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1. Nut Type Location Nut Torque Lug Nut Front and Rear 30 ft los 41 Nm PLUS 1 4 TURN Aluminum Wheels Nut and Washer Front and Rear 35 ft lbs 47 Nm Steel Wheels O Spindle Nut Front 70 ft Ibs 95 Nm Hub Retaining Nuts Center and Rear 110 ft Ibs 150 Nm 75 MAINTENANCE Tires Wheel Removal 1 Apply the brakes 2 Place the transmission in PARK 3 Stop the engine 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 Place the transmission in PARK 2 Place the wheel in the correct position on the wheel hub Be sure the valve stem is toward the outside and rotation arrows on the tire point toward forward rotation WARNING Improperly installed wheels can adversely affect tire wear and vehicle handling which can result in serious injury or death Always ensure that all nuts are torqued to specification Do not service axle nuts that have a cotter pin installed See your POLARIS dealer 3 Attach the wheel nuts and washers and fin ger tighten d 4 Carefully lower the vehicle to the ground 5 Torque the wheel nuts to specification See page 75 Power Steering Unit If your model is equipped with power steering frequently clean the areas around and on the power steering unit to allow proper cooling Clean these areas thorough
2. Use the following chart to record periodic maintenance DATE MILES KM OR HOURS TECHNICIAN SERVICE PERFORMED COMMENTS 100 A Accessory Outlets ree e eh em 22 Adjustment Shock Spring eren knees 74 Throttle Freeplay 72 Ar Filter i orecchie RR Here 70 All Wheel Drive ere RR m ERR 46 All Wheel Drive Switch 0 23 Auxiliary Outlets 0 002 eee 22 Axle Nut Torque cen me reece ess 75 B Battery es sie ek RR ER e EUR ERES 79 82 Charging Conventional 82 Charging Sealed 82 Fluid Conventional 79 Installation vem Rec 81 Removal o eser eret tias 80 DIOFABe ceo ee eset aces Woe eae 81 Warnings 2 2 leis eee 79 Belt Burning 2i cascavdwiavidewdeadeades 91 Belt Lhe eere e EE aee bated acne stares 43 Belt Replacement 000 000 67 Belt Weak sasae ie dE REGE UR redes 91 BOOS sissies ei eke ER ER ERR Rmus 9 Brake Fluid ed epe deo 73 Brake Inspection e coercere eme 73 Brake Lights icc sec e RE ET E RERO 78 Brake Pedal Sip bald Adana chars 24 jc e Em 73 Biagi stetit rine iiio S EES 35 Break In Period 5 2 dane be dk Dea eee eae 33 C Cab Frame ROPS 2 lel bee 27 Cab Nels PRESS 26 CATE O ou aod Sake EEE E S EP E 42 Cargo Box Dumping 0 44 Chart Periodic Maintenance 57 59 Check E
3. 68 Dumping the Cargo Box 0 44 E Electronic Power Steering 24 Emissions Limited Warranty 98 99 Engaping AWD 22 cecscatcsbegaciestasdebeaactauatva doe 46 Engine Break In 5 5 space vey es aoa cae os 33 Engine Fogging cess acca ater bee Sa ae odes 86 Engine Idle Speed 2 0 eee eee 72 Engine Oll 55 isse bre Reps 60 61 Engine Starting 02 eee eee ees 35 Engine Stopping 1 2 0 2 22 e eee eee eee 35 BPS zur uere oae ane bet diede d ades 24 Equipment Modifications 15 Error Codes Engine lees 32 Exhaust Cleaning s sees eese 71 Exhaust Emission Control System 56 Exhaust System Warning 71 Eye Protections 2e re RO RR eve REI 9 101 INDEX F Filter Systems 4 cas sectastancdads oesae ed 70 Filter Apu aci cce crue a ete 70 Fluid Battery Fluid 79 Fluid Change Engine Oil secca 61 Front Gearc se ee Ren 63 Main Gearcase 00005 62 Transmission 0 0000 62 Fluid Level Coolant Overflow Bottle 66 Coolant Radiator 66 Engine Oil usce Lene tnd 60 Front Gearcase 04 63 Main Gearcase 0 005 62 TRANSMISSION ius n catre 62 Fluid Levels During Storage 86 Fluid Recommendation Coolant xs tp Ebr DRE 65 Engine Oll esser etes 60 I ICLIIO M RM 62 Fluid Brake 4 sce dna cede
4. Cleaning and Storage 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 Avoid the use of automotive products some of which can scratch the finish of your vehi cle 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 Chrome Wheel Care if equipped Proper maintenance will protect chrome wheels from corrosion preserve wheel life and ensure a like new appearance for many years Chrome wheels exposed to road salt or salt in the air in coastal areas are more susceptible to corrosion if not properly cleaned Clean chrome wheels more often if they re exposed to salt or other corrosive elements 1 Wash chrome wheels frequently Use a mild detergent 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 polished 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 r
5. PEDETTTPETPUUIPSUEUC 8 Features and Controls 000c cece eee eee eee 21 Operation cccccceactkiseapesioosteeceteseseeeuuss 33 Winch Guide 254 ods ccdee Se Soest eeeweNcaeeededesees 47 Emission Control Systems 0000 cece ee ee eee 56 Maintenance senes oe RUEE Shee sees ae sere eieie ee eee 57 Specifications ooh ebvereseaphesdechetecess caches aa 88 POLARIS Producis lt 4 62655ss0c055e e20eee6eeeews 90 WOUDIESHOOUNG 5 s cane x tee Rice Geen ee deee cena ees 91 WarraNty iade RR Roe UR RR eee E ee ee ieee eee eeeec en 94 Maintenance LOG cisco REFERRE UR ees eee aeee Ree SS 100 Index correctus E RRERISOPREEREEEEZENSEEQCSRPIMSRREERER 101 INTRODUCTION The RANGER is an off road vehicle Familiarize yourself with all laws and regulations con cerning the operation of this vehicle in your area The following signal words and symbols appear throughout this manual and on your vehicle Your safety is involved when these words and symbols are used Become familiar with their meanings before reading the manual A The safety alert symbol indicates a potential personal injury hazard DANGER A DANGER indicates a hazardous situation that if not avoided will result in death or serious injury WARNING A WARNING indicates a hazardous situation that if not avoided could result in death or serious injury CAUTION A CAUTION indicates a hazardous situation that if not avoided could result in minor or moderate injury
6. _ LN RANGER 800 EFI Midsize RANGER 800 EPS Midsize Owner s Manual for Maintenance and Safety 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 A WARNING The engine exhaust from this product contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm WELCOME Thank you for purchasing a POLARIS vehicle and welcome to our world wide family of POLARIS enthusiasts Be sure to visit us online at www polaris com for the latest news new product introductions upcoming events career opportunities and more Here at POLARIS we proudly produce an exciting line of utility and recreational products Snowmobiles e All terrain vehicles ATVs Low emission vehicles LEVs RANGERQ utility vehicles RZR sport vehicles VICTORY motorcycles e GEMQ electric vehicles We believe POLARIS sets a standard of excellence for all utility and recreational vehicles manufactured in the world today Many years of experience have gone into the engineering design and development of your POLARIS vehicle making it the finest machine we ve ever produced For safe and enjoyable operation of your vehicle be sure to follow the instructions and rec ommendations in this owner s manual Your m
7. Secure cab nets and keep hands and feet inside vehicle at all times Wear a helmet eye protection gloves long sleeve shirt long pants and over the ankle boots Reduce speed and use extra caution when carrying passengers Avoid sharp turns or turns while applying heavy throttle Operate slowly in reverse avoid sharp turns or sudden braking Make sure passengers read and understand all safety labels ALL RIDERS MUST WEAR AN APPROVED HELMET AND PROTECTIVE GEAR ALL RIDERS MUST WEAR SEAT BELTS NEVER USE ON PUBLIC ROADS NEVER USE WITH DRUGS OR ALCOHOL READ OWNER S MANUAL FOLLOW ALL INSTRUCTIONS AND WARNINGS For your nearest Polaris dealer call 1 800 POLARIS Pe sLARiIS or visit www polaris com Polaris Sales Inc 2100 Hwy 55 Medina MN 55340 Phone 1 888 704 5290 Part No 9924303 Rev 01 Printed in USA
8. driving or on a passenger hand hold Never permit a guest to operate this vehicle unless the guest has read this manual and all product labels Always use the cab nets or doors while riding in this vehicle Always keep hands feet and all other body parts inside the vehicle at all times Always wear a helmet eye protection gloves long sleeve shirt long pants and over the ankle boots Never use this vehicle with drugs or alcohol as these conditions impair judgment and reduce operator reaction time INTRODUCTION Vehicle Identification Numbers Record your vehicle s identification numbers and key number in the spaces provided Remove the spare key and store it in a safe place An ignition key can be duplicated only by ordering a POLARIS key blank using your key number and mating it with one of your existing keys The ignition switch must be replaced if all keys are lost xp eo Key Number Vehicle Model Number Frame VIN Engine Serial Number Key Number INTRODUCTION European Vibration and Noise The driver perceived noise and hand arm and whole body vibration levels of this machinery is measured per prEN 15997 The operating conditions of the machinery during testing The vehicles were in like new condition The environment was controlled as indicated by the test procedure s The uncertainty of vibration exposure measurement is dependent on many factors including Instrument a
9. 00 64 Specifications 2 0 0 cee eee eee 88 89 Specifications Gearcase 0 00 62 Speed Towing cene i eas pese anne ee 43 Speedometer 12s cere era Dese ew qs 28 S Starting the Engine lese esses 35 Steering Wheel Inspection 74 Stopping the Engine 0 35 LOLA SS 1 Sod bya hie oe EEEE deg 83 86 Storage ATCA sss er ea T ERES EY 86 Storage Tips iov er REIR EXT 85 Storage Battery 4 seek etes 81 Storage COVeIS e emere e ae Yon quede es 86 Storage Removal from 0 87 Switches AWD Switch isses 23 Differential Lock Switch 23 Ignition Switch 23 Light Switch coe mds wea 23 T Tachometer ssec rte duds dom d Uenicn 31 Throttle Freeplay Adjustment T2 Throttle Freeplay Inspection 72 Throttle Pedal oero ecre pter ep RR age ce 24 Throttle System se sio ieee eh nn 72 INS sy CHEF NE UXOR OP DRE as 75 76 Nut Torque cec mm RR RR 75 Tread Depth wrs oer RR RR 75 Wheel Installation 76 Wheel Removal 76 Torque Spark Plug 0000 64 Towing Loads oe RURPD RBS quer enn 43 Towing Speed uet ee eh emm a0 43 Trailer Hitch Bracket 27 Transmissi ai ccs eee pe cb ERE CUT Bah URS 62 Transmission Operation 67 68 Transmission System 000005 68 Transmission Warning 67 6
10. 1 Remove the seat 2 Remove the clutch cover screws and open the clutch cover Remove all debris wrapped in and around the PVT system w Remove all debris from the entire clutch air duct passage B Check for signs of damage to seals on the transmission and engine See your dealer promptly for service if any seals appear to be damaged Tip Belt slip is responsible for creating excessive heat that destroys belts wears clutch components and causes outer clutch covers to fail Switch to low range while operating at slower speeds to extend the life of the PVT components belt cover etc 67 MAINTENANCE POLARIS Variable Transmission PVT System PVT Drying There may be some instances when water is ingested into the PVT system Use the following instructions to dry it out before operating Position the vehicle on a level surface Remove the drain plug Allow the water to drain completely Reinstall the drain plug Place the transmission in PARK Start the engine WP Wd PE Apply varying throttle for 10 15 seconds to expel the moisture and air dry the belt and clutches Do not hold the throttle wide open for more than 10 seconds 6 Allow the engine RPM to settle to idle speed Apply the brakes Shift the transmission to the lowest available range Test for belt slippage If the belt slips repeat the process 8 Take the vehicle to your dealer for service as soon as possible 68 MAINTENANCE Vehicle Immersion N
11. 5 full turns of winch cable are wrapped around the winch drum at all times The friction provided by this wrapped cable allows the drum to pull on the winch cable and move the load Always apply your vehicle s park brake and or park mechanism to hold the vehicle in place during winching Use wheel chocks if needed Always align the vehicle and winch with the load directly in front of the vehicle as much as possible Avoid winching with the winch cable at an angle to the winching vehicle s centerline whenever possible If winching at an angle is unavoidable follow these precautions A Lookat the winch drum occasionally Never let the winch cable stack or accumulate at one end of the winch drum Too much winch cable at one end of the winch drum can damage the winch and the winch cable B If stacking occurs stop winching Follow step 15 on page 52 to feed and rewind the cable evenly before continuing the winch operation 47 WINCH GUIDE Winch Safety Precautions 13 14 15 16 17 18 19 20 21 22 23 24 25 48 Never winch up or down at sharp angles This can destabilize the winching vehicle and possibly cause it to move without warning Never attempt to winch loads that weigh more than the winch s rated capacity The winch motor may become hot during winch use If you winch for more than 45 seconds or if the winch stalls during operation stop winching and permit the winch to cool down fo
12. NOTICE A NOTICE indicates a situation that could result in property damage The Prohibition Safety Sign indicates an action NOT to take in order to avoid a hazard O 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 Your POLARIS RANGER is not a toy and can be hazardous to operate This vehicle handles differently than other vehicles such as cars trucks or other off road vehicles A collision or rollover can occur quickly even during routine maneuvers like turning or driving on hills or over obstacles if you fail to take proper precautions Read this owner s manual and review the safety DVD that came with your vehicle A free extra copy of the DVD can be obtained by contacting your local POLARIS dealer Understand all safety warnings precautions and operating procedures before operating the vehicle Keep this manual with the vehicle Review the safety DVD and take the free online Recreational Off Highway Vehicle Association ROHVA training course at www rohva org This vehicle is an ADULT VEHICLE ONLY You MUST be at least age 16 and have a valid driver s license to operate this vehicle No person under the age of 12 may ride as a passenger in this vehicle All riders must be able to sit with backs against the seat both feet flat on the floor and both hands on the steering wheel if
13. OPERATION Driving with a Passenger 1 2 9 a epe Perform the pre ride inspection See page 34 Make sure all passengers are at least 12 years of age and tall enough to comfortably and safely sit in a passenger seat with the seat belt secured put both feet on the floor and grasp the hand hold Make sure all passengers are wearing helmet eye protection gloves long sleeve shirt long pants and over the ankle boots Make sure all passengers secure their seat belt Make sure all cab nets or doors are properly secured Do not carry more than the recommended number of passengers for your vehicle See page 11 Allow a passenger to ride only in a passenger seat Slow down Always travel at a speed appropriate for your skills your passengers skills and operating conditions Avoid unexpected or aggressive maneuvers that could cause discomfort or injury to a passenger Vehicle handling may change with a passenger and or cargo on board Allow more time and distance for braking 10 Always follow all operating guidelines as outlined on safety labels and in this manual Driving Over Obstacles Follow these precautions when operating over obstacles 1 2 Always check for obstacles before operating in a new area Look ahead and learn to read the ter rain Be constantly alert for hazards such as logs rocks and low hanging branches Travel slowly and use extra caution when operating on unfamiliar ter
14. Position the vehicle on a level surface 2 Place the transmission in PARK 3 Start the engine Allow it to idle for two to three minutes Stop the engine 4 Clean the area around the drain plug 5 Place a drain pan beneath the engine crankcase CAUTION Hot oil can cause burns to skin Do not allow hot oil to contact skin 6 Remove the drain plug Allow the oil to drain completely 7 Install a new sealing washer on the drain plug The sealing surfaces on drain plug and crankcase should be clean and free of burrs nicks or scratches 8 Reinstall the drain plug Torque to 20 ft lbs 27 Nm Remove the seat 10 Place shop towels beneath the oil filter Using an oil filter wrench turn the filter counter clockwise to remove it 11 Using a clean dry cloth clean the filter sealing surface on the crankcase 12 Lubricate the o ring on the new filter with a film of fresh engine oil Check to make sure the o ring is in good condition 13 Install the new filter and turn by hand until the filter gasket contacts the sealing surface then turn and additional 1 2 turn 14 Remove the dipstick and fill the sump with two quarts 1 9 1 of recommended oil 15 Place the transmission in PARK 16 Start the engine Allow it to idle for one to two minutes 17 Stop the engine Inspect for leaks 18 Check the oil level on the dipstick and add oil as necessary to bring the level to the upper mark on the dipstick 19 Reinstall the se
15. Tip To exit the set up mode at any time wait 10 seconds The display automatically exits and returns to the odometer display Standard Display Metric Display Distance Miles Kilometers Fuel U S Gallons Liters Imperial Gallons Temperature Fahrenheit Celsius Time 12 Hour Clock 24 Hour Clock 1 Turn the key to the OFF position 2 Press and hold the MODE button while turning the key to the ON position 3 When the display flashes the distance setting tap the MODE button to advance to the desired setting 4 Press and hold the MODE button to save the setting and advance to the next display option 5 Repeat the procedure to change remaining display settings Clock Mode Tip The clock must be reset any time the battery has been disconnected or discharged 1 Turn the key to the ON position Use the MODE button to toggle to the odometer dis play Press and hold the MODE button until the hour segment flashes Release the button With the segment flashing tap the MODE button to advance to the desired setting Press and hold the MODE button until the next segment flashes Release the button Repeat steps 3 4 twice to set the 10 minute and 1 minute segments After completing the 1 minute segment step 4 will save the new settings and exit the clock mode 6 Turn the key to the OFF position wae wn 30 FEATURES AND CONTROLS Instrument Cluster Rider Information Center Odometer Mode The odometer re
16. and latches for tightness wear and damage before each use of the vehicle Use the strap adjusters to tighten any loose straps Promptly replace worn or dam aged cab nets and latches with new cab nets and latches Please see your authorized POLARIS dealer Securing a Net 1 After entering the vehicle insert the lower net rod into the net mount on the floor Make sure the ball at the end of the rod is properly secured in the slot at the base of the mount 2 Connect the latch at the top edge of the net to the receiver latch mounted on the front frame Opening a Net 1 To exit the vehicle release the top front latch 2 Rotate the net rearward and slide the lower net rod out of the mount to remove it 3 Allow the net to hang freely outside the vehicle while dismounting 26 FEATURES AND CONTROLS Rollover Protective Structure ROPS The Rollover Protective Structure ROPS on this vehicle meets OSHA 1928 53 rollover performance requirements Always have your authorized POLARIS dealer thoroughly inspect the ROPS if it ever becomes damaged in any way No device can assure occupant protection in the event of a rollover Always follow all safe operating practices outlined 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 Trailer Hitch Bracket This vehicle is equipped with a receiver hitch bracket for a t
17. as recommended in the Periodic Maintenance Chart beginning on page 57 Front and rear gearcase fluid if equipped Transmission fluid Brake fluid change every two years and any time the fluid looks dark or contaminated Coolant test strength fill Fog the Engine 1 Treat the fuel system with POLARIS Carbon Clean Follow the instructions on the con tainer Start the engine Allow it to idle for several minutes so the Carbon Clean reaches the injectors Stop the engine 2 Remove the spark plugs and add 2 3 tablespoons of engine oil To access the plug holes use a section of clear 1 4 hose and a small plastic squeeze bottle filled with the pre measured amount of oil Do this carefully If you miss the plug holes oil will drain from the spark plug cavities into the hole at the front of the cylinder head and appear to be an oil leak 3 Reinstall the spark plugs Torque to specification See page 64 4 Apply dielectric grease to the inside of each spark plug cap and reinstall the caps onto the plugs 5 Turn the engine over several times Oil will be forced in and around the piston rings and ring lands coating the cylinder with a protective film of fresh oil 6 If POLARIS fuel system additive is not used fuel tank fuel lines and injectors should be completely drained of gasoline Storage Area Covers Be sure the storage area is well ventilated Cover the vehicle with a genuine POLARIS cover Do not use plastic or co
18. cable and move the load 50 WINCH GUIDE Winch Operation 8 10 11 12 Read and adhere to the following information for winch damping to ensure safe winch use A In order to absorb energy that could be released by a winch cable failure always place a damper on the winch cable A damper can be a heavy jacket tarp or other soft dense object A damper can absorb much of the energy released if a winch cable breaks when winching Even a tree limb can help as a damper if no other items are available to you B Lay the damper on top of the mid point of the winch cable length that is spooled out C On a long pull it may be necessary to stop winching so that the damper can be repositioned to the new mid point of the winch cable Always release the tension on the winch cable before repositioning the damper D Avoid being directly in line with the winch cable whenever possible Also never permit others to stand near or in line with the winch cable during winch operation Never hook the winch cable back onto itself This will damage the winch cable and may result in winch cable failure Never use straps chains or other rigging items that are damaged or worn The ONLY time a winch equipped vehicle should be moving when using the winch is when that vehicle itself is stuck The winch equipped vehicle should NEVER be in motion to shock load the winch cable in an attempt to move a second stuck vehicle See the Shock Lo
19. component identification Always use the cab nets or doors Not all models come with all features Refer to the specifications section beginning on page 88 ROPS Cab Console PELARIS i SER Nef M Cab Net Headlights Tailgate Tailgate H Latch H eleases PELARE ee Radiator Front Bumper Brush Guard ane Muffler J Spark Arrester OO pe CV Boot Rear Caliper 21 FEATURES AND CONTROLS Console Auxiliary Outlet Instrument Mods Storage The 12 volt receptacle has spade Cluster Button Compartment connections on the back that may be used to power an auxiliary light or other optional accessories or lights The connections are behind the console under the hood Mode Button The yellow button located in the instrument cluster is used to toggle through mode options available See pages 28 32 Gear Selector H High Gear Storage L Low Gear Gear Selector Tray 12V Auxiliary Cup N Neutral Shifter Outlet Holder R Reverse P Park Low gear is the primary driving range for the RANGER High gear is intended for use on hard packed surfaces with
20. flammable See page 18 for fuel safety warnings Always remove the ignition key when the vehicle is not in use to prevent unauthorized use by someone under the age of 16 or without a driver s license and proper training or acci dental starting FOR MORE INFORMATION ABOUT SAFETY call POLARIS at 1 800 342 3764 Equipment Modifications Do not install any non POLARIS approved accessory or modify the vehicle for the purpose of increasing speed or power Any modifications or installation of non POLARIS approved accessories could create a substantial safety hazard and increase the risk of bodily injury The warranty on your POLARIS vehicle will be terminated if any non POLARIS approved equipment and or modifications have been added to the vehicle that increase speed or power The addition of certain accessories including but not limited to mowers blades tires sprayers or large racks may change the handling characteristics of the vehicle Use only POLARIS approved accessories and familiarize yourself with their function and effect on the vehicle SAFETY Operator Safety AWARNING Failure to operate the RANGER properly can result in a collision loss of control accident or rollover which may result in serious injury or death Heed all safety warnings outlined in this section of the owner s manual See the OPERATION section of the owner s manual for proper operating procedures Age Restrictions This vehicle is an ADULT VEHI
21. gal 3 8 Grease Specialized Lubricants 2871312 Grease Gun Kit All Season Grease 2871322 All Season Grease 3 0z 89 ml cartridge 2871423 All Season Grease 14 0z 414 ml cartridge 2876160 ATV Angle Drive Fluid qt 95 I 2872276 ATV Angle Drive Fluid 2 5 gal 9 5 I 2871460 Premium Starter Grease 2871515 U Joint Grease 3 0z 89 ml cartridge 2871551 U Joint Grease 14 0z 414 ml cartridge 2871329 Dielectric Grease Nyogel Additives Miscellaneous 2871326 Carbon Clean 2870652 Fuel Stabilizer 2872189 DOT 4 Brake Fluid 2871956 Loctite 565 Thread Sealant 90 TROUBLESHOOTING Drive Belt Wear Burn Possible Cause Driving onto a pickup or tall trailer in high range Solution Use low range during loading Starting out going up a steep incline Use low range See warnings on page 39 Driving at low RPM or ground speed 3 7 MPH Drive at a higher speed or use low range more frequently See page 67 Insufficient warm up at low ambient temperatures Warm the engine at least 5 minutes With the transmission in neutral advance the throttle to about 1 8 throttle in short bursts 5 to 7 times The belt will become more flexible and prevent belt burning Slow easy clutch engagement Use the throttle quickly and effectively Towing pushing at low RPM low ground speed Use low range only Utility use plowing Use low range only Stuck in mud or snow Shift the tran
22. hotels meals shipping or handling fees product pick up or delivery replacement rentals loss of product use loss of profits or loss of vacation or personal time THE EXCLUSIVE REMEDY FOR BREACH OF THIS WARRANTY SHALL BE AT POLARIS OPTION REPAIR OR REPLACEMENT OF ANY DEFECTIVE MATERIALS 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 WARRANTY OR ANY OTHER CONTRACT NEGLIGENCE OR OTHER TORT OR OTHERWISE THIS EXCLUSION OF CONSEQUENTAL INCIDENTAL AND SPECIAL DAMAGES IS INDEPENDENT FROM AND SHALL SURVIVE ANY FINDING THAT THE EXCLUSIVE REMEDY FAILED OF ITS ESSENTIAL PURPOSE THE IMPLIED WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE IS EXCLUDED FROM THIS LIMITED WARRANTY ALL OTHER IMPLIED WARRANTIES INCLUDING BUT NOT LIMITED TO THE IMPLIED WARRANTY OF MERCHANTABILITY ARE LIMITED IN DURATION TO THE ABOVE SIX MONTH WARRANTY PERIOD POLARIS DISCLAIMS ALL EXPRESS WARRANTIES NOT STATED IN THIS WARRANTY SOME STATES DO NOT PERMIT THE EXCLUSION OR LIMITATION OF INCIDENTAL OR CONSEQUENTIAL DAMAGES OR ALLOW LIMITATIONS ON THE DURATION OF IMPLIED WARRANTIES SO THE ABOVE LIMITATIONS MAY NOT APPLY TO YOU IF INCONSISTENT WITH CONTROLLING STATE LAW 95 WARRANTY HOW TO OBTAIN WARRANTY SERVICE If your ve
23. injury Always perform the maintenance procedures as outlined in the Periodic Maintenance Chart Oil Recommendations POLARIS recommends the use of POLARIS PS 4 5W 50 4 Cycle Oil or a similar oil See page 90 for the part numbers of POLARIS products NOTICE Mixing brands or using a non recommended oil may cause serious engine damage Always use the recommended oil Never substitute or mix oil brands Oil Check The oil tank is located under the seat 1 Position the vehicle on a level surface Place the trans mission in PARK 2 Remove the seat See page 24 Dipstick 3 Lift the lever lock to remove the dipstick Wipe it dry with a clean cloth 4 Reinstall the dipstick completely but do not lock it The dipstick must be screwed completely in to keep the angle and depth of the stick consistent 5 Remove the dipstick and check the oil level Maintain the oil level in the safe range Do not overfill Tip Due to the dipstick entry angle into the crankcase the oil level will read higher on the bottom side of the dipstick Always read the level on the upper surface of the dipstick 6 After reinstalling the dipstick be sure to seat the lever lock 7 Reinstall the seat Check Level on Top Side 60 MAINTENANCE Engine Oil Oil and Filter Change Always change the oil and filter at the intervals outlined in the Periodic Maintenance Chart beginning on page 57 Always change the oil filter whenever changing oil 1
24. instructions return the vehicle to your dealer for service 1 Stop the vehicle 2 Operate in reverse for at least 10 feet 3 Stop completely 4 Shift into low gear and drive forward 46 WINCH GUIDE These safety warnings and instructions apply if your vehicle came equipped with a winch or if you choose to add an accessory winch to your vehicle AWARNING Improper winch use can result in SEVERE INJURY or DEATH Always follow all winch instructions and warnings in this manual Your winch may have a cable made of either wire rope or specially designed synthetic rope The term winch cable will be used for either unless noted otherwise Winch Safety Precautions APP WNP o 10 11 12 Read all sections of this manual Never use alcohol or drugs before or while operating the winch Never allow children under 16 years of age to operate the winch Always wear eye protection and heavy gloves when operating the winch Always keep body hair clothing and jewelry clear of the winch cable fairlead and hook when operating winch Never attempt to jerk a load attached to the winch with a moving vehicle See the Shock Loading section on page 54 Always keep the area around the vehicle winch winch cable and load clear of people especially children and distractions while operating the winch Always turn the vehicle ignition power OFF when it and the winch are not being used Always be sure that at least five
25. light loads Whenever the vehicle is left unattended always place the transmission in PARK To change gears stop the vehicle and with the engine idling move the lever to the desired gear Do not attempt to shift gears with engine speed above idle or while the vehicle is mov ing Tip Maintaining shift linkage adjustment is important to assure proper transmission function See your dealer if you experience any shifting problems NOTICE Shifting gears with the engine speed above idle or while the vehicle is moving could cause transmission damage Always shift when the vehicle is stationary and the engine is at idle Using Low Range Always shift into low gear for any of the following conditions Operating in rough terrain or over obstacles Loading the vehicle onto a trailer Towing heavy loads 22 FEATURES AND CONTROLS Switches START Turr kay io APER x a HI AWD Differential Switch Ignition Switch Light Switch Ignition Switch Light Switch The ignition switch is a four position key operated switch The key can be removed from the switch when it is in the OFF position OFF The engine is off All electrical circuits are off including 12V LIGHTS ON Lights are on Electrical circuits are on Electrical equipment can be used LIGHTS OFF Lights are off Electrical circuits are on Electrical equipment can be used START Turn the key to the START position to engage the electric starter Tur
26. 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 59 for fluid recommendations 1 2 Position the vehicle on a level surface 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 If the fluid level is lower than the upper level line add brake fluid to the upper MAX line Apply the brake forcefully for a few seconds and check for fluid leakage around the fittings Brake Inspection 1 2 Check the brake system for fluid leaks Check the brake pedal for excessive travel or a spongy feel Check the friction pads for wear damage and looseness Check brake discs for signs of cracks excessive corrosion warping or other damage Clean any grease using an approved brake cleaner or alcohol WARNING Do not apply WD 40 or any petroleum product to brake discs These types of products are flammable and may also reduce the friction between the brake pad and caliper Inspect the brake disc spline and pad wear surface for excessive wear Change pads when 2 worn to 3 64 1 mm MAINTENANCE Maximum Minimu
27. trailer to the trailer hitch bracket only Do not attach a trailer to any other loca tion or you may lose control of the vehicle 7 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 1250 Ibs 567 kg 850 Ibs 386 kg 150 Ibs 68 1 kg 10 MPH 16 km h 800 EFI EPS Midsize Belt Life To extend belt life use the lowest gear possible when hauling or towing heavy cargo 43 OPERATION Dumping the Cargo Box 1 Select a level site to dump the cargo box Do not attempt to dump or unload the vehicle while parked on an incline 2 Apply the brakes 3 Place the transmission in PARK Dismount the vehicle 4 Ensure that the cargo is positioned evenly or toward the front of the cargo box 5 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 6 Stand clear and pull up on the cargo box release lever Lift the front of the cargo box to dump the cargo 7 Lower the cargo box and push down securely to latch 8 Close the tailgate and secure both tailgate latches Release Lever WARNING Operati
28. with ethanol content greater than 10 percent such as E 85 fuel Seat Removal Pull up on the front of the seat and slide it toward the front of the vehicle Install the seat by sliding the tabs into the rear of the seat base Push down firmly on the front of the seat until the pins are fully seated into the grommets Electronic Power Steering EPS Electronic power steering if equipped engages when the ignition key is turned to the ON position EPS remains engaged whether the vehicle is moving or idle To conserve battery power the EPS will shut down 5 minutes after the engine is stopped if the key remains in the ON position The EPS warning indicator will illuminate to indicate the EPS has shut down Turn the key off and on to reset the unit See page 28 for EPS warning indicator information 24 FEATURES AND CONTROLS Seat Belts This POLARIS vehicle is equipped with three point lap and diagonal seat belts on all external seats Always make sure the seat belts are secured for all riders before operating 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 diago nally across your chest
29. 8 Transmission Drying 000 68 Transporting the Vehicle suus 87 V Vehicle Identification Numbers 6 Vehicle Immersion 000005 69 Vehicle Transport 1s coe ns 87 W Warning Symbols 0 000 000 ee 4 Warning Transmission Modification 67 68 Washing the Vehicle 0 83 Wheel Installation 00 0004 76 Wheel Nut Torque isses esr RERREPRES 75 Wheel Removal sis eee scettr etr es 76 Winch Cable Cate e eeieti ede gott 53 Winch Maintenance and Service Safety 55 Winch Operation 004 49 52 Winch Safety Precautions 47 48 Winch Shock Loading suuss 54 103 PMS 419 AWARNING Improper vehicle use can result in SEVERE INJURY or DEATH NEVER Operate If you are under age 16 and without a valid driver s license Without first viewing safety video and taking a ROHVA training course at www rohva org On excessively steep hills On public roads unless designated for off road use With a passenger who is not seated in a passenger seat or with passengers under age 12 or who cannot 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 can cause severe injury or death
30. AXIMUM WEIGHT CAPACITY INCLUDES WEIGHT OF 1000 Ibs 1000 Ibs 1250 Ibs 1000 Ibs OPERATOR PASSENGER 454 kg 454 kg 547 kg 454 kg CARGO AND ACCESSORIES Read Operation amp Maintenance Manual for more detailed loading information 7179550 SAFETY Safety Labels and Locations Clutch Cover Warning WARNING Moving parts hazard under belt clutch guard To prevent serious injury do not operate vehicle with guard removed Do not modify engine or clutch Doing so can cause part failure pos sible imbalance and excessive engine RPM which can result in seri ous injury or death 7175488 Shift Caution CAUTION To avoid transmission damage shift only when vehicle is stationary and at idle APPLY BRAKE TO START When this vehicle is not in operation or unattended place shift in the park position 7176170 12 Clutch Cover Warning Shift Caution SAFETY Operator Safety Serious injury or death can result if you do not follow these instructions and procedures which are outlined in further detail within your owner s manual Read this entire manual and all labels carefully Follow the operating procedures described Never allow anyone under the age of 16 to operate this vehicle and never allow anyone without a valid driver s license to operate this vehicle Do not carry a passenger until you have at least two hours of driving experience with this vehicle No person under the age
31. Allow the engine to warm up for several minutes before operating the vehicle Stopping the Engine 1 Release the throttle pedal completely and brake to a complete stop 2 Turn the engine off 3 Place the transmission in PARK WARNING A rolling vehicle can cause serious injury Always place the transmission in PARK when stopping the engine Braking 1 Release the throttle pedal completely 2 Press on the brake pedal evenly and firmly 3 Practice starting and stopping using the brakes until you re familiar with the controls Tip When the throttle pedal is released completely and the engine speed drops near an idle the vehi cle has no engine braking 35 OPERATION Driving Procedure 1 Wear a helmet eye protection gloves long sleeve shirt long pants and over the ankle boots 2 Sit in the driver s seat and fas ten the seat belt 3 Start the engine and allow it to warm up 4 Always use the cab nets or doors while riding in this vehicle 5 Apply the service brakes and shift the transmission into gear 6 Check your surroundings and determine your path of travel 7 Keeping both hands on the steering wheel slowly release the brakes and depress the throttle with your right foot to begin driving 8 Drive slowly Practice maneuvering and using the throttle and brakes on level surfaces Do not carry a passenger until you have at least two hours of driving experience with this vehicle 36
32. CLE ONLY NEVER operate this vehicle if you are under age 16 and NEVER operate without a valid driver s license Never operate with a passenger under the age of 12 All riders must be able to sit with backs against the seat both feet flat on the floor and both hands on the steering wheel if driving or on a passenger hand hold 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 and understand the Owner s Manual and all warning and instruction labels before operating the vehicle All operators should review the safety DVD provided with this vehicle and take a ROHVA training course www rohva org Using Alcohol or Drugs Operating the vehicle after consuming alcohol or drugs could adversely affect operator judgment reaction time balance and perception A Never drink alcohol or use drugs or medications before or while aA operating this vehicle Seat Belts Riding in this vehicle without wearing the seat belt increases the risk of serious injury in the event of rollover loss of control other accident or sudden stop Seat belts may reduce the severity of injury in these circumstances All riders must wear seat belts at all times Protective Apparel Riding in this vehicle without wearing an approved helmet and pro
33. Daily Inspect daily clean often Headlamp tail lamp Daily Check operation apply dielectric grease if replacing E Air filter main element Weekly Inspect replace as needed A Brake pad wear 10H Monthly Inspect periodically Battery 20H Monthly Check terminals clean test gt Clutch Intake pre filter 25H Monthly Inspect clean with compressed air replace if necessary E Engine breather filter if equipped 25 H Monthly A Inspect replace if necessary gt Front Gearcase oil if equipped 25H 1M Perform a break in oil level check gt Middle Gearcase oil if equipped 25H 1M Perform a break in oil level check gt Rear gearcase oil if equipped 25H 1M Perform a break in oil level check gt Transmission oil 25H 1M Perform a break in oil level check gt Engine oil change break in 25H 1M et a break in oil change at one mon gt General lubrication 50H 3M Lubricate all fittings pivots cables etc Shift Linkage 50H 6M Inspect lubricate adjust D Steering 50 H 6M Lubricate gt Front Suspension 50 H 6M Lubricate gt Rear Suspension 50 H 6M Lubricate D Throttle cable 50 H 6M Inspect adjust lubricate replace if nec E essary E Maid body air intake ducts 50 H 6M Inspect duct for proper sealing air leaks ange Drive belt 50H 6M Inspect adjust replace as needed Cooling system if applicable 50 H 6M Inspect coolant strength seasonally pressure test system yearly gt Pe
34. GER has been designed to carry or tow specific capacities Always read and under stand the load distribution warnings listed on the warning labels 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 Maximum Capacities Model Level Ground Cargo Box 1000 Ibs 455 kg 500 Ibs 226 kg RANGER 800 EFI EPS Midsize WARNING Driving with passengers in the cargo box can result in severe injury or death Never allow passengers to ride in the cargo box Passengers must always ride in the cab with seat belts fastened securely 42 OPERATION Towing Loads Towing improperly can alter vehicle handling and may cause loss of control or brake insta bility Always follow these precautions when towing 1 Never load more than 150 Ibs 68 1 kg tongue weight on the towing bracket 2 Always shift to low gear for towing 3 When towing a disabled RANGER vehicle place the disabled vehicle s transmission in neutral Do not operate the vehicle faster than 10 MPH 16 km h when towing 4 Do not operate the vehicle faster than 10 MPH 16 km h when towing See page 42 Towing a trailer increases braking distance 5 Do not tow more than the recommended weight for the vehicle See the towing capacity chart below and the specifications charts beginning on page 88 6 Attach a
35. 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 har ness Be sure to pull on the connector not on the wiring Wiring Harness D 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 head light assembly TI MAINTENANCE Lights Headlight Beam Adjustment 5 6 7 Place the vehicle on a level surface with the headlight approximately 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 Start the engine Turn on the headlights 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 If a headlight needs adjustment locate the adjustment screw at the back of the headlight Loosen the screw adjust the headlight and tighten the screw Repeat steps 4 6 until the lamp is properly adjusted Brake Lights When the brake pedal is depressed the console brake light comes on Check the brake light before each ride 1 2 78 Turn the ignition switch to the ON position De
36. Make sure the belt is not twisted 2 Push the latch plate into the buckle until it clicks 3 Release the strap it will self tighten Tip The center belt must be tightened manually by pulling on the strap 4 To release the seat belt press the square red button in the buckle s center Seat Belt Inspection Inspect all seat belts for proper operation before each use of the vehicle Latch Plate Buckle 1 Push the latch plate into the buckle until it clicks The latch plate must slide smoothly into the buckle A click indicates that it s securely latched 2 Push the red release latch in the middle of the buckle to make sure it releases freely 3 Pulleach 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 oper ate properly have the seat belt system checked and or replaced by an authorized POLARIS dealer 4 To clean dirt or debris from the seat belts sponge the straps with mild soap and water Do not use bleach dye or household detergents 25 FEATURES AND CONTROLS Cab Nets Riding in this vehicle without using the cab nets or doors if equipped increases the risk of serious injury or death in the event of an accident or rollover Cab nets or doors must be used by both operator and passengers at all times Make sure all latches are secure before operating the vehicle Always inspect cab nets
37. Midsize Maximum Weight Capacity includes weight of operator passenger cargo accessories 1000 Ibs 454 kg Dry Weight 1055 Ibs 478 5 kg Test GVW Rollover Protection System ROPS 2750 lbs 1247 kg per OSHA 29 CFR 1928 53 Fuel Capacity 8 8 gal 33 3 D Engine Oil Capacity 2 qts 1 91 Coolant Capacity 120 oz 3 5 Overall Length 108 in 274 3 cm Overall Width 56 5 in 143 5 cm Overall Height 73 in 185 cm Wheelbase 72 in 183 cm Cargo Box Dimensions Inside 32x42x11 5 in 81x107x29 cm Ground Clearance 10 in 25 4 cm Min Turning Radius 150 in 381 cm Towing Capacity 1250 lbs 567 kg Hitch Tongue Capacity 150 Ibs 68 kg Max Cargo Box Load 500 Ibs 227 kg Engine 4 valve 4 stroke twin cylinder with counter balance Displacement 760 cc Bore x Stroke mm 80 x 76 5 Alternator Output 500 W 3000 RPM Compression Ratio 10 0 1 Starting System Electric Fuel System Electronic Fuel Injection Ignition Timing 30 5000 RPM Spark Plug Gap RC7YC3 035 in 0 9 mm Lubrication System Dry Sump Cooling Liquid Front Suspension Dual A arm w 9 6 in 24 4 cm of travel Rear Suspension Independent w 9 in 23 cm of travel 88 SPECIFICATIONS RANGER 800 EFI Midsize RANGER 800 EPS Midsize Driving Syst
38. OTICE If your vehicle becomes immersed major engine damage can result if the machine is not thoroughly inspected Take the vehicle to your dealer before starting the engine If it s impossible to take your RANGER to a dealer before starting it follow the steps outlined below 1 Move the vehicle to dry land or at the very least to water below the footrests 2 Dry any water present in the air box Filter replacement is required if water is present 3 Thoroughly dry the air pre cleaner located under the hood 4 Remove the spark plugs Turn the engine over several times using the electric start 5 Dry the spark plugs and reinstall or replace with new plugs 6 Attempt to start the engine If necessary repeat the drying procedure 7 Take the vehicle to your dealer for service as soon as possible whether you succeed in starting it or not 8 If water has been ingested into the PVT follow the procedure on page 68 for drying 69 MAINTENANCE Filter Systems Air Filter Always change the air filter at the intervals outlined in the Periodic Maintenance Chart beginning on page 57 Service the air filter more frequently if the vehicle is operated in wet conditions or at high throttle openings for extended periods 1 Lift the cargo box to access the air box 2 Remove the air box cover and inspect the gasket It should adhere tightly to the cover and Air Filter seal all the way around Tip Grasp the filter end to pre
39. PERSON FOR INCIDENTAL CONSEQUENTIAL OR SPECIAL DAMAGES OF ANY DESCRIPTION WHETHER ARISING OUT OF EXPRESS OR IMPLIED WARRANTY 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 EXCLUSIVE REMEDY FAILED OF ITS ESSENTIAL PURPOSE ALL IMPLIED WARRANTIES INCLUDING BUT NOT LIMITED TO ANY IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE ARE LIMITED IN DURATION TO THE WARRANTY PERIOD DESCRIBED HEREIN POLARIS DISCLAIMS ALL EXPRESS WARRANTIES NOT STATED IN THIS WARRANTY Some states do not allow limitations on how long an implied warranty lasts so the above limitation may not apply if it is inconsistent with the controlling state law This limited warranty excludes failures not caused by a defect in material or workmanship This limited warranty does not cover damage due to accidents abuse or improper handling maintenance or use This limited warranty also does not cover any engine that has been structurally altered or when the vehicle has been used in racing competition This limited warranty also does not cover physical damage corrosion or defects caused by fire explosions or other similar causes beyond the control of POLARIS Owners are responsible for performing the scheduled maintenance identified in the owner s manual POLARIS may deny warranty claims for failures that have been caused by
40. PVT Br ak Ini sss cnrenrshbeep XAR Eee 33 PVT Drying erennere t e5x ie xDD IE ere 68 PN TS VSG Mite uaa aententia h uentis 8 68 PVT System Operation 0 67 PVT Warning es ccc omni Rh d 67 68 PVT Cleaning Debris 67 R Rad ators eont a ar eare a a 65 Radiator Coolant Level 66 Removing the Vehicle from Storage 87 Reverse Operation lessen 41 Rider Information Center 29 32 Riding Gar lt eco dessin ced etae riei 8 9 Rollover Protective Structure 27 ROPS Cab Frame soes niania ntes ry rnt 27 S Safety Labels 5 ioc ese beer Rees 10 12 Safety Symbols 22d c paste SU tens 4 Safety Warhing eresia denuar a 16 20 Safety Winch Maintenance 55 Seat Belt Inspection 0 00 25 Seat Belts sanee es eee tare tace rec dec dra 25 Neat Removal 2e a eh e rhe a 24 Severe Use Definition 65 57 Nnnc E 22 Shifting Gears sese 22 Shock Loading the Winch 54 Shock Spring Adjustment 74 signal WOrdS seige oe acetate doni thoi d Spark Arrester Warning 000 71 Spark Arrestor Cleaning 71 spark Plug Gap ves RR hens eee 64 Spark Plug Inspection 04 64 Spark Plug Recommendations 64 Spark Plug Torque sires trm 64 Spark Plugs e meme Re ert 64 Spark Plugs Fouled 0 00
41. RIS warrants that the vehicle is free from defects in materials and workmanship that would cause it to fail to meet these regulations The warranty period for off road vehicles 100cc or greater emissions certified vehicles starts on the date of purchase by original retail purchaser and continues for a period of 500 hours of engine operation 5000 kilometers 3100 miles of vehicle travel or 30 calendar months from the date of purchase whichever comes first The warranty period for ATVs less than 100cc emissions certified vehicles starts on the date of purchase by original retail purchaser and continues for a period of 250 hours of engine operation 2500 kilometers 3100 miles of vehicle travel or 30 calendar months from the date of purchase whichever comes first This EPA emissions warranty period is extended for at least as long as the standard factory warranty that Polaris provides on the vehicle as a whole The EPA emissions warranty period does not further extend if you purchase additional warranty coverage in the form of a service contract or other paid warranty extension but emission related parts may be covered subject to the terms of any such paid service contract or paid warranty extension This emissions limited warranty covers components whose failure increases the vehicle s regulated emissions and it covers components of systems whose only purpose is to control emissions Repairing or replacing other components not covered by this warran
42. Rame 73 Fogging the Engine 00 86 Fouled PIU SS io iet iae rore dees css x 64 Freeplay Adjustment Throttle 72 Front Gearcase s o tar er E ER RA een 63 Fuel Cap ees 2S ceasing oe de bh eee 24 Fuel Safety eoe OR eee e Rhin 18 Fuel Stabilizer 4 5 secutae doeet hend 85 Fuel Tank Filler Cap 5 22 eor 24 PUSES TIT TI G Gap Spark Plug eveniet etre 64 Gasoline Handling 004 18 Gear Selectors esee S 22 Gearcase Specification Chart 62 Gearcase Front issus duel DR RR rea 63 Gearcase Mam amp isor eer egesta vs 62 GearCaseSs s essor eere nha aah da ane Ee 62 63 Gears Shifting esl Ree 22 GLOVES Ea 9 H Hauling Cargo oo cete ee ce en 42 Headlight Beam Adjustment 78 Headlight Lamp Replacement TI Helmet scope ees Saver eS WE s 8 Hitch Br cket uer tote ee 27 Hitch Weight esseri rt 43 102 l Idl Speed pca sci goat ERI v REESE eVodR 72 Ignition Switch insere esee ek nt 23 Immersion of Vehicle 2 005 69 Indicator Eanips vedete rer EA 28 Instrument Cluster 05 28 32 K Key Periodic Maintenance Chart 57 L Eight Swithin e aee te t Ru inis 23 Lights 1 222229 eleven sd bra r Bad vee since 77 78 Brake Lights 78 Headlight Beam Adjustment 78 Headlight Lamp Replacement TI Lubricants Gearcase 000 cee eee 62 Lubrication R
43. S x c Q4 38 OPERATION Driving Uphill Whenever traveling uphill follow these pre cautions 1 Always travel straight uphill 2 Avoid excessively steep hills 3 Keep both feet on the floor 4 Always check the terrain carefully before ascending any hill Never climb hills with J om excessively slippery or loose surfaces 5 Proceed at a steady rate of speed and throt M tle opening Never open the throttle sud denly 6 Never go over the crest of a hill at high speed An obstacle a sharp drop or another vehi cle or person could be on the other side of the hill Driving on a Sidehill Sidehilling Driving on a sidehill is not recommended Improper procedure could cause loss of control or rollover 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 Driving Downhill When driving downhill follow these precau tions 1 Avoid excessively steep hills 2 Drive straight downhill Avoid descending a hill at an angle which would cause the vehicle to lean sharply to one side Travel straight downhill when possible 3 Slow down Apply the brakes slightly to aid in slowing 39 OPERATION Driving Through Water Your POLARIS RANGER can operate through water up to a maximum recommended depth equal to the flo
44. SC 8 V 8 Z87 1 or CE Make sure protective eye wear is kept clean Gloves Wear gloves for comfort and for protection from sun cold weather and other elements Boots Wear sturdy over the ankle boots for support and protection Never ride a POLARIS vehicle with bare feet or sandals Clothing Wear long sleeves and long pants to protect arms and legs Rider Comfort Under certain operating conditions heat generated by the engine and exhaust system can ele vate temperatures in the driver and passenger cab area The condition occurs most frequently when a vehicle is being operated in high ambient temperatures at low speeds and or high load conditions for an extended period of time The use of certain windshield roof and or cab systems may contribute to this condition by restricting airflow Any discomfort due to heat buildup in this area can be minimized by wearing proper riding apparel and by varying speeds to increase airflow SAFETY Safety Labels and Locations Warning labels have been placed on the vehicle for your protection Read and follow the instructions of the labels on the vehicle carefully If any of the labels depicted in this manual differ from the labels on your vehicle always read and follow the instructions of the labels on the vehicle If any label becomes illegible or comes off contact your POLARIS dealer to purchase a replacement Replacement safety labels are provided by POLARIS at no charge The part number i
45. a hill If all forward speed is lost Apply the brakes Place the transmission in reverse and slowly allow the vehicle to roll straight downhill while applying light brake pressure to control speed If you begin rolling downhill Never apply engine power Apply the brakes gradually until the vehicle is fully stopped Place the transmission in reverse and slowly allow the vehicle to roll straight downhill while applying light brake pressure to control speed 19 SAFETY Operator Safety Improper Tire Maintenance Operating this vehicle with improper tires or with improper or uneven tire pressure could 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 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 rollover Do not operate on excessively slippery surfaces Always slow down and use additional caution when operating on slippery surfaces Skidding or sliding due to loss of traction can cause loss of control or rollover if tires regain traction unexpectedly Always follow proper procedures for operating on slippery surfaces as described in this owner s manual See page 38 Operating on Frozen Bodies of Water Severe injury or death can result if the ve
46. ading section on page 54 For your safety always follow these guidelines when winching a vehicle free A Release the winch clutch and spool out the necessary length of winch cable B Align the winch cable as close as possible to the winching vehicle s centerline C Attach the winch cable hook to the anchor point or the stuck vehicle s frame following instructions in this manual D Re engage the clutch on the winch E Slowly winch in the slack in the winch cable F Select the proper vehicle gear to propel the stuck vehicle in the direction of winching G Shift to the lowest gear available on the stuck vehicle H Slowly and carefully apply vehicle throttle and winch together to free the vehicle l Stop inching as soon as the stuck vehicle is able to propel itself without the help of the winch J Detach the winch cable hook K Rewind the winch cable evenly back onto the winch drum following the instructions in this manual Never attempt to winch another stuck vehicle by attaching the winch cable to a suspension component brush guard bumper or cargo rack Vehicle damage may result Instead attach the winch to a strong portion of the vehicle frame or hitch 51 WINCH GUIDE Winch Operation 13 Extensive winching will run down the battery on the winching vehicle Let the winching vehicle s engine run while operating the winch to prevent the battery from running low if winching for long periods 14 The winch motor m
47. ame nuts bolts fasteners Inspect ensure tightness Fuel and oil Ensure proper levels R Coolant level Ensure proper level 66 Coolant hoses Inspect for leaks Throttle Ensure proper operation 72 Indicator lights switches Ensure operation 23 Air filter pre filter Inspect clean 70 Air box sediment tube Drain deposits whenever visible 70 Headlamp Check operation apply POLARIS dielectric grease 77 when lamp is replace Brake light tail lamp Check operation apply POLARIS dielectric grease 78 when lamp is replace Seat Belts Check length of belt for damage check latches for 25 proper operation Cab nets or doors Check for wear or damage ensure proper installation 26 34 OPERATION Starting Engine 1 Always start the engine outdoors or in a well ventilated area 2 Sitin the driver s seat and fasten the seat belt Secure the cab nets or doors 3 Apply the brakes Place the transmission in PARK 4 Do not press the throttle pedal while starting the engine Turn the ignition key past the ON RUN position to START Engage the starter for a maximum of five seconds Release the key when the engine starts 5 If the engine does not start within five seconds release the ignition switch and wait five seconds Repeat steps 4 and 5 until the engine starts 6 Vary the engine RPM slightly with the throttle to aid in warm up until the engine idles smoothly NOTICE Operating the vehicle immediately after starting could cause engine damage
48. anual contains instructions for minor mainte nance but information about major repairs is outlined in the POLARIS Service Manual and should be performed only by a factory certified Master Service Dealer MSD technician Your POLARIS dealer knows your vehicle best and is interested in your total satisfaction Be sure to return to your dealership for all of your service needs during and after the warranty period POLARIS POLARIS and RANGER are registered trademarks of POLARIS Industries Inc Copyright 2013 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 produc tion components some minor discrepancies may result between the actual vehicle and the information presented in this publication Depictions and or procedures in this publication are intended for reference use only No liabil ity 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 The original instructions for this vehicle are in English Other languages are provided as translations of the origi nal instructions Printed in U S A 2014 RANGER 800 EFI Midsize RANGER 800 EPS Midsize Owner s Manual P N 9924303 TABLE OF CONTENTS Introduction cc eceensespesteddd nieseenedesdewee tence s 4 Safely d P
49. as the copy of the Warranty Registration Form will be your proof of warranty coverage If you have not signed the original registration and received the customer copy please contact your dealer immediately NO WARRANTY COVERAGE WILL BE ALLOWED UNLESS YOUR VEHICLE IS REGISTERED WITH POLARIS Initial dealer preparation and set up of your vehicle is very important in ensuring trouble free operation Purchasing a machine in the crate or without proper dealer set up will void your warranty coverage WARRANTY COVERAGE AND EXCLUSIONS LIMITATIONS OF WARRANTIES AND REMEDIES This POLARIS limited warranty excludes any failures that are not caused by a defect in material or workmanship THIS WARRANTY DOES NOT COVER CLAIMS OF DEFECTIVE DESIGN This warranty also does not cover acts of God accidental damage normal wear and tear abuse or improper handling This warranty also does not cover any vehicle component or part that has been altered structurally modified neglected improperly maintained or used for purposes other than for which it was designed This warranty excludes damages or failures resulting from improper lubrication improper engine timing improper fuel surface imperfections caused by external stress heat cold or contamination operator error or abuse improper component alignment tension adjustment or altitude compensation snow water dirt or other foreign substance ingestion contamination improper maintenance modified components us
50. at 20 Dispose of used filter and oil properly 61 MAINTENANCE Gearcases Gearcase Specification Chart Gearcase Lubricant Capacity Fill Plug s Drain Plug Torque Torque Main Gearcase AGL Gearcase 34 oz 12 ft Ibs 12 ft Ibs Transmission Lubricant amp 1000 ml 16 3 Nm 16 3 Nm Transmission Fluid Front Gearcase Demand Drive Fluid 9 3 oz 8 10 ft Ibs 11 ft Ibs 275 ml 11 13 6 Nm 15 Nm Transmission Main Gearcase Always check and change the transmission oil at the intervals outlined in the Periodic Main tenance Chart beginning on page 57 Maintain the oil level even with the bottom of the fill plug hole threads Refer to the Gearcase Specifications Chart for recommended lubricants capacities and torque specifications See page 90 for the part numbers of POLARIS products Oil Check The fill plug is located on the rear of the gearcase A level check alternate fill plug is located on the side of the gearcase Maintain the oil level even with the bottom of the level check fill plug hole threads 1 Position the vehicle on a level surface 2 Remove the level Rear Fill check fill plug Plug Check the oil level 3 Remove the rear fill Fill plug and add the Level recommended oil as needed 4 Reinstall both fill iaiia ks z plugs Torque to Level Check l specification and Alternate Drain Plug Fill Plug Oil Change The drain plug is located near the bottom of the gearca
51. ated materials They do not allow enough ventilation to pre vent condensation and may promote corrosion and oxidation 86 MAINTENANCE Removal from Storage 1 PU Check the battery electrolyte level and charge the battery if necessary Install it in the vehicle Make sure the battery vent hose is routed properly and that it s not pinched or restricted in any way Make sure the spark plug is tight Fill the fuel tank with fuel Check all the points listed in the Daily Pre Ride Inspection section on page 34 Tightness of the bolts nuts and other fasteners should be checked by an authorized POLARIS dealer Lubricate at the intervals outlined in the Periodic Maintenance Chart beginning on page 57 Transporting the RANGER Follow these procedures when transporting the vehicle 1 2 3 4 Apply the brakes Place the transmission in PARK Stop the engine Secure the fuel cap hood and cargo box Ensure that the seats are attached correctly and are not loose WARNING Cargo and other loose vehicle parts may fly off while transporting this vehicle Secure or remove all cargo and inspect the unit for loose parts prior to transport 5 6 Always tie the frame of the RANGER to the transporting unit securely with suitable straps or rope Do not attach tie straps to the front A arm bolt pockets Remove the key to prevent loss during transporting 87 SPECIFICATIONS RANGER 800 EFI Midsize RANGER 800 EPS
52. ay become hot during winch use If you winch for more than 45 seconds or if the winch stalls during operation stop winching and permit the winch to cool down for 10 minutes before using it again 15 After winching is complete especially if winching at an angle it may be necessary to re distribute the winch cable across the winch drum You will need an assistant to perform this task Release the clutch on the winch Feed out the winch cable that is unevenly bunched up in one area Re engage the winch clutch Have an assistant pull the winch cable tightly with about 100 Ibs 45 kg of tension using the hook strap Slowly winch the cable in while your assistant moves the end of the winch cable back and forth horizontally to evenly distribute the winch cable on the drum Doing this reduces the chances of the winch cable wedging itself between lower layers of winch cable m gom m 52 WINCH GUIDE Winch Cable Care For your safety always replace POLARIS winch parts including the cable with genuine POLARIS replacement parts available at your authorized POLARIS dealer WARNING Use of worn or damaged cable could lead to sudden failure and SEVERE INJURY 1 Always inspect your winch before each use Inspect for worn or loose parts including mounting hardware Never use the winch if any part needs repair or replacement 2 Always inspect your winch cable before each use Inspect for worn or kinked winch cable A Ak
53. ccur 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 45 OPERATION All Wheel Drive AWD The illuminated amber AWD switch indicates that the vehicle is in AWD When the AWD switch is on the front gearcase will automatically engage any time the rear wheels lose traction When the rear wheels regain traction the front gearcase will automati cally disengage There is no limit to the length of time the vehicle may remain in AWD Initially the vehicle s electronic system will not enable the AWD until the engine RPM is below 3100 Once enabled the AWD remains enabled until the AWD switch is turned off If the switch is turned off while the front gearcase is moving it will not disengage until the rear wheels regain traction Engage the AWD before getting into conditions where front wheel drive may be needed If the rear wheels are spinning release the throttle before switching to AWD NOTICE Switching to AWD while the rear wheels are spinning may cause severe drive shaft and clutch damage Always switch to AWD while the rear wheels have traction or are at rest Disengaging AWD Under certain conditions it may be possible for the front gearcase to remain locked unneces sarily This condition causes increased steering effort and some vehicle speed restriction If the front gearcase remains locked after following these
54. ce with fresh recommended fuel Clogged air filter Inspect and clean or replace Other mechanical failure See your dealer Overheated engine Clean radiator screen and core clean engine exterior see your dealer 93 WARRANTY LIMITED WARRANTY POLARIS Sales Inc 2100 Highway 55 Medina MN 55340 POLARIS gives a SIX MONTH LIMITED WARRANTY on all components of your POLARIS vehicle against defects in material or workmanship POLARIS further warrants that the spark arrestor in this product will meet the efficiency requirements of USFS standard 5100 1C for at least 1000 hours when subjected to normal use and when maintenance and installation are in accordance with POLARIS recommendations This warranty covers parts and labor charges for repair or replacement of defective parts and begins on the date of purchase by the original retail purchaser This warranty is transferable to another owner during the warranty period through a POLARIS dealer but any such transfer will not extend the original term of the warranty The duration of this warranty may vary by international region based upon local laws and regulations REGISTRATION At the time of sale the Warranty Registration Form must be completed by your dealer and submitted to POLARIS within ten days of purchase Upon receipt of this registration POLARIS will record the registration for warranty No verification of registration will be sent to the purchaser
55. code menu See an authorized POLARIS dealer for code details and diagnosis OPERATION Failure to operate the vehicle properly can result in a collision loss of control accident or rollover which may result in serious injury or death Read and understand all safety warnings outlined in the safety section of this owner s manual Break In Period The break in period for your new POLARIS RANGER is the first twenty hours of operation or the time it takes to use the first two tanks full of gasoline No single action on your part is as important as a proper break in period Careful treatment of a new engine will result in more efficient performance and longer life for the engine Perform the following procedures carefully NOTICE Excessive heat build up during the first three hours of operation will damage close fitted engine parts Do not operate at full throttle or high speeds for extended periods during the first three hours of use Engine and Drivetrain Break in 1 Fill the fuel tank with gasoline Review the fuel warnings on page 18 2 Check the oil level See page 60 Add the recommended oil as needed to maintain the oil level in the normal safe operating range 3 Drive slowly at first Select an open area that allows room to familiarize yourself with vehicle operation and handling Vary throttle positions Do not operate at sustained idle 5 Perform regular checks on fluid levels controls and areas outlined on the daily p
56. cords and displays the distance traveled by the vehicle Trip Meter Mode The trip meter records the distance traveled by the vehicle if reset before each trip To reset select the trip meter mode Press and hold the MODE button until the meter resets to zero In the Rider Information Center the trip meter display contains a decimal point but the odome ter displays without a decimal point Hour Meter Mode This mode logs the total hours the engine has been in operation Tachometer Mode The engine RPM is displayed digitally Tip Small fluctuations in the RPM from day to day may be normal because of changes in humidity temperature and elevation Programmable Service Interval When the hours of engine operation equal the programmed service interval setting the wrench icon will flash for 5 seconds each time the engine is started When this feature is enabled it provides a convenient reminder to perform routine maintenance The service interval is programmed at 50 hours at the factory Use the following procedure to change the service interval 1 Press the MODE button until remaining service hours display 2 Press and hold the MODE button 3 When the service hours flash press and release the MODE button to advance the hours to the desired setting including OFF Press and hold the MODE button to set the new service hour interval Diagnostic Display Mode The EFI diagnostic display mode is for informational purposes only Pleas
57. e 1 Always check for obstacles or people behind the vehicle Always inspect left and right fields of vision before backing 2 Always avoid backing downhill 3 Back slowly 4 Apply the brakes lightly for stopping 5 Avoid turning at sharp angles 6 Never open the throttle suddenly Parking the Vehicle 1 Apply the brakes Stop the vehicle on a level surface 2 When parking inside a garage or other structure be sure that the structure is well venti lated and that the vehicle is not close to any source of flame or sparks including any appliance with pilot lights 3 Place the transmission in PARK 4 Turn the engine off 5 Remove the ignition switch key to prevent unauthorized use Parking on an Incline Avoid parking on an incline if possible If it s unavoidable follow these precautions 1 2 3 4 Apply the brakes Place the transmission in PARK Turn the engine off Block the rear wheels on the downhill side 41 OPERATION 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
58. e of aftermarket or unapproved components accessories or attachments unauthorized repairs or repairs made after the warranty period expires or by an unauthorized repair center 94 WARRANTY LIMITATIONS OF WARRANTIES AND REMEDIES This warranty excludes damages or failures caused by abuse accident fire or any other cause other than a defect in materials or workmanship and provides no coverage for consumable components general wear items or any 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 and fluids Steering components Circuit breakers Fuses Batteries Electronic components Light bulbs Sealed beam lamps Spark plugs Filter Sealants Lubricants Coolants Bushings Bearings Lubricants and Fluids 1 Mixing oil brands or using non recommended oil may cause engine damage We recommend the use of POLARIS engine oil 2 Damage or failure resulting from the use of non recommended lubricants or fluids is not covered by this warranty This warranty provides no coverage for personal loss or expense including mileage transportation costs
59. e see your POLARIS dealer for all major repairs The diagnostic mode is accessible only when the check engine warning indicator activates after the key has been turned on Leave the key on if you want to view the active code fail ure code The diagnostic mode becomes inaccessible if the key is turned off and on and the warning indicator is no longer active This allows the determination of persistent as well as intermit tent faults Inactive codes are stored in the history of the unit 31 FEATURES AND CONTROLS Instrument Cluster Rider Information Center Engine Error Codes The error screen displays only when the CHECK ENGINE light is on or when it goes on and off during one ignition cycle Error codes are not stored When the key is turned OFF the code and message is lost but will reappear if the fault reoccurs after restarting the engine If the CHECK ENGINE light illuminates retrieve the error codes from the display 1 Ifthe error codes are not displayed use the MODE button to toggle until Ck ENG displays on the main line of the display 2 Press and hold the MODE button to enter the diagnostics code menu Nw Pw 32 Suspect Parameter Number SPN Error Code Number 0 9 Failure Mode Indicator FMI Record the three numbers displayed in the gear position clock and odometer displays Press the MODE button to advance to the next error code Press and hold the MODE button to exit the diagnostics
60. e use of POLARIS Antifreeze 60 40 premix or a 50 50 mixture of high quality aluminum compatible anti freeze coolant and distilled water POLARIS Antifreeze is already premixed and ready to use Do not dilute with water See page 90 for the part numbers of POLARIS products Always follow the manufacturer s mixing recommendations for the freeze protection required in your area Any time the cooling system has been drained for maintenance or repair replace the coolant If the recovery bottle has run dry the level in the radiator should be inspected Add coolant as needed Radiator and Cooling Fan Always check and clean the screen and radiator fins at the intervals outlined in the Periodic Maintenance Chart beginning on page 57 Do not obstruct or deflect air flow through the radiator by installing unauthorized accessories in front of the radiator or behind the cooling fan Interference with the radiator air flow can lead to overheating and consequent engine damage NOTICE Washing the vehicle with a high pressure hose could damage the radiator fins and impair the radiator s effectiveness Using a high pressure system is not recommended 65 MAINTENANCE Cooling System Overflow Bottle Coolant Level Always check and change the coolant at the intervals outlined in the Periodic Maintenance Chart beginning on page 57 Maintain the coolant level between the min imum and maximum marks on the bottle when the fluid is cool 1 Position the v
61. eck the battery voltage with a voltmeter or multimeter A fully charged battery will register 12 8 V or higher If the voltage is less than 12 8 volts recharge the battery at 1 2 amps or less until battery voltage is 12 8 or greater 2 When using an automatic charger refer to the charger manufacturer s instructions for recharging When using a constant current charger use the guidelines below for recharg ing Always verify battery condition before and 1 2 hours after the end of charging State of Charge Time Voltage Action Using constant current Charge charger standard amps specified on top of battery 100 12 8 13 0 volts None check at 3 mos from date of None required manufacture 75 100 12 5 12 8 volts May need slight charge if no charge 3 6 hours given check in 3 months 50 75 12 0 12 5 volts Needs charge 5 11 hours 25 50 11 5 12 0 volts Needs charge At least 13 hours verify state of charge 0 25 11 5 volts or less Needs charge with desulfating charger At least 20 hours 82 MAINTENANCE Cleaning and Storage Washing the Vehicle Keeping your POLARIS vehicle clean will not only improve its appearance but it can also extend the life of various components 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 surfac
62. ecommendations 59 M Main G arcas lt s 25 6 c s ie ies nae ug 62 Maintenance Log 0 000000 eee 100 Maintenance Periodic 57 59 Metric Display cem eive RS 30 Mode Bulttoti 1 5 tco RI IOS TR aS 22 Modifications 4 ep ae abra IR US Ce een 15 N Noise Emission Control System 56 0 ODSIGCIeS sen e dade a ees 37 Ou BASING sc over e m yxI E RES EQ 60 61 Oil Change ENGNG MC 61 Front Gearcase 05 63 Main Gearcase 005 62 Transmissie ev Rr RS 62 Oil Level Engine dod Sy Vad Se ets 60 Front Gearcase cso gesc ees 63 Main Ge tcase 4 se Leser peLr EA 62 Transmission eese res 62 Oil Recommendation Engine Oil 5 ceste ea 60 Gearcases vocas e uo dae PE OS 62 Operation on Public Lands 56 Operator Safety oj seta eee e e 13 20 Outlets Auxillaty s v beeEeVRRE ada das 22 P Parking on an Incline 0004 41 Parking the Vehicle 0000 41 Periodic Maintenance Chart 57 59 Plug Gap skies sek iier tieshudasusuenyaatnyactoeyac gt 64 Plug Torque i c ss tetne ereen wae hah ae dass 64 Plug AGCeSSOLy 4c ry eb we MEX 22 Plugs Fouled esses ette apertas atio as 64 Polaris Product 2st ceres 90 Polishing the Vehicle 0 84 Power Steering s oseiro b ehh adie cee es 24 Power Steering Unit Cleaning 76 Pre Ride Inspection 004 34
63. ediately if the oil level begins to rise Monitor the oil level and if it continues to rise discontinue use and determine the cause or see your dealer Maintenance Chart Key P Perform these operations more often for vehicles subjected to severe use E Emission related service Failure to conduct this maintenance will not void the emis sions warranty but may affect emissions D Have an authorized POLARIS dealer perform these services WARNING Improperly performing the procedures marked with a D could result in component failure and lead to serious injury or death Have an authorized POLARIS dealer perform these services 57 MAINTENANCE Periodic Maintenance Chart Perform all services at whichever maintenance interval is reached first Item Maintenance Interval Remarks whichever comes first Hours Calendar Miles Km Steering Front suspension Rear suspension Tires Brake fluid level Pre Ride Make adjustments as need ed See Brake pedal travel Pre Ride Checklist on page 34 Brake system Wheels fasteners Frame fasteners Engine oil level x Air filter pre filter Daily Inspect clean often replace as needed E Air box sediment tube Daily Drain deposits when visible Coolant if applicable Daily 7 Check level daily change coolant every 2 years gt Power steering unit if equipped 3
64. ehicle on a level surface 2 Lift the hood View the coolant level in the over flow bottle 3 If the coolant level is below the safe operating range lift the hood and locate the overflow bottle lid Remove the cap and use a funnel to add coolant through the filler opening Reinstall the cap Tip If coolant must be added often or if the overflow bottle runs completely dry there may be a leak in the system Have the cooling system inspected by your POLARIS dealer Radiator Coolant Level Always check and clean the screen and radiator fins at the intervals outlined in the Periodic Maintenance Chart beginning on page 57 Do not obstruct or deflect air flow through the radiator by installing unauthorized accesso ries in front of the radiator or behind the cooling fan Interference with the radiator air flow can lead to over heating and consequentially engine damage 1 Lift the hood CAUTION Escaping steam can cause burns Never remove the pressure cap while the engine is warm or hot Always allow the engine to cool before removing the pressure cap 2 Slowly remove the radiator cap 3 View the coolant level through the opening 4 Use a funnel and slowly add coolant as needed Tip This procedure is required only if the cooling system has been drained for maintenance and or repair But if the overflow bottle has run dry the level in the radiator should also be inspected 5 Reinstall the pressure cap Use of a non
65. em Type PVT Shift Type Single Lever console Gear Reduction Low 7 70 1 Gear Reduction Reverse 7 00 1 Gear Reduction High 4 12 1 Drive Ratio Front 3 818 1 Tire Size Front 25x 8 12 Tire Size Rear 25x 11 12 Tire Pressure Front 10 psi 68 9 kPa Tire Pressure Rear 12 psi 82 7 kPa Brakes Front Rear Foot Activated 4 wheel hydraulic disc Hood Headlights 2 single beam 50W quartz halogen Taillights 10 L E D 28W Brake Light 10 L E D 3 1W Indicator Light 1 0 W Clutching See your POLARIS dealer for clutching specifications 89 POLARIS PRODUCTS Part Number Description Engine Lubricant 2870791 Fogging Oil 12 0z 355 ml Aerosol 2876244 PS 4 Full Synthetic 5W 50 4 Cycle Oil qt 95 I 2876245 PS 4 Full Synthetic 5W 50 4 Cycle Oil gal 3 8 1 2878920 PS 4 Extreme Duty Synthetic 10W 50 4 Cycle Oil qt 95 I 2878919 PS 4 Extreme Duty Synthetic 10W 50 4 Cycle Oil gal 3 8 I Gearcase Transmission Lubricants 2878068 AGL Full Synthetic Gearcase Lubricant amp Transmission Fluid qt 95 1 2878069 AGL Full Synthetic Gearcase Lubricant amp Transmission Fluid gal 3 8 I 2877922 Demand Drive Fluid qt 95 I 2877923 Demand Drive Fluid gal 3 8 I 2870465 Pump for Gallon 3 8 I Jug Coolant 2871534 Polaris Antifreeze 60 40 Premix qt 95 1 2871323 Polaris Antifreeze 60 40 Premix
66. ention to your surroundings You may need to change your winching strategy if it is not working Always remember that your winch is very powerful There are simply some situations that you and your winch will not be able to deal with Do not be afraid to ask others to help when this happens 1 Always inspect the vehicle winch winch cable and winch controls for any signs of dam age or parts in need of repair or replacement before each use Pay particular attention to the first 3 feet 1 meter of winch cable if the winch is being used or has been used for lifting an accessory plow assembly Promptly replace any worn or damaged cable 2 Never operate a winch or a vehicle in need of repair or service 3 Always apply your vehicle s park brake and or park mechanism to hold the vehicle in place during winching Use wheel chocks if needed Hook Strap A moe JU Ca 49 WINCH GUIDE Winch Operation 4 Always use the hook strap when handling the hook WARNING Never put your fingers into the hook This could lead to SEVERE INJURY A Attach the hook itself onto the load or use a tow strap or NET chain to secure the load to the winch cable Tip A tow strap is NOT intended to stretch A recovery strap NO YES is designed to stretch WARNING Never use a recovery strap when winching due to the excessive energy that can be released if the winch cable breaks This can result in SEVERE INJURY or DEATH See the Shock Load
67. es Do not allow these types of products to contact the vehicle The best and safest way to clean your POLARIS vehicle is with a garden hose and a pail of mild soap and water 1 Use a professional type washing cloth cleaning the upper body first and the lower parts last 2 Rinse with clean water frequently 3 Dry surfaces with a chamois to prevent water spots 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 Grease all zerk fittings immediately after washing Allow the engine to run for a while to evaporate any water that may have entered the engine or exhaust system 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 following items Wheel bearings Brakes Switches and controls e Radiator Cab and body panels Electrical components and wiring Transmission seals Labels and decals If an informational or graphic label becomes illegible or comes off contact your POLARIS dealer to purchase a replacement Replacement safety labels are provided by POLARIS at no charge 83 MAINTENANCE
68. ever operate this vehicle on any public street road or highway including dirt and gravel roads unless designated for off highway use In some areas it s unlawful to operate this vehicle on public streets roads and highways Turning Improperly Turning improperly could cause loss of traction loss of control accident or rollover Always follow proper procedures for turning as described in this owner s manual 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 rollover 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 rollover Unfamiliar terrain may contain hidden rocks bumps or holes that could cause loss of control or rollover Travel slowly and use extra caution when operating on unfamiliar terrain Always be alert to changing terrain conditions Improper Hill Climbing Climbing hills improperly can cause loss of control or vehicle rollover Always follow proper procedures for climbing hills as described in this owner s manual See page 39 Stalling While Climbing a Hill Stalling or rolling backwards while climbing a hill could cause a rollover Always maintain a steady speed when climbing
69. he engine or let it run in an enclosed area The engine exhaust from this product contains chemicals known to cause cancer birth defects or other reproductive harm Operate this vehicle only outdoors or in well ventilated areas Operating a Damaged Vehicle Operating a damaged vehicle can result in an accident After any rollover or other accident have a qualified service dealer inspect the entire machine for possible damage including but not limited to seat belts rollover protection devices brakes throttle and steering systems Operating at Excessive Speeds Operating this vehicle at excessive speeds increases the operator s risk of losing control Always operate at a speed that s appropriate for the terrain the visibility and operating conditions your skills and experience and your passengers skills and experience 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 may increase the risk of loss of control and accident or rollover Avoid operating the vehicle on pavement If it s unavoidable travel slowly travel short distances and avoid sudden turns or stops 18 SAFETY Operator Safety Operating on Public Roads Operating this vehicle on public streets roads or highways could result in a collision with another vehicle N
70. hicle 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 ignition can lead to unauthorized use of the vehicle by someone under the age of 16 without a drivers license or without proper training This could result in an accident or rollover Always remove the ignition key when the vehicle is not in use Hot Exhaust Systems Exhaust system components are very hot during and after use of the vehicle Hot components can cause burns and fire Do not touch hot exhaust system components Always keep combustible materials away from the exhaust system Use caution when traveling through tall grass especially dry grass to avoid debris build up around the exhaust system 20 Component Locations FEATURES AND CONTROLS Your vehicle is equipped with cab nets on both sides of the vehicle Cab nets or doors if equipped must be used by both operator and passengers at all times The vehicle illustrated below is shown without cab nets only to allow
71. hicle 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 From to the dealer THE COST OF TRANSPORTATION TO AND FROM THE DEALER IS YOUR RESPONSIBILITY POLARIS suggests that you use your original selling dealer however you may use any POLARIS Servicing Dealer to perform warranty service In the country where your product 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 product was purchased Warranty and Service Bulletin repairs may be requested from any authorized POLARIS dealer that sells the same line as your product Outside the country where your product was purchased If you are traveling temporarily outside the country where your product was purchased you should take your product 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 Product importation rules vary considerably from country to country You may be required to present documentation of your m
72. ine and the service The tip should not be white A white insulator tip indicates overheating caused by use of an improper spark plug or incorrect throttle body adjustments Wet Fouled Plug The wet fouled insulator tip is black A damp oil film covers the firing end There may be a carbon layer over the entire nose Generally the electrodes are not worn General causes of fouling are excessive oil use of non recommended injection oil or incorrect throttle body adjustments 64 MAINTENANCE Cooling System The engine coolant level is controlled or maintained by the recovery system The recovery system components are the overflow bottle radiator filler neck radiator pressure cap and connecting hose As coolant operating temperature increases the expanding heated excess coolant is forced out of the radiator past the pressure cap and into the overflow bottle As engine coolant tem perature decreases the contracting cooled coolant is drawn back up from the tank past the pressure cap and into the radiator Some coolant level drop on new vehicles is normal as the system is purging itself of trapped air Observe coolant levels and maintain as recommended by adding coolant to the overflow bottle Adding or Changing Coolant To ensure that the coolant maintains its ability to protect the engine we recommend that the system be completely drained every two years and a fresh mixture of antifreeze and water added POLARIS recommends th
73. ing section on page 54 B Never hook the winch cable back onto itself This will damage the winch cable and may result in winch cable failure WARNING Replace the winch cable at the first sign of damage to prevent SEVERE INJURY or DEATH in the event of failure For your safety always replace POLARIS winch parts including the cable with genuine POLARIS replacement parts available at your authorized POLARIS dealer C If possible keep the winch cable aligned with the centerline of the winching vehicle This will help the spooling of the winch cable and reduce the load on the fairlead D If freeing a stuck vehicle by attaching to a tree use an item such as a tow strap to avoid damaging the tree during winch operation Sharp cables and chains can damage and even kill trees Please remember to TreadLightly treadlightly org E Before operating the winch be sure that the safety latch on the winch cable hook is fully seated when the load is attached F Never operate your winch with a damaged hook or latch Always replace damaged parts before using the winch 5 Never remove the hook strap from the hook NO 6 Release the winch clutch and pull out the winch cable ES 7 Pulling out as much cable as possible maximizes the winch s pulling capacity Always be sure that at least five 5 full turns of winch cable are wrapped around the winch drum at all times The friction provided by this wrapped cable allows the drum to pull on the winch
74. inked winch cable made of wire rope is shown at right Even after being straightened out this cable has already been permanently and severely damaged Promptly discontinue use of a winch cable in this condition B Akinked winch cable made of wire rope that has been straightened out is shown at right Even though it may look usable the cable has been permanently and severely damaged It can no longer transmit the load that it could prior to kinking Promptly discontinue use of a winch cable in this condition C Awinch cable made of synthetic rope should be inspected for signs of fraying Replace the cable if fraying is observed shown at right Promptly discontinue use of a winch cable in this condition D Also replace the winch cable if there are fused or melted fibers Such an area of the synthetic rope will be stiff and appear smooth or glazed Promptly discontinue use of a winch cable in this condition 53 WINCH GUIDE Shock Loading WARNING Your winch cable is very strong but it is NOT designed for dynamic or shock loading Shock loading may tension a winch cable beyond its strength and cause the cable to break The end of a broken winch cable under such high loading can cause SEVERE INJURY or DEATH to you and other bystanders Winch cables are designed to NOT absorb energy This is true of both wire rope and syn thetic rope winch cables 1 Never attempt to jerk a load with the winch For example never
75. ion when operating on unfamiliar terrain Be alert to changing terrain Never operate on excessively rough slippery or loose terrain Always follow proper procedures for turning Practice turning at slow speeds before attempting to turn at faster speeds Never turn at excessive speeds Always have this vehicle checked by an authorized POLARIS dealer if it has been involved in an accident Never operate this vehicle on hills too steep for the vehicle or for your abilities Practice on smaller hills before attempting larger hills Always follow proper procedures for climbing hills as described in this manual See page 39 Check the terrain carefully before attempting to climb a hill Never climb hills with excessively slippery or loose surfaces Never apply throttle suddenly Never make sudden gear changes Never go over the top of a hill at high speed Always follow the proper procedures outlined in this manual for traveling downhill and for braking on hills See page 39 Check the terrain carefully before descending a hill Never travel downhill at high speed Avoid going downhill at an angle which would cause the vehicle to lean sharply to one side Travel straight down the hill where possible Always check for obstacles before operating in a new area Never attempt to operate over large obstacles such as large rocks or fallen trees Always follow the proper procedures outlined in this manual when operating over obstacles See page 37 A
76. l Battery Lower Upper A poorly maintained battery will deteriorate rapidly Check Mark Man the battery fluid level often Maintain the fluid level between the upper and lower level marks Add only distilled water Tap water contains minerals that are harmful to a battery 79 MAINTENANCE Battery Battery Removal AWARNING Improperly connecting or disconnecting battery cables can result in an explosion and cause serious injury or death When removing the battery always disconnect the negative black cable first When reinstalling the battery always connect the negative black cable last 1 Remove the seat 2 On conventional batteries remove the battery vent tube 3 Disconnect the black battery cable first Discon nect the red battery cable last 4 Remove the battery hold down strap 5 Lift the battery out of the vehicle Be careful not to tip a conventional battery sideways which could spill electrolyte NOTICE If electrolyte spills immediately wash it off with a solution of one tablespoon baking soda and one cup water to prevent damage to the vehicle 80 MAINTENANCE Battery Battery Installation Using a new battery that has not been fully charged can damage the battery and result in a shorter life It can also hinder vehicle performance Follow the battery charging instructions on page 82 before installing the battery Ensure that the battery is fully charged 2 Place the full
77. lways be careful of skidding or sliding On slippery surfaces such as ice travel slowly and exercise caution to reduce the chance of skidding or sliding out of control Never operate your vehicle in fast flowing water or in water deeper than that specified in this manual See page 40 Wet brakes may have reduced stopping ability Test your brakes after leaving water If necessary apply them lightly several times to let friction dry out the pads 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 SAFETY Operator Safety 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 non POLARIS approved accessories Never exceed the stated load capacity for this vehicle Cargo should be properly distrib uted and securely attached Reduce speed and follow the instructions in this manual for hauling cargo or pulling a trailer Allow a greater distance for braking Always place the transmission in PARK before getting out of the vehicle Always stop the engine before refueling Remove flammable material containers from the box before filling them with fuel Make sure the refueling area is well ventilated and free of any source of flame or sparks Gasoline is extremely
78. lways remember that the winch and winch cable are NOT designed for shock loading 54 WINCH GUIDE Winch Maintenance and Service Safety WARNING Improper or lack of winch maintenance and service could lead to SEVERE INJURY or DEATH Always follow all winch instructions and warnings in this manual 1 Always inspect your winch before each use Inspect for worn or kinked winch cable Also inspect for worn or loose parts including mounting hardware Permit your winch motor to cool down prior to servicing your winch 3 Never work on your winch without first disconnecting the battery connections to prevent accidental activation of the winch 4 For your safety always replace POLARIS winch parts including the cable with genuine POLARIS replacement parts available at your authorized POLARIS dealer 5 Some winch models use wire rope as the winch cable Other winches use a specially designed synthetic rope as the winch cable 6 Never replace a synthetic rope winch cable with a consumer grade polymer rope such as can be purchased in a hardware store Although they may look similar they are NOT alike A polymer rope not designed for winch use will stretch and store excessive energy when winching WARNING Failure of a stretched rope under winching conditions will release all of the stored energy This will increase the chances of SEVERE INJURY or DEATH 59 EMISSION CONTROL SYSTEMS Noise Emission Control System Do not modify the engi
79. ly Clean Often 76 MAINTENANCE Fuses If the engine stops or will not start or if you expe R rience other electrical failures a fuse may need aE EAN FOE Pue MeapuisHr Ss replacement Locate and correct any short circuits a ae me TO O u that may have caused the blown fuse then replace ESTE UBHWE the fuse Spare fuses are provided in the fuse box chassis 20 10A The power steering fuse if equipped is located on ae FUEL BUMP ol the power steering wiring harness near the fuse box If you suspect that a fuse or relay may not be working properly please see your POLARIS dealer Fuse Feature Supported 20A Lights Headlights Taillights 10A Drive AWD 20A_ Accessory Winch Switch 12V Power Receptacle 10A Fuel Pump 20A Electronic Engine Control Starting 30A Power Steering if equipped Lights Poor lighting can result in reduced visibility when driving Headlight and taillight lenses become dirty during normal operation Clean lights frequently and replace burned out lamps promptly Do not operate this vehicle at night or in low light conditions until the headlight is replaced Always make sure lights are adjusted properly for best visibility When servicing a halogen lamp don t touch the lamp with bare fingers Oil from your skin leaves a residue causing a hot spot that will shorten the life of the lamp Headlight
80. m 73 MAINTENANCE Steering Wheel Inspection Check the steering wheel for specified freeplay and smooth operation at the intervals out lined in the Periodic Maintenance Chart beginning on page 57 1 Position the vehicle on a level surface 2 Lightly turn the steering wheel left and right 3 There should be 0 8 1 0 20 25 mm of freeplay 4 If there is excessive freeplay or strange noises or the steering feels rough or catchy have the steering system inspected by an authorized POLARIS dealer Spring Adjustment Adjust the front and rear shock absorber springs by rotating the adjustment cam either clockwise or counter clockwise to increase or decrease spring tension 74 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 POLARIS approved size and type of tires for this vehicle when replacing tires Tire Tread Depth i Always replace tires when tread depth is 1 8 3 mm Z worn to 1 8 3 mm or less Axle and Wheel Nut Torque GA ANS Specifications Inspect the following items occasionally for tightness and if they ve been loosened for main tenance service Do not lubricate the stud or the lug nut
81. n the key to the LIGHTS ON position after starting the engine AWD Differential Lock Switch The AWD Differential Switch has three positions All Wheel Drive AWD Differential Lock Two Wheel Drive 2WD and Off 1 WD Turf Mode Press the top of the rocker switch to engage All Wheel Drive AWD See page 46 for AWD operating instructions Move the rocker switch to the center position to lock the differential and operate in two wheel drive 2WD See page 45 for Differential Lock operating instructions Press the bottom of the switch to unlock the differential and allow the rear drive wheels to operate independently 1WD This mode of operation is well suited to turf driving or when active traction is not needed 23 FEATURES AND CONTROLS Brake Pedal Depress the brake pedal to slow or stop the vehicle Apply the brakes while starting the engine Throttle Pedal Throttle Push the pedal down to increase engine speed Brake p Spring pressure returns the pedal to the rest position when released Always check that the throttle pedal returns normally before starting the engine Make sure there s adequate throttle pedal freeplay See page 72 for throttle pedal adjustment procedures Fuel Cap The fuel tank filler cap is located on the right hand side of the vehicle near the passenger seat When refueling always use either leaded or unleaded gasoline with a minimum pump octane number of 87 R M 2 octane Do not use fuel
82. nd calibration uncertainty Variations in the machine such as wear of components Variation of machine operators such as experience or physique Ability of the worker to reproduce typical work during measurements Environmental factors such as ambient noise or temperature SAFETY Safe Riding Gear The driver and all passengers must wear helmet eye protection gloves long sleeve shirt long pants over the ankle boots and seat belt at all times Protective gear reduces the chance of injury E e Protection Over the Ankle Boots Helmet Helmet Wearing a helmet can prevent a severe head injury Whenever riding this POLARIS vehicle always wear a helmet that meets or exceeds established safety standards Approved helmets in the USA and Canada bear a U S Department of Transportation DOT label Approved helmets in Europe Asia and Oceania bear the ECE 22 05 label The ECE mark consists of a circle surrounding the letter E fol lowed by the distinguishing number of the country which has granted approval The approval number and serial number will also be displayed 051039 on the label 0005 31 SAFETY Safe Riding Gear Eye Protection Do not depend on eyeglasses or sunglasses for eye protection Whenever riding this POLARIS vehicle always wear shatterproof goggles or use a shatterproof helmet face shield POLARIS recommends wearing approved Personal Protective Equipment PPE bearing markings such as VE
83. ne intake or exhaust components as doing so may affect compliance with U S A EPA noise control requirements 40 CFR 205 and local noise level require ments Operation on Public Lands in the U S A Your POLARIS vehicle has a spark arrester that was tested and qualified to be in accordance with the USFS standard 5100 1c Federal law requires that this spark arrester be installed and functional when the vehicle is operated on public lands Operation of off road vehicles on public lands in the U S A is regulated by 43 CFR 420 Violations are subject to monetary penalties Federal regulations can be viewed online at www gpoaccess gov ecfr Crankcase Emission Control System This engine is equipped with a closed crankcase system Blow by gases are forced back to the combustion chamber by the intake system All exhaust gases exit through the exhaust system Exhaust Emission Control System Exhaust emissions are controlled by engine design An electronic fuel injection EFI system controls fuel delivery The engine and EFI components are set at the factory for optimal per formance and are not adjustable The emissions label is located on the frame under the seat Electromagnetic Interference This spark ignition system complies with Canadian ICES 002 This vehicle complies with the EMC requirements of European directives 97 24 EC and 2004 108 EC Non ionizing Radiation This vehicle emits some electromagnetic energy People with acti
84. ng 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 Differential Operation Modes The 4X4 rear axle is equipped with a lockable differential that allows the operator to choose between an open differential or a closed differential AWD Press the top of the rocker switch to engage All Wheel Drive AWD When in AWD the rear wheels rotate at the same speed The front wheels also rotate at the same speed See page 46 for AWD operating instructions 2WD Rear Differential Locked Move the rocker switch to the center position to lock the differen tial and operate in two wheel drive 2WD Locking the differen tial in slippery or low traction conditions helps improve traction When the rear differential is locked both rear wheels rotate at the same speed OFF Differential Unlocked OPERATION T tT f in f T ww Press the bottom of the switch to unlock the differential and allow the rear drive wheels to operate independently 1WD When the rear differential is unlocked the rear wheels can rotate at different speeds Unlock the differential to make maneuvering easier and minimize damage to turf NOTICE Damage to the differential can o
85. ngine Indicator 32 Chrome Wheel Care 0000005 84 Cleaning and Storage 83 86 Cleaning the Exhaust System 71 Cleaning the Spark Arrestor 71 Clothing diu oe eere ee terret oot acd 9 Glutching iR SeRERR EYE yd Es 89 Component Locations sse esse 21 CONSOLE EET eae 22 C Coolant Level Overflow Bottle 66 Coolant Level Radiator 66 Coolant Adding or Changing 65 Cooling Fan 135a rerpas tmu amer cte 65 Cooling System ccr ne bb E waves 65 66 Corrosion Removal Chrome 84 Crankcase Emission Control System 56 D Differential Lock Switch suuu 23 Differential Operation 020 45 Disengaging AWD 0000000 46 Display Units Standard Metric 30 Drive Belt Wear 5d eeu etos estos 91 Drivetrain Break In 00 33 Driving Downhill 000 39 Driving in Reverse 00 000 000 41 Driving on a Sidehill 0000 39 Driving on Slippery Surfaces 38 Driving Over Obstacles 0 37 Driving Procedure 5 005 codes ker 6e 36 Driving Through Water 40 Driving Uphill secs crore RR men 39 Driving with a Passenger 37 Driving After Driving in Water 68 Drying the Transmission
86. o high beam Helmet Seat Belt This lamp flashes for several seconds when the key is turned to the ON position The lamp is a reminder to the operator to ensure all riders are wearing helmets and seat belts before operating NI ED Check Engine This indicator appears if an EFI related fault occurs Do not operate the vehicle if this warning appears Serious engine damage could result See your dealer 28 Instrument Cluster Rider Information Center The rider information center is located in the instrument cluster All segments will light up for one sec ond at start up If the instrument cluster fails to illuminate a battery over voltage may have occurred and the instrument cluster may have shut off to protect the electronic speedometer If this occurs take the vehicle to your POLARIS dealer for proper diagnosis The information center is set to dis play standard units of measurement FEATURES AND CONTROLS BE oe Ph Trip 1 NA iT ioe INTENTI NA IAN V VANUS YANN AN and a 12 hour clock at the factory To change to metric and or a 24 hour clock see page 30 1 Gear Indicator This indicator displays gear shifter position H High Gear L Low Gear N Neutral R Reverse Gear Gear Signal Error or shifter between gears Fuel Gauge The segments of the fuel gauge show the level of fuel in the fuel tank When the last segment clears a low fuel warning is activated All
87. of 12 may ride as a passenger in this vehicle All riders must be able to sit with backs against the seat both feet flat on the floor and both hands on the steering wheel if driving or on a passenger hand hold The driver and all passengers must wear helmet eye protection gloves long sleeve shirt long pants over the ankle boots and seat belt at all times Always use the cab nets or doors while riding in this vehicle Always keep hands and feet inside the vehicle at all times 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 rollover 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 unless marked for off road use 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 visibil ity and operating conditions and your experience Never attempt jumps or other stunts Always inspect the vehicle before each use to make sure it s in safe operating condition Always follow the inspection procedures described in this manual S O 14 AFETY perator Safety Always travel slowly and use extra caut
88. orboards NOTICE Immersion can result in major damage if the vehicle isn t serviced correctly and promptly After immersion always take the vehicle to your dealer service Do not start the engine If it s impossible to bring the vehicle to your dealer before starting the engine perform the service outlined on page 69 and take the vehicle to your dealer at the first opportunity Follow these procedures when operating through water 1 Determine water depths and current before entering water 2 Choose a crossing where both banks have gradual inclines 3 Proceed slowly avoiding rocks and obsta cles 4 Avoid operating through deep or fast flowing water WARNING The large tires on your RANGER may cause the vehicle to float in deep or fast flowing water which could result in loss of control and lead pears to serious injury or death Never cross deep or fast eat Floorboard ea flowing water with your RANGER mm af es 5 After leaving water always dry the brakes by applying light pressure to the pedal repeatedly until braking action is normal NOTICE After running your vehicle in water it s critical that you perform the services outlined in the Periodic Maintenance Chart beginning on page 57 Give special attention to engine oil transmission oil front and rear gearcases if equipped and all grease fittings 40 OPERATION Driving in Reverse Follow these precautions when operating in revers
89. ove to POLARIS in order to continue your warranty coverage You may also be required to obtain documentation from POLARIS in order to register your product in your new country You should warranty register your product at a local POLARIS dealer in your new country immediately after you move to continue your warranty coverage and to ensure that you receive information and notices regarding your vehicle If you purchase from a private party If you purchase a POLARIS product from a private party to be kept and used outside of the country in which the product was originally purchased all warranty coverage will be denied You must nonetheless register your product under your name and address with a local POLARIS dealer in your country to ensure that you receive safety information and notices regarding your product 96 WARRANTY EXPORTED PRODUCTS EXCEPT WHERE SPECIFICALLY REQUIRED BY LAW THERE IS NO WARRANTY OR SERVICE BULLETIN COVERAGE ON THIS PRODUCT IF IT IS SOLD OUTSIDE THE COUNTRY OF THE SELLING DEALER S AUTHORIZED LOCATION This policy does not apply to products that have received authorization for export from POLARIS Dealers may not give authorization for export You should consult an authorized dealer to determine this product s warranty or service coverage if you have any questions This policy does not apply to products registered to government officials or military personnel on assignment outside the country of the selling dealer
90. ow a pre determined point See page 90 for the part numbers of POLARIS products 81 MAINTENANCE Battery Battery Charging Conventional Battery 1 Remove the battery from the vehicle to prevent damage from leaking or spilled electro lyte during charging See page 80 2 Charge the battery with a charging output no larger than 1 10 of the battery s amp hr rat ing Charge as needed to raise the specific gravity to 1 270 or greater 3 Reinstall the battery See page 81 Make sure the positive terminal is toward the driver s side of the vehicle Battery Charging Sealed Battery The following battery charging instructions apply only to the installation of a sealed battery Read all instructions before proceeding with the installation of this battery The sealed battery is already filled with electrolyte and has been sealed and fully charged at the factory Never pry the sealing strip off or add any other fluid to this battery The single most important thing about maintaining a sealed battery is to keep it fully charged Since the battery is sealed and the sealing strip cannot be removed you must use a voltmeter or multimeter to measure DC voltage WARNING An overheated battery may explode causing severe injury or death Always watch charging times carefully Stop charging if the battery becomes very warm to the touch Allow it to cool before resuming charging For a refresh charge follow all instructions carefully 1 Ch
91. part to prevent injuries Do not allow careless or reckless driving Make sure operators are 16 or older with a valid driver s license Do not let people drive or ride after using alcohol or drugs Do not allow operation on public roads unless designated for off highway vehicle access collisions with cars and trucks can occur Do not exceed seating capacity 2 occupants 7179978 Load Passenger Tire Pressure Warning WARNING Passengers can be thrown off This can cause serious injury or death Never carry passengers in cargo box If total payload is greater than 500 Ibs the vehicle must be operated in LOW range WARNING IMPROPER TIRE PRESSURE OR OVERLOADING CAN CAUSE LOSS OF CONTROL RESULTING IN SERIOUS INJURY OR DEATH Reduce speed and allow greater distance for braking when carrying cargo 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 RANGER MID SIZE 400 570 800 570 Crew LSV EV MAXIMUM CARGO BOX LOAD 500 Ibs 500 Ibs 500 Ibs 500 Ibs 226 kg 226 kg 226 kg 226 kg TIRE PRESSURE IN PSI KPa FRONT 10 69 REAR 10 69 FRONT 10 69 REAR 16 110 FRONT 10 69 REAR 14 96 FRONT 20 138 REAR 20 138 M
92. press 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 MAINTENANCE Battery AWARNING 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 Your vehicle may have either a sealed battery which requires little maintenance or a con ventional battery A sealed battery can be identified by its flat covers on the top of the bat tery A conventional battery has six filler caps on the top of the battery Always keep battery terminals and connections free of corrosion If cleaning is necessary remove the corrosion with a stiff wire brush Wash with a solution of one tablespoon baking soda and one cup water Rinse well with tap water and dry off with clean shop towels Coat the terminals with dielectric grease or petroleum jelly Be careful not to allow cleaning solu tion or tap water into the battery Battery Fluid Conventiona
93. r 10 minutes before using it again Never touch push pull or straddle the winch cable while winching a load Never let the winch cable run through your hands even if wearing heavy gloves Never release the clutch on the winch when the winch cable is under load Never use the winch for lifting or transporting people Never use the winch to hoist or suspend a vertical load Never immerse or submerse your winch in water Take your winch to your dealer for service if this occurs Always inspect your winch and winch cable before each use Never winch the hook fully into the winch This can cause damage to winch components Unplug the remote control from the vehicle when the winch is not in use to prevent inadvertent activation and use by unauthorized persons Never grease or oil the winch cable This will cause the winch cable to collect debris that will shorten the life of the cable WINCH GUIDE Winch Operation Read the Winch Safety Precautions in the preceding pages before using your winch Tip aad practicing the operation and use of your winch before you actually need to use it in the field AWARNING Improper winch use can result in SEVERE INJURY or DEATH Always follow all winch instructions and warnings in this manual Each winching situation is unique Take your time to think through the winching you are about to do Proceed slowly and deliberately Never hurry or rush during winching Always pay att
94. railer hitch Trailer towing equip ment is not supplied with this vehicle To avoid injury and property damage always heed the warnings and towing capacities out lined on pages 42 43 27 FEATURES AND CONTROLS Instrument Cluster High water pressure may damage components Wash the vehicle by hand or with a garden hose using mild soap Do not use alcohol to clean the instrument cluster Do not allow insect sprays to contact the lens Speedometer The speedometer displays vehicle speed in either miles per hour MPH or kilometers per hour km h See page 30 Center Indicator Lamps Speedometer Indicator Rider Information MODE Button Lamp Indicates Condition Vehicle Speed When standard mode is selected speed displays in miles per hour When metric mode is selected speed displays in kilometers per hour E Over Temperature This lamp illuminates to indicate an overheated engine If the indicator flashes the overheating condition remains and the system will automatically reduce engine power f EPS Warning This indicator illuminates briefly when the key is turned to the ON position If the light remains on the EPS system is inoperative See your authorized POLARIS dealer for service Neutral This lamp illuminates when the transmission is in neutral and the ignition key is in the ON position High Beam This lamp illuminates when the headlamp switch is set t
95. rain Not all obstacles are immediately vis ible Avoid operating over large obstacles such as large rocks and fallen trees If unavoidable use extreme caution and operate slowly Always have all passengers dismount and move away from the vehicle before operating over an obstacle that could cause a rollover 37 OPERATION Driving On Slippery Surfaces AWARNING Skidding or sliding can cause loss of control or rollover if tires regain traction unexpectedly When operating on slippery surfaces such as ice or loose gravel reduce speed and use extra caution to reduce the chance of skidding or sliding out of control Do not operate on excessively slippery surfaces Whenever riding on slippery surfaces such as wet trails or loose gravel or during freezing 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 br of Osa D LA NA I CIKLS lt S La O Coeco
96. re ride inspection checklist See page 34 6 Pull only light loads 7 Check fluid levels of transmission and all gearcases after the first 25 hours of operation and every 100 hours thereafter 8 During the break in period change both the oil and the filter at 25 hours PVT Break in Clutches Belt A proper break in of the clutches and drive belt will ensure a longer life and better perfor mance Break in the clutches and belt by operating at slower speeds during the break in period as recommended Pull only light loads Avoid aggressive acceleration and high speed operation during the break in period If a belt fails always clean any debris from the duct and from the engine compartment 33 OPERATION Pre Ride Inspection Failure to inspect and verify that the vehicle is in safe operating condition before operating increases the risk of an accident Always inspect the vehicle before each use to make sure it s in safe operating condition Item Remarks Page Brake system pedal travel Ensure proper operation 2 Brake fluid Ensure proper level 73 Park gear Ensure vehicle does not roll when in PARK Ensure PARK light illuminates Front suspension Inspect lubricate if necessary 59 Rear suspension Inspect lubricate if necessary 59 Steering Ensure free operation 74 Tires Inspect condition and pressure l l Wheels fasteners Inspect ensure fastener tightness 75 Fr
97. rform these procedures more often for vehicles subjected to severe use E Emission Related Service D Have an authorized POLARIS dealer perform these services 58 Periodic Maintenance Chart MAINTENANCE Item Maintenance Interval Remarks whichever comes first Hours Calendar Miles Km gt Oil lines fasteners 50H 6M Inspect for leaks and loose fittings gt Engine oil change 100 H 6M Perform a break in oil change at one month gt Oil filter change 100 H 6M Replace with oil change gt Front Gearcase oil if equipped 100 H 6M Inspect level change yearly gt Middle Gearcase oil if equipped 100 H 6M Inspect level change yearly gt Rear gearcase oil if equipped 100 H 6M Inspect level change yearly gt Transmission oil 100 H 6M Inspect level change yearly D Fuel system 100 H 12M Check for leaks at tank cap lines fuel E valve pump throttle body replace lines every 2 years gt Radiator if applicable 100 H 12M Inspect clean external surfaces gt Cooling Hoses 100 H 12M Inspect for leaks gt Engine mounts 100 H 12M 2 Inspect Exhaust muffler pipe 100 H 12M Inspect E Spark plug 100 H 12M Inspect replace as needed D Ignition timing 100 H 12M Inspect gt Wiring 100 H 12M Inspect for wear routing security apply dielectric grease to connectors sub jected to water mud etc x Clu
98. s 5 If carbon is expelled cover or plug the exhaust outlet and rap on the pipe around the clean out plug while revving the engine sev eral more times 6 If particles are still suspected to be in the muffler elevate the rear of the vehicle one foot higher than the front Block the wheels Repeat steps 4 and 5 until no more particles are expelled when the engine is revved 8 Stop the engine Allow the arrester to cool 9 Reinstall the arrester plug and remove the outlet cover or plug 71 MAINTENANCE Throttle System AWARNING Failure to check or maintain proper operation of the throttle system can result in an accident and lead to serious injury or death if the throttle pedal sticks during operation Always check the pedal for free movement and return before starting the engine and occasionally during operation Never start or operate this vehicle if it has a sticking or improperly operating throttle pedal Immediately contact your dealer for service if throttle problems arise Throttle Freeplay Inspection If the throttle pedal has excessive play due to cable stretch or misadjustment it will cause a delay in throttle response especially at low engine speed The throttle may also not open fully If the throttle pedal has no freeplay the throttle may be hard to control and the idle speed may be erratic Check the throttle pedal freeplay at the intervals outlined in the Periodic Maintenance Chart beginning on page 57 Adju
99. s Over Fails to Start Possible Cause Out of fuel Solution Refuel Water is present in fuel Drain the fuel system and refuel Old or non recommended fuel Replace with fresh recommended fuel Fouled or defective spark plugs Inspect plugs and replace if necessary No spark to spark plug Inspect plugs and replace if necessary Water or fuel in crankcase Immediately see your POLARIS dealer Low battery voltage Recharge the battery to 12 8 VDC Mechanical failure See your dealer Engine Backfires Possible Cause Weak spark from spark plug Solution Inspect clean and or replace spark plugs Incorrect spark plug gap or heat range Set gap to specs or replace plugs Old or non recommended fuel Replace with fresh recommended fuel Incorrectly installed spark plug wires See your dealer Incorrect ignition timing See your dealer Mechanical failure See your dealer Loose ignition connections Check all connections and tighten Water present in fuel Replace with fresh recommended fuel Engine Pings or Knocks Possible Cause TROUBLESHOOTING Solution Poor quality or low octane fuel Replace with recommended fuel Incorrect ignition timing See your dealer Incorrect spark plug gap or heat range Set gap to specs or replace plugs Engine Runs Irregularly Stalls or Misfires Possible Cause Sol
100. s authorized location This policy does not apply to Safety Bulletins NOTICE If your product is registered outside of the country where it was purchased and you have not followed the procedure set above your product will no longer be eligible for warranty or service bulletin coverage of any kind other than safety bulletins Products registered to Government officials or military personnel on assignment outside of the country where the product was purchased will continue to be covered by the Limited Warranty 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 or in different countries If any of the above terms are void because of federal state local law all other warranty terms will remain in effect For questions call POLARIS Customer Assistance United States amp Canada 1 800 POLARIS 1 800 765 2747 French 1 800 268 6334 97 WARRANTY U S A EPA Emissions Limited Warranty This emissions limited warranty is in addition to the POLARIS standard limited warranty for your vehicle POLARIS Industries Inc warrants that at the time it is first purchased this emissions certified vehicle is designed built and equipped so it conforms with applicable U S Environmental Protection Agency emission regulations POLA
101. s printed on the label Seat Belt Drive Responsibly Warning WARNING Improper vehicle use can result in SEVERE INJURY or DEATH Be Prepared Fasten seat belts Wear an approved helmet and protective gear ALWAYS use vehicle cab nets and or doors Each rider must be able to sit with back against seat feet flat on the floor and hands on steering wheel or hand holds Stay completely inside the vehicle Seat Belt Drive Drive Responsibly Responsibly Warning Avoid loss of control and rollovers Avoid abrupt maneuvers sideways sliding skidding or fishtailing and never do donuts Slow down before entering a turn Avoid hard acceleration when turning even from a stop Plan for hills rough terrain ruts and other changes in traction and terrain Avoid paved surfaces e Avoid sidehilling riding across slopes Rollovers have caused i severe injuries and death Be Sure Riders Pay Attention and Plan Ahead even on flat open areas If you think or feel the vehicle may tip or roll reduce your risk of injury Keep a firm grip on the steering wheel or hand holds and brace yourself Do not put any part of your body outside of the vehicle for any reason LOCATE AND READ OWNER S MANUAL FOLLOW ALL INSTRUCTIONS AND WARNINGS ALWAYS REVIEW SAFETY VIDEO AND TAKE ROHVA TRAINING rohva org 7179982 10 SAFETY Safety Labels and Locations Proper Use Warning Require Proper Use of Your Vehicle Do your
102. se J v ston Qu zo CFs S ch Remove the rear fill plug and the level check fill plug Place a drain pan under the gearcase Remove the drain plug Allow the oil to drain completely Clean and reinstall the drain plug Torque to specification Add the recommended oil Reinstall both fill plugs Torque to specification D19 e eo o Check for leaks Dispose of used oil properly 62 MAINTENANCE Gearcases Front Gearcase Always check and change the front gearcase oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 57 Maintain the oil level even with the bottom thread of the fill plug hole Refer to the Gearcase Specifications Chart on page 62 for recommended lubricants capaci ties and torque specifications See page 90 for the part numbers of POLARIS products Oil Check The front gearcase fill plug is located on the right side of the front gearcase 1 Position the vehicle on a level surface 2 Remove the fill plug Check the oil level 3 Addthe recommended oil as needed 4 Reinstall the fill plug Torque to specification Oil Change 1 Support the vehicle securely with a jackstand Fill Plug 2 Remove the front tire on the driver s side 3 Remove the fill plug P 4 Place a drain pan under the drain plug on the bottom right hand side Drain Plug 5 Remove the drain plug Drain the oil 6 Clean the drain plug Reinstall the drain plug Torq
103. segments including If the fuel icon fails to display an open or short circuit has occurred in the fuel sensor circuit See Information Display Area This area displays odometer trip meter engine hour meter Under Over Voltage This warning usually indicates that the vehicle is operating at an RPM too low to keep the battery charged It may also occur when the engine is at idle Clock The clock displays time in a 12 hour or 24 hour format See page 30 for reset Service Indicator A flashing wrench symbol alerts the operator that the preset service interval has been reached The vehicle should be brought to your dealer for scheduled 4X4 Indicator This indicator illuminates when the 4X4 system is engaged switch is 2 the fuel icon will flash Refuel immediately Tip your dealer 3 and programmable service hour interval 4 and high electrical load lights cooling fan accessories is applied Drive at a higher RPM or recharge the battery to clear the warning 5 ting instructions 6 maintenance See page 30 for resetting instructions 7 on 4X4 8 Turf Mode Indicator This indicator illuminates when the operator unlocks the differ ential See page 45 29 FEATURES AND CONTROLS Instrument Cluster Rider Information Center Use the MODE button to toggle through the information area options Display Units Standard Metric The display can be changed to display either standard or metric units of measurement
104. smission to low range and carefully use fast aggressive throt tle application to engage clutch WARNING Excessive throttle may cause loss of control and vehicle roll over Climbing over large objects from a stopped position Shift the transmission to low range and carefully use fast brief aggressive throttle application to engage clutch WARNING Excessive throttle may cause loss of control and vehicle roll over Belt slippage from water or snow ingestion into the PVT system Dry out the PVT See page 68 Inspect clutch seals for damage if repeated leaking occurs Clutch malfunction See your POLARIS dealer Poor engine performance Check for fouled plugs or foreign material in fuel tank or fuel lines See your dealer Slippage from failure to warm up belt Always warm up the belt by operating below 30 MPH for one mile 5 miles or more when temperature is below freezing Wrong or missing belt Install the recommended belt Improper break in Always break in a new belt and or clutch See pages 33 and 67 91 TROUBLESHOOTING Engine Doesn t Turn Over Possible Cause Low battery voltage Solution Recharge the battery to 12 8 VDC Loose battery connections Check all connections and tighten Loose solenoid connections Check all connections and tighten Loose electronic control box connections Inspect clean reinstall connectors Engine Turn
105. ssenger weight is added cargo weight may need to be reduced accordingly The recommended tire pressures are listed in the specifications section of this manual and on a label on the vehicle Always follow these guidelines Under ANY of these conditions Do ALL of these steps Passenger and or cargo exceeds half the maximum weight capacity 1 Slow down Operating in rough terrain 2 Verify tire pressure 3 Use extra caution when Operating over obstacles operating Climbing an incline Towing 17 SAFETY Operator Safety Handling Gasoline Gasoline is highly flammable and explosive under certain conditions Always exercise extreme caution whenever handling gasoline Always turn off the engine when refueling Always refuel outdoors or in a well ventilated area free of any source of flame or sparks Always use an approved gasoline container to store fuel and remove the container from the vehicle before filling to avoid fuel ignition due to electrical static discharge Do not smoke or allow open flames or sparks in or near the area where refueling is performed or where gasoline is stored Do not overfill the tank Do not fill the tank neck If gasoline spills on your skin or clothing immediately wash it off with soap and water and change clothing Exposure to Exhaust Engine exhaust fumes are poisonous and can cause loss of consciousness or death in a short time Never start t
106. st the freeplay if necessary 1 Place the transmission in PARK 2 Start the engine Allow it to warm up thoroughly Throttle Pedal 3 Measure the distance the throttle pedal moves before the engine begins to pick up speed Freeplay should be 1 16 to 1 8 inches 1 6 3 2 mm Throttle Body Idle RPM Idle RPM is preset by the manufacturer If the engine idle speed is not satisfactory please see your POLARIS dealer for adjustment Throttle Freeplay Adjustment 1 Remove the seat 2 Locate the throttle cable adjuster 3 Squeeze the end of the rubber boot and slide it far enough to expose the end of the inline cable adjuster 4 Loosen the adjuster lock nut 5 Rotate the boot to turn the adjuster until 1 16 to 1 8 1 5 3 Boot mm of freeplay is achieved at the throttle pedal Tip While adjusting lightly flip the throttle pedal up and down 6 Tighten the lock nut 7 Squeeze the end of the rubber boot and slide it over the Lock Nut cable adjuster to its original position djuster 72 Brakes The front and rear brakes are hydraulic disc type brakes Press down on the brake pedal to engage the brakes See page 24 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
107. standard pressure cap will not allow the recov ery system to function properly See your dealer for the correct replacement part 66 MAINTENANCE POLARIS Variable Transmission PVT System AWARNING Failure to comply with the instructions in this warning can result in severe injury or death Do not modify any component of the PVT system Doing so may reduce its strength so that a failure may occur at a high speed The PVT system has been precision balanced Any modification will cause the system to be out of balance creating vibration and additional loads on components The PVT system rotates at high speeds creating large amounts of force on clutch components As the owner you have the following responsibilities for your own safety and the safety of others Always follow all recommended maintenance procedures Always look for and remove debris inside and around the clutch and vent system when replacing the belt See your dealer as outlined in the owner s manual This PVT system is intended for use on POLARIS products only Do not install it in any other product Always make sure the PVT housing is securely in place during operation Belt Replacement Debris Removal If a belt fails always clean any debris from the duct and from the clutch and engine compart ments when replacing the belt WARNING Failure to remove ALL debris when replacing the belt could result in vehicle damage loss of control and severe injury or death
108. take up slack in the winch cable by moving the winching vehicle in an attempt to move an object This is a dangerous practice It generates high winch cable loads that may exceed the strength of the cable Even a slowly moving vehicle can create large shock loads in a winch cable WARNING SEVERE INJURY or DEATH can result from a broken winch cable 2 Never quickly turn the winch ON and OFF repeatedly jogging This puts extra load on the winch winch cable and generates excessive heat from the motor This is a form of shock loading 3 Never tow a vehicle or other object with your winch Towing an object with a winch produces shock loading of the cable even when towing at slow speeds Towing from a winch also positions the towing force high on the vehicle This can cause instability of the vehicle and possibly lead to an accident 4 Never use recovery straps with your winch Recovery straps are designed to stretch and can store energy This stored energy in the recovery strap is released if a winch cable fails making the event even more hazardous Similarly never use elastic bungie cords for winching 5 Never use the winch to tie down a vehicle to a trailer or other transportation vehicle This type of use also causes shock loading that can cause damage to the winch winch cable or vehicles used Your winch cable is designed and tested to withstand the loads produced by the winch motor when operated from a stationary vehicle A
109. tches drive and driven 100 H 12M Inspect clean replace worn parts D Front wheel bearings 100 H 12M Inspect replace as needed D Brake fluid 200 H 24M Change every two years Spark arrester 300 H 36 M Clean out Idle speed Adjust as needed D Toe adjustment Inspect periodically adjust when parts are replaced Auxiliary brake if equipped Inspect daily adjust as needed Headlight aim Adjust as needed Lubrication Recommendations Check and lubricate all components at the intervals outlined in the Periodic Maintenance Chart beginning on page 57 or more often under severe use such as wet or dusty conditions Items not listed in the chart should be lubricated at the general lubrication interval Item Lube Method Engine Oil PS 4 5W 50 4 Cycle Oil See page 60 Brake Fluid DOT 4 Brake Fluid See page 73 Main Gearcase Oil AGL Gearcase Lubricant amp Transmission See page 62 Transmission Fluid Front Gearcase Oil Demand Drive Fluid See page 63 Front Prop Shaft Yoke U Joint Grease Locate fittings and grease 3 pumps maximum 59 Engine Oil Always check and change the engine oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 57 Always change the oil filter whenever changing oil WARNING Vehicle operation with insufficient deteriorated or contaminated engine oil will cause accelerated wear and may result in engine seizure accident and
110. tective eyewear increases the risk of a serious injuries in the event of an accident Operator and all passengers must always wear an approved helmet that fits properly and eye protection goggles or face shield 16 SAFETY Operator Safety Cab Nets Riding in this vehicle without using the cab nets or doors if equipped increases the risk of serious injury or death in the event of an accident or rollover Always use the cab nets or doors while riding in this vehicle Always keep hands and feet inside the vehicle at all times Failure to Inspect Before Operating Failure to inspect and verify that the vehicle is in safe operating condition before operating increases the risk of an accident Always perform the pre ride inspection before each use of your RANGER to make sure it s in safe operating condition See page 34 Always follow all inspection and maintenance procedures and schedules described in this owner s manual See page 57 Operating With a Load on the Vehicle The weight of both cargo and passengers impacts vehicle operation For your safety and the safety of others carefully consider how your vehicle is loaded and how to safely operate the vehicle Follow the instructions in this manual for loading tire pressure gear selection and speed Do not exceed vehicle weight capacities The vehicle s maximum weight capacity is listed in the specifications section of this manual and on a label on the vehicle When more pa
111. the owner s or operator s improper maintenance or use by accidents for which POLARIS has no responsibility or by acts of God Any qualified repair shop or person may maintain replace or repair the emission control devices or systems on your vehicle POLARIS recommends that you contact an authorized POLARIS dealer to perform any service that may be necessary for your vehicle POLARIS also recommends that you use only Pure POLARIS parts It is a potential violation of the Clean Air Act if a part supplied by an aftermarket parts manufacturer reduces the effectiveness of the vehicle s emission controls Tampering with emission controls is prohibited by federal law California Residents Certain POLARIS off road vehicles are available in 49 state and 50 state versions Only the 50 state models are certified for sale in California The 50 state models available for sale in California are identified by the letter C in the model name e g R13UH88A C The POLARIS 50 state models are designed and built with features such as a reduced cargo box capacity Any modifications to these features may be a violation of the applicable California regulations and may void this limited emissions warranty offered by the manufacturer If you have any questions regarding your warranty rights and responsibilities please contact POLARIS Customer Assistance United States amp Canada 1 800 POLARIS 1 800 765 2747 French 1 800 268 6334 99 MAINTENANCE LOG
112. ty is the responsibility of the vehicle owner This emissions limited warranty does not cover components whose failure does not increase the vehicle s regulated emissions For exhaust emissions emission related components include any engine parts related to the following systems Air induction system Ignition system Fuel system Exhaust gas recirculation systems The following parts are also considered emission related components for exhaust emissions Aftertreatment devices Sensors Crankcase ventilation valves Electronic control units The following parts are considered emission related components for evaporative emissions Fuel Tank Vacuum Control Diaphragms Fuel Cap Control Cables Fuel Line Control Linkages FuelLine Fittings Purge Valves Clamps Vapor Hoses Pressure Relief Valves Liquid Vapor Separator Control Valves Carbon Canister Control Solenoids Canister Mounting Brackets Electronic Controls e Carburetor Purge Port Connector As related to the evaporative emission control system 98 WARRANTY U S A EPA Emissions Limited Warranty The exclusive remedy for breach of this limited warranty shall be at the exclusive option of POLARIS repair or replacement of any defective materials components or products THE REMEDIES SET FORTH IN THIS LIMITED WARRANTY ARE THE ONLY REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF THIS WARRANTY POLARIS SHALL HAVE NO LIABILITY TO ANY
113. ub the affected areas with the steel wool until the corrosion has been removed Clean and polish the wheel as outlined above 84 MAINTENANCE Cleaning and Storage Storage Tips NOTICE Starting the engine during the storage period will disturb the protective film created by fogging and damage could occur Never start the engine during the storage period Clean the Exterior Make any necessary repairs and clean the vehicle as recommended See page 83 Stabilize the Fuel 1 Fill the fuel tank 2 Add POLARIS Carbon Clean Fuel Treatment or POLARIS Fuel Stabilizer Follow the instructions on the container for the recommended amount Carbon Clean removes water from fuel systems stabilizes fuel and removes carbon deposits from pistons rings valves and exhaust systems 3 Allow the engine to run for 15 20 minutes to allow the stabilizer to disperse through the entire fuel delivery system Cil and Filter Change the oil and filter See page 61 Air Filter Air Box 1 Inspect and clean or replace the pre cleaner and air filter See page 70 2 Clean the air box 3 Drain the sediment tube 85 MAINTENANCE Cleaning and Storage Storage Tips Inspect and Lubricate Inspect all cables and lubricate all areas of the vehicle as recommended in the Periodic Main tenance Chart beginning on page 57 Battery Maintenance See pages 81 82 for storage and charging procedures Fluid Levels Inspect the fluid levels Add or change fluids
114. ue to specification 7 Add the recommended oil 8 Reinstall the fill plug Torque to specification 9 Check for leaks 10 Discard used oil properly 63 MAINTENANCE Spark Plugs Spark Plug Recommendations Refer to the specifications section beginning on page 88 for the recommended spark plug type for your vehicle Always torque spark plugs to specification NOTICE Using non recommended spark plugs can result in serious engine damage Always use POLARIS recommended spark plugs Spark Plug Gap Torque Electrode Gap New Plug Torque Used Plug Torque 035 9 mm 18 ft Ibs 24 Nm 18 ft Ibs 24 Nm Spark Plug Inspection Spark plug condition is indicative of engine operation The spark plug firing end condition should be read after the engine is warmed up and the vehicle is driven at higher speeds Immediately check the spark plug for correct color CAUTION A hot exhaust system and engine can cause burns Wear protective gloves when removing a spark plug for inspection 1 Remove the seat 2 Remove the spark plug cap Using the spark plug wrench provided in the tool kit remove the plug by rotating it counter clockwise 3 Reverse the procedure for spark plug installation Torque to specification Normal Plug The normal insulator tip is gray tan or light brown There will be few combustion deposits The electrodes are not burned or eroded This indicates the proper type and heat range for the eng
115. ution Fouled or defective spark plugs Inspect clean and or replace spark plugs Worn or defective spark plug wires See your dealer Incorrect spark plug gap or heat range Set gap to specs or replace plugs Loose ignition connections Check all connections and tighten Water present in fuel Replace with new fuel Low battery voltage Recharge battery to 12 8 VDC Kinked or plugged fuel tank vent line Inspect and replace Incorrect fuel Replace with recommended fuel Clogged air filter Inspect and clean or replace Other mechanical failure Possible Lean Fuel Cause Low or contaminated fuel See your dealer Solution Add or change fuel clean the fuel system Low octane fuel Possible Rich Fuel Cause Fuel is very high octane Replace with recommended fuel Solution Replace with lower octane fuel Engine Stops or Loses Power Possible Cause Solution Out of fuel Refuel Kinked or plugged fuel vent line Inspect and replace Water is present in fuel Replace with new fuel Fouled or defective spark plugs Inspect clean and or replace spark plug Worn or defective spark plug wires See your dealer Incorrect spark plug gap or heat range Set gap to specs or replace plug Loose ignition connections Check all connections and tighten Low battery voltage Recharge the battery to 12 8 VDC Incorrect fuel Repla
116. ve or non active implantable medical devices such as heart monitoring or controlling devices should review the limitations of their device and the applicable electromagnetic standards and directives that apply to this vehicle 56 MAINTENANCE Periodic Maintenance Chart Careful periodic maintenance will help keep your vehicle in the safest most reliable condi tion 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 100 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 Vehicles subjected to heavy or severe use patterns must be inspected and serviced more fre quently Severe Use Definition Frequent immersion in mud water or sand Frequent or prolonged operation in dusty environments Racing or race style high RPM use Prolonged low speed heavy load operation Extended idle Short trip cold weather operation Pay special attention to the oil level A rise in oil level during cold weather can indicate con taminants collecting in the oil sump or crankcase Change oil imm
117. vent damage to the filter paper 3 Remove the air filter 4 Do not attempt to clean the main element Install a new air filter Tip Apply a small amount of general purpose grease to the sealing edges of the filter before installing 5 Inspect the air box for oil or water deposits If present drain them into a suitable container 70 MAINTENANCE Spark Arrester AWARNING Failure to heed the following warnings while servicing the spark arrester could result in serious injury or death Do not perform service on the spark arrester while the system is hot Exhaust system temperatures can reach 1000 F Allow components to cool sufficiently before proceeding Remove any combustible materials from the area Wear eye protection and gloves Do not stand behind or in front of the vehicle while purging Never run the engine in an enclosed area Exhaust contains poisonous carbon monoxide gas that can cause loss of consciousness or death in a very short time Never operate without the spark arrestor Never go under the vehicle while it s inclined Use the following procedure to periodically purge accumulated carbon from the exhaust pipe 1 Remove the arrester clean out plug located on the bottom of the muffler 2 Place the transmission in PARK Start the engine d Clean Out ue Plug c Exhaust Outlet 4 Purge accumulated carbon from the system by momentarily revving the engine several time
118. 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 situations 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 a rollover 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 The RAN
119. y charged battery in the battery holder 3 With conventional batteries install the battery vent tube sealed batteries do not have a vent tube The vent tube must be free of obstructions and securely installed Route the tube away from the frame and vehicle body to prevent contact with electrolyte WARNING Battery gases could accumulate in an improperly installed vent tube and cause an explosion resulting in serious injury or death Always ensure that the vent tube is free of obstructions and is securely installed as recommended 4 Coatthe terminals with dielectric grease or petroleum jelly 5 Connect and tighten the red cable first Connect and tighten the black cable last 6 Verify that cables are properly routed Cables should be safely tucked away at the front and rear of the battery 7 Install the battery hold down strap Battery Storage Whenever the vehicle is not used for a period of three months or more remove the battery from the vehicle ensure that it s fully charged and store it out of the sun in a cool dry place Check battery voltage each month during storage and recharge as needed to maintain a full charge See page 82 POLARIS recommends maintaining battery charge by using a POLARIS Battery Tender charger or by charging about once a month to make up for normal self discharge Battery Tender can be left connected during the storage period and will automatically charge the bat tery if the voltage drops bel
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