charged to minimum voltage damaged cells 5 Charger shut down due to Ensure sufficient cooling air flow overheating open the hood and reset the charger interrupt AC power for 15 seconds 6 Charger internal fault Reset charger interrupt AC power for 15 seconds return to qualified service provider if fault persists 31 FEATURES AND CONTROLS Batteries This vehicle is equipped with eight 12 volt batteries that supply the power needed to operate the vehicle The batteries are located under the seat See page 73 for battery access instructions Always observe all battery safety warnings and safe handling proce dures as outlined on vehicle safety labels and in this manual Refer to the battery maintenance section beginning on page 71 Battery Handling Precautions Always make sure that all electrical accesso
76. ys follow all safe operating practices out lined in this manual to avoid vehicle rollover WARNING Vehicle rollover could cause severe injury or death Always avoid operating in a manner that could result in vehicle rollover Seat Removal Pull up on the front of the seat to disengage the front latches Slide the seat forward and lift it away from the seat base To reinstall the seat align the rear seat tabs with the slots on the rear of the seat base Slide the seat fully rearward then push down firmly along the front edge of the seat to secure the latches 36 FEATURES AND CONTROLS Seat Belts This POLARIS vehicle is equipped with three point lap and diagonal seat belts for the operator and passenger Always make sure the seat belts are secured for all rid Latch Plate ers before operating The center of the seat is NOT equipped with a seat belt Never allow a passenger to ride between the operator and passen ger seats 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 To wear the seat belt properly follow this procedure 1 For 3 point belts pull the seat belt latch downward and across your chest toward the buckle at the inner edge of the seat The belt should fit snugly across your hips and diagonally across your chest Make sure the belt is not twisted 2 Push the

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