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1. proper installation Item Remarks Page Brake system pedal travel Ensure proper operation ion Brake fluid Ensure proper level 106 Front suspension Inspect lubricate if necessary 80 Rear suspension Inspect lubricate if necessary 80 Steering Ensure free operation 107 Tires Inspect condition and pressure ipa Wheels fasteners Inspect ensure fastener tightness 109 Frame nuts bolts fasteners Inspect ensure tightness Fuel and oil Ensure proper levels 48 83 Coolant level Ensure proper level 05 Coolant hoses Inspect for leaks Throttle Ensure proper operation 103 Indicator lights switches Ensure proper operation 43 Air filter pre filter Inspect clean 101 Headlamp Check operation apply Polaris dielec 111 tric grease when lamp is replaced Brake light tail lamp Check operation apply Polaris dielec 113 tric grease when lamp is replaced Seat Latches Push down on both seat backs to 35 ensure the latches are secure Seat Belts Check length of belt for damage 40 check latches for proper operation Cab Nets Check for wear or damage ensure 38 56 OPERATION Starting the Engine A WARNING Engine exhaust contains poisonous carbon monoxide and can cause loss of consciousness resulting in severe injury or death Never run an engine in an enclosed area 1 Sit in the driver s seat and fasten the seat belt 2 Place the transmission in PARK 3 Apply the brakes NOTE
2. Model Total Towed Total Towed Total Hitch Maximum Load Weight Load Weight Vertical Towin Level Ground 15 grade Weight Spee RANGER 1500 Ibs 850 165 150 Ibs 10 mph RZR 681 kg 386 kg 68 1 kg 16 kph 73 EMISSION CONTROL SYSTEMS Noise Emission Control System Do not modify the engine intake or exhaust components as doing so may affect compliance with U S A EPA noise control requirements 40 CFR 205 and local noise level requirements Operation on Public Lands in the U S A Your Polaris vehicle has a spark arrestor that was tested and qualified to be in accordance with the USDA Forest Service Standard 5100 1C Fed eral law requires that this spark arrestor be installed and functional when the vehicle is operated on public lands Operation of off road vehicles on public lands in the U S A is regulated by 43 CFR 8343 Violations are subject to monetary penalties Federal regulations can be viewed online at www gpoaccess gov ecft 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 com ponents are set at the factory for optimal performance and a
3. 69 OPERATION Driving in Reverse Follow these guidelines when operating in reverse 1 2 3 4 5 Alwavs check for obstacles or people behind the vehicle Apply the throttle ightly Never open the throttle suddenly Back slowly Apply the brakes lightly for stopping Avoid making sharp turns A WARNING Failure to use caution when operating in reverse can result in serious injury or death Before shifting into reverse always check for obstacles or people behind the vehicle When it s safe to proceed back slowly Avoid making sharp turns 70 OPERATION Parking on an Incline Avoid parking on an incline if possible If it s unavoidable follow these precautions 1 Place the transmission in PARK 2 Turn the engine off 3 Block the rear wheels on the downhill side WARNING A rolling vehicle can cause property damage and serious injury Always place the transmission in PARK when stopping the engine Always block the downhill side of the wheels if leaving the vehicle on a hill or park the vehicle in a sidehill position instead 71 OPERATION Hauling Cargo A WARNING Overloading the vehicle or carrying or towing cargo improperly can alter vehicle handling and may cause loss of control or brake instability Always follow these precautions when hauling cargo Never exceed the stated load capacity for this vehicle REDUCE SPEED AND ALLOW G
4. 86 87 Transmission 88 89 142 Oil and Filter Care During Storage 123 Oil Change Demand Drive 90 Engine acces sez 85 Engine Oil esp il 84 Front Gearcase 90 Main Gearcase 89 Rear Gearcase 91 Transfer Case 87 Transmission 89 Oil Check Demand Drive 90 Engine 83 Front Gearcase 90 Main Gearcase 88 Transfer Case 86 Transmission 88 Operation on Public Lands 74 Operation Cooling System 95 Operation Transmission 99 100 P Parking on an Incline 71 Parking the Vehicle 59 Passenger Hand Hold Adjustment 36 Periodic Maintenance Chart 75 79 Plug Condition 94 Plug Gap l kirja oa LIS aes 93 Plug 93 Plug 43 Plugs 94 Plugs 93 94 Polaris Products 128 Polishing the Vehicle 121 Pre Ride Inspection 56 Programmable Service Interval 51 Public Lands 74 PVT Break In 55 PVT 100 PVT System Operation 99 100 R Radiator stan as 96 Radiator Coolant Level 98 Rear Gearcase Fluid Change 91 Rear Gearca
5. A WARNING POTENTIAL HAZARD Operating on excessively rough slippery or loose terrain WHAT CAN HAPPEN Loss of traction loss of control accident or overturn resulting in serious injury or death HOW TO AVOID THE HAZARD Do not operate on excessively rough slippery or loose terrain A WARNING POTENTIAL HAZARD Operating this vehicle at excessive speeds WHAT CAN HAPPEN Loss of control and accident resulting in serious injury or death HOW TO AVOID THE HAZARD Operate at speeds appropriate for your skills the conditions and the terrain 27 SAFETY Rider Safety A WARNING POTENTIAL HAZARD Attempting jumps and other stunts WHAT CAN HAPPEN Loss of control accident or overturn resulting in serious injury or death HOW TO AVOID THE HAZARD Never attempt jumps and other stunts Avoid exhibition driving A WARNING POTENTIAL HAZARD Operating frozen bodies of water _ Ma j WHAT CAN HAPPEN Severe injurv or death if the vehicle and or riders fall through the ice HOW TO AVOID THE HAZARD Never operate this vehicle on a frozen bodv of water 28 SAFETY Rider Safety A WARNING POTENTIAL HAZARD Failure to use extra caution when operating this vehicle on unfamiliar terrain WHAT CAN HAPPEN Loss of control or overturn resulting in serious injury or death HOW TO AVOID THE HAZARD Travel slowly and use extra caution wh
6. SPECIFICATIONS RANGER RZR Lubrication System Wet Sump Engine Oil OW 40 Driving Svstem Tvpe Automatic Polaris Variable Transmission Shift Tvpe Dual Range P R N L H Gear Reduction Low 8 71 1 Gear Reduction Reverse 5 94 1 Gear Reduction High 3 14 1 Drive Ratio Front 3 82 1 Drive Ratio Final 3 70 1 Tire Size Front 25x 8 12 Tire Size Rear 25 10 12 Tire Pressure Front 8 psi 55 KPa Tire Pressure Rear 8 psi 55 KPa Brakes Front Rear Foot Activated 4 wheel hydraulic disc Headlights 2 single beam 55W quartz halogen Taillights 2 single beam 5W Brake Lights 2 single beam 5W Instrument Cluster LCD Auxiliary DC Outlet 12V NOTE See your Polaris dealer for clutching specifications 127 POLARIS PRODUCTS Part Number Description Engine Lubricant 2870791 Fogging Oil 12 oz Aerosol 2871281 Premium 4 Synthetic OW 40 4 Cycle Engine Oil qt 2871844 Premium 4 Svnthetic OW 40 4 Cvcle Engine Oil gal Gearcase Transmission Lubricants 2873602 Premium AGL Svnthetic Gearcase Lubricant qt 2873603 Premium AGL Synthetic Gearcase Lube gal 2871653 Premium ATV Angle Drive Fluid 8 oz 2872276 Premium ATV Angle Drive Fluid 2 5 gal 2870465 Pump for Gallon Jug 2876251 Demand Drive LT Premium Fluid 8 0z 237 ml Coolant 2871323 60 40 Cool
7. Steering Wheel Headlights Brush Guard FEATURES AND CONTROLS Component Locations S 7 A Taillights SNIA l DAS Muffler Bae Spark Arrestor itc Trailer Receiver Hitch Bracket This vehicle is equipped with a receiver hitch bracket for a trailer hitch Trailer towing equipment is not supplied with this vehicle To avoid injury and property damage always heed the warnings and towing capacities outlined on pages 72 73 34 FEATURES AND CONTROLS Rear Service Panel The rear service panel is located behind the seats on the frame of the vehicle Remove the seats to access the service panel Remove the ser vice panel to access serviceable engine components and clutches Seats Before operating the vehicle always push down on both seat backs to ensure the latches are secure Seat Adjustments Loosen do not remove the four screws located on the seat bottom Slide the seat forward or rearward to the desired position Tighten the screws to 4 ft lbs 5 4 Nm Do not overtighten Seat Removal 1 Pull up on the seat latch lever located under the rear edge of the seat Tilt the seat forward 3 Lift the seat upward to remove it from the vehicle Reverse this procedure to reinstall the seat Make sure the front edge of the Front Seat Seat Latch seat is properly installed to Retainer the seat retainer bar Press down firmly at the rear of th
8. 74 Emission Control Noise 74 Emissions Limited Warrantv 136 Engaging AWD 46 Engine Break In 55 Engine Fogging 124 Engine Idle Speed 104 Engine 82 85 Engine Speed Displav 50 Engine Starting 57 Engine Stopping 57 Equipment Modifications 13 Etiquette Trail Riding 17 Exhaust Cleaning 102 Exhaust Emission Control System 74 Exhaust System Warning 102 Eye Protection 15 F Fan Cooling 96 Filling the Batterv 117 Filter Care During Storage 123 Filter Cleaning 101 Filter 101 Filter AIT L vase ace celts 101 Fluid Demand Drive 90 Front Gearcase 90 Main Gearcase 88 89 Rear Gearcase 91 Transfer Case 86 87 Transmission 88 89 Fluid Change Demand Drive 90 Front Gearcase 90 Main Gearcase 89 Rear Gearcase 91 Transfer Case 87 Transmission 89 Fluid Check Demand Drive 90 Front Gearcase 90 Main Gearcase 88 Transfer Case 86 Transmission 88 INDEX F Fluid Levels During Storage 123 Fluid Recommendations Gea
9. POLARIS The Way Out 2008 Owner s Manual for Maintenance and Safety AWARNING Improper vehicle use can result in SEVERE INJURY or DEATH NEVER Operate without first viewing safety video and quick start guide e with more than one passenger on hills steeper than 15 degrees on public roads on paved surfaces pavement may seriously affect handling and control with non Polaris approved accessories they may seriously affect stability ALWAYS keep hands and feet inside vehicle reduce speed and use extra caution when carrying a passenger operate slowly in reverse avoid sharp turns or sudden braking make sure passenger reads and understands all safety labels watch for branches or other hazards that could enter vehicle ALWAYS USE AN APPROVED HELMET AND PROTECTIVE GEAR FOR OPERATOR AND PASSENGER NEVER USE ON PUBLIC ROADS NEVER USE WITH DRUGS OR ALCOHOL LOCATE AND READ OWNER S MANUAL FOLLOW ALL INSTRUCTIONS AND WARNINGS IF OWNER S MANUAL IS MISSING CONTACT A POLARIS DEALER FOR A REPLACEMENT For your nearest Polaris dealer GO PGLARIS or visit www polarisindustries com Polaris Sales Inc 2100 Hwy 55 Medina MN 55340 Phone 763 417 8650 Fax 763 542 0599 Part No 9921181 Rev 02 Printed in USA A WARNING Read understand and follow all of the instructions and safety precautions in this manual and on all product labels
10. 137 INQEX eee 140 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 Vehicle Identification Key Number Engine Serial Number Vehicle Model Number Vehicle Identification Number Engine Serial Number Kev Number SAFETY Rider Safety The following signal words and symbols appear throughout this manual and on your vehicle Your safety is involved when these words and sym bols are used Become familiar with their meanings before reading the manual A The safety alert symbol on your vehicle or in this manual alerts you to the potential for injury A WARNING The safetv alert warning indicates a potential hazard that mav result in serious injurv or death CAUTION The safety alert caution indicates a potential hazard that may result in minor injury or damage to the vehicle CAUTION A caution indicates a situation that may result in damage to the vehicle NOTE A note will alert you to important information or instructions SAFETY Safety Decals and Locations Warning decals have been placed on the vehicle for your protection Read and follow the instructions of
11. 11 SAFETY Rider Safety Always follow the proper procedures outlined in this manual for trav eling downhill and for braking on hills Check the terrain carefully before descending a hill Never travel downhill at high speed Avoid going downhill at an angle which would cause the vehicle to lean sharply to one side Travel straight down the hill where possible Avoid crossing the side of a hill e Always check for obstacles before operating in a new area Never attempt to operate over large obstacles such as rocks or fallen trees Always follow the proper procedures outlined in this manual when operating over obstacles Always be careful of skidding or sliding On slippery surfaces such as ice travel slowly and exercise caution to reduce the chance of skid ding or sliding out of control e Never operate in fast flowing water or in water that exceeds the rec ommended maximum depth See page 68 Wet brakes may have reduced stopping ability To dry out the pads apply the brakes lightly several times while driving slowly e 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 making sharp turns in reverse Always use the proper size and type of tires specified for your vehi cle Always maintain proper tire pressure Never exceed the stated load capacity for this vehicle Cargo should be properly distributed and s
12. Always heed the following rules if you make adjustments to this suspen sion e Always return the suspension to the lowest softest setting after the load is removed from the vehicle The increased suspension height will negatively impact vehicle stability when operating without a load Always apply the same adjustment setting to all four wheels Never operate the vehicle on the highest stiffest or second highest preload settings without a total combined payload in the vehicle of 450 165 204 kg or more Payload includes the driver passenger Polaris approved accessories and cargo Never exceed the stated load capacity for this vehicle See page 126 108 MAINTENANCE Tires A WARNING Operating your vehicle with worn tires will increase the possibility of skidding loss of control and an accident which could result in serious injury or death Always replace tires when the tread depth measures 1 8 3 mm or less Improper tire inflation or the use of non standard size or type of tires may adversely affect vehicle handling which could result in vehicle damage or personal injury Always maintain proper tire pressure When replacing tires always use original equipment size and type Tire Tread Depth Always replace tires 1 8 3 mm when tread depth is 4 worn to 1 8 3 mm or less 272 WS Axle and Wheel Nut Torque Specifications Inspect the following items occasionally for tightness and if they
13. Do not press the throttle pedal while starting the engine 4 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 Ifthe engine does not start within five seconds return the ignition switch to the OFF position 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 CAUTION Operating the vehicle immediately after starting could cause engine damage 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 Place the transmission in PARK 3 Turn the engine off A WARNING A rolling vehicle can cause property damage and serious injury Always place the transmission in PARK when stopping the engine 57 OPERATION Braking 1 Release the throttle pedal completely 2 Press on the brake pedal evenly and firmly Practice starting and stopping using the brakes until you re familiar with the controls NOTE When the throttle pedal is released completely and engine speed slows to near idle the vehicle has no engine braking A WARNING Failure to allow for increased braking distance when hauling cargo or towing a trailer may result in accident and injury Always slow down and a
14. 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 owners We proudly produce an exciting line of utility and recreational products e Snowmobiles e All terrain vehicles ATVs e RANGER utility vehicles Victory motorcycles We believe Polaris sets a standard of excellence for all utility and recre ational vehicles manufactured in the world today Many years of experi ence have gone into the engineering design and development of your Polaris vehicle making it the finest machine we ve ever produced For safe and enjoyable operation of your vehicle be sure to follow the instructions and recommendations in this owner s manual Your manual contains instructions for minor maintenance but information about major repairs is outlined in the Polaris Service Manual and should be performed only by a Factory Certified Master Service Dealer MSD Technician Your Polaris dealer knows your vehicle best and is interested in your total satisfaction Be sure to return to your dealership for all of your ser vice needs during and after the warranty period We also take great pride in our complete line of apparel parts and acce
15. Gearcase Lube Transmission Oil Premium AGL Synthetic See page 86 Transfer Case Gearcase Lube Demand Drive Fluid Demand Drive LT Premium See page 90 Front Gearcase Fluid Rear Gearcase Oil Premium ATV Angle Drive page 91 Prop Shaft Polaris Premium U Joint Lube Locate fittings and grease Control Arm Pivot Bushings Front Rear Polaris Premium all Season Grease or grease conforming to NLGI No 2 Locate fittings and grease Stabilizer Bar Bushings Front Rear Polaris Premium all Season Grease or grease conforming to NLGI No 2 Locate fittings and grease Prop Shaft Grease Fitting 80 MAINTENANCE Lubrication Recommendations Stabilizer Bar Bushings Control Arm Pivot Bushings 81 MAINTENANCE Engine Oil Always check and change the engine oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 75 Always change the oil filter whenever changing oil Premium 4 Synthetic Oil Polaris Premium 4 All Season Synthetic engine oil has been specially formulated for use in Polaris 4 cycle engines It s a fully synthetic high performance multi viscosity oil designed to provide the ultimate in lubrication performance and protection See page 128 for the part num bers of Polaris products Premium 4 possesses unsurpassed film strength over the widest possible temperature range It resists viscosity and frictional breakd
16. NOTE The ignition switch must be in the ON position to operate the headlights All Wheel Drive AWD Switch The AWD Switch has two positions OFF All Wheel Drive AWD Two Wheel Drive 2WD Press the top of the rocker switch to engage All Wheel Drive Press the bottom of the switch to operate in two wheel drive AWD See page 46 for AWD operating instructions Auxiliary Outlet The 12 volt accessory plug receptacle has spade connections on the back that may be used to power an auxiliary light or other optional accessories or lights The connections are under the dash 2WD 43 FEATURES AND CONTROLS Gear Selector P Park R Reverse N Neutral L Low Gear H High Gear To change gears stop the vehicle and with the engine idling move the lever to the desired gear Do not attempt to shift gears with engine speed above idle or while the vehicle is moving NOTE Maintaining shift linkage adjustment is important to assure proper transmission function See your dealer if you experience any shifting problems CAUTION Do not attempt to shift the transmission while the vehicle is moving or damage to the transmission could result Always shift when the vehicle is stationary and the engine is at idle Using Low Range and High Range Condition Range to Use Operating at speeds less than 7 MPH 11 km h Low Operating in rough terrain
17. Short Circuit to Battery 55 Diag Lamp Open Load 55 Diag Lamp Short Circuit to Ground 55 Diag Lamp Short Circuit to Battery 56 Pump Relay Open Load 56 Pump Relay Short Circuit to Ground 56 Pump Relay Short Circuit to Battery 58 Cooling Fan Open Load 58 Cooling Fan Short Circuit to Ground 58 Cooling Fan Short Circuit to Battery 41 Intake Air Temp Sensor Open or Short Circuit to Sensor Voltage 41 Intake Air Temp Sensor Short Circuit to Ground 61 END 53 OPERATION Vehicle Break In Period The break in period for your new Polaris vehicle is the first 25 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 and drive components will result in more efficient performance and longer life for these components Per form the following procedures carefully CAUTION Excessive heat build up during the first three hours of operation will damage close fitted engine parts and drive components Do not operate at full throttle or high speeds during the first three hours of use Use of any oils other than those recommended by Polaris may cause serious engine damage We recommend the use of Polaris Premium 4 Synthetic Oil for your 4 cycle engine 54 OPERATION Vehicle Break In Period The break in period for your vehicle is defined on the previous page Please read the informatio
18. grade to remove it Gently rub the affected areas with the steel wool until the corrosion has been removed Clean and polish the wheel as out lined above 122 MAINTENANCE Cleaning and Storage Storage Tips CAUTION 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 120 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 NOTE Carbon Clean removes water from fuel systems stabilizes fuel and removes carbon deposits from pistons rings valves and exhaust sys tems 3 Allow the engine to run for 15 20 minutes to allow the stabilizer to disperse through the entire fuel delivery system Oil and Filter Change the oil and filter See page 84 Air Filter Air Box Inspect and clean or replace the pre filter and air filter See page 101 Clean the air box Drain the sediment tube Fluid Levels Inspect the fluid levels Add or change fluids as recommended in the Periodic Maintenance Chart beginning on page 75 Demand drive fluid front gearcase Rear gearcase fluid e Transmission fluid e Brake fluid change every two years and any time the fluid looks d
19. the minimum and maxi mum marks on the bottle when the fluid is cool 1 Position the vehicle on a level surface 2 Remove the hood See page 37 3 View the coolant level in the overflow bottle 4 Ifthe coolant level is below the safe operating range remove the cap and use a funnel to add coolant through the opening Reinstall the cap NOTE If coolant must be added often or if the overflow bottle runs completely dry there may be a leak in the system Have the cooling system inspected by your Polaris dealer 97 MAINTENANCE Cooling System Radiator Coolant Level Always check and clean the screen and radiator fins at the intervals out lined in the Periodic Maintenance Chart beginning on page 75 Do not obstruct or deflect air flow through the radiator by installing unautho rized accessories in front of the radiator or behind the cooling fan Inter ference with the radiator air flow can lead to overheating and consequentially engine damage A WARNING Escaping steam can cause severe burns Never remove the pressure cap while the engine is warm or hot Always allow the engine to cool before removing the pressure cap 1 Remove the hood See page 37 2 Slowly remove the radiator cap 3 View the coolant level through the opening 4 Use a funnel and slowly add coolant as needed NOTE This procedure is required only if the cooling system has been drained for maintenance and or repair But if the
20. Conventional Battery 1 Remove the battery from the vehicle to prevent damage from leak ing or spilled electrolyte during charging See page 115 2 Charge the battery with a charging output no larger than 1 10 of the battery s amp hr rating Charge as needed to raise the specific grav ity to 1 270 or greater 3 Reinstall the battery See page 116 Make sure the positive terminal is toward the front of the vehicle Battery Charging Sealed Battery The following battery charging instructions apply only to the installa tion 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 Check the battery voltage with a voltmeter or multimeter A fully charged battery will register 12 8 V or higher
21. General causes of fouling are excessive oil use of non recommended injection oil or incorrect throttle body adjust ments Spark Plug Removal and Replacement 1 Remove both seats 2 Remove the rear service Spark Plugs panel See page 35 3 Remove the spark plug cap Using the spark plug wrench provided in the tool kit remove the plug by rotating it counterclockwise 5 Reverse the procedure for spark plug installation Torque to specification See page 93 94 MAINTENANCE Cooling System Operation The engine coolant level is controlled or maintained by the recovery system The recovery system components are the overflow bottle radia tor filler neck radiator pressure cap and connecting hose As coolant operating temperature increases the expanding heated excess coolant is forced out of the radiator past the pressure cap and into the overflow bottle As engine coolant temperature decreases the contracting cooled coolant is drawn back up from the tank past the pressure cap and into the radiator NOTE Some coolant level drop on new vehicles is normal as the system is purging itself of trapped air Observe coolant levels and maintain as recommended by adding coolant to the overflow bottle Adding or Changing Coolant To ensure that the coolant maintains its ability to protect the engine we recommend that the system be completely drained every two years and a fresh mixture of antifreeze and water added
22. HAZARD Never consume alcohol or drugs before or while riding this vehicle A WARNING POTENTIAL HAZARD Removing hands from the steering wheel or hand holds or removing feet from the floor while riding WHAT CAN HAPPEN Loss of control and accident resulting in serious injury or death HOW TO AVOID THE HAZARD The operator should always keep both hands on the steering wheel during operation A passenger should securely grasp the hand holds and plant both feet firmly on the floor A WARNING POTENTIAL HAZARD Failure to inspect the vehicle before operating Failure to properly maintain the vehicle WHAT CAN HAPPEN A Accident equipment damage HOW TO AVOID THE HAZARD l N Always inspect your vehicle before each use to make sure it s in safe operating condition Always follow the inspection and maintenance procedures and schedules described in the owner s manual 20 SAFETY Rider Safety A WARNING POTENTIAL HAZARD Using accessories not approved by Polaris for use on this vehicle WHAT CAN HAPPEN Loss of control accident or overturn resulting in serious injury or death HOW TO AVOID THE HAZARD Never operate with accessories not approved by Polaris for use on this vehicle Non approved accessories may seriously affect vehicle stability A WARNING POTENTIAL HAZARD Operating this vehicle on paved surfaces including sidewalks paths parking lots and driveways WHA
23. Please see your Polaris dealer for all major repairs See page 53 for Blink Codes and Failure Descriptions Use the follow ing procedure to download blink codes failure codes from the EFI module 1 Place the transmission in PARK 2 Stop the engine 3 Turn the key switch to the ON position 4 Turn the key switch off and on three times in less than five seconds then leave the switch on Any blink code numbers stored in the EFI module will display one at a time on the screen The number 61 and the word END displays after all codes have been transmitted 52 FEATURES AND CONTROLS Instrument Cluster Rider Information Center Downloading Codes Blink Failure Description Code No RPM Signal 21 Loss of Synchronization 45 Barometric Pressure Sensor Circuit Low Input 46 Barometric Pressure Sensor Circuit High Input 22 TPS Open or Short Circuit to Ground 22 TPS Short Circuit to Battery 23 RAM Error Defective ECU 42 Engine Temp Sensor Circuit Short to Ground 42 Engine Temp Sensor Circuit Open or Short to Battery 51 Injector 1 Open Load 51 Injector 1 Short Circuit to Ground 51 Injector 1 Short Circuit to Battery 52 Injector 2 Open Load 52 Injector 2 Short Circuit to Ground 52 Injector 2 Short Circuit to Battery 54 Engine Temp Lamp Open Load 54 Engine Temp Lamp Short Circuit to Ground 54 Engine Temp Lamp
24. Should your dealer require any additional assistance they will contact the appropriate person at Polaris This warranty gives you specific legal rights and you may also have other rights which vary from state to state If any of the above terms are void because of state or federal law all other warranty terms will remain in effect Lubricants 1 Mixing oil brands or using non recommended oil may cause engine damage We rec ommend the use of Polaris engine oil 2 Damage resulting from the use of non recommended lubricants may not be covered by warranty SPARK ARRESTOR Polaris warrants that the spark arrestor in this vehicle will meet the efficiency require ments of 43 CFR 8343 1 c for at least 1000 hours when subjected to normal use and when maintenance and installation are in accordance with Polaris recommendations 134 WARRANTY Exported Vehicles EXCEPT WHERE SPECIFICALLY REQUIRED BY LAW THERE IS NO WAR RANTY OR SERVICE BULLETIN COVERAGE ON THIS VEHICLE IF IT IS SOLD OUTSIDE THE COUNTRY OF THE SELLING DEALER S AUTHORIZED LOCA TION This policy does not apply to vehicles that have received authorization for export from Polaris Industries Dealers may not give authorization for export You should consult an authorized dealer to determine this vehicle s warranty or service bulletin coverage if you have any questions This policy does not apply to vehicles registered to government officials or military per sonnel on
25. Turns Over Fails to Start Possible Cause Out of fuel Solution Refuel Clogged fuel filter See vour Polaris dealer Water is present in fuel Drain the fuel svstem 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 Mechanical failure Recharge the battery to 12 8 VDC 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 Incorrectiv installed spark plug wires See vour 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 130 Engine Pings or Knocks TROUBLESHOOTING Possible Cause Poor qualitv or low octane fuel Solution 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 R
26. and handling Check your surroundings and deter mine your path of travel 4 Keeping both hands on the steering wheel slowly release the brakes and depress the throttle with your right foot to begin driving 60 OPERATION New Operator Driving Procedures 5 Drive slowly at first On level surfaces practice starting stopping turning maneuvering using the throttle and brakes and driving in reverse Learn how the vehicle handles when making both left and right turns at a slow speed Check for upper cab net interference See page 39 Increase speed only after mastering all maneuvers at a slow speed After you become skilled at making turns and begin to operate at faster speeds follow these precautions e Avoid sharp turns Never turn while applying heavy throttle e Never make abrupt steering maneuvers e Operate at speeds appropriate for your skills the conditions and the terrain DO NOT do power slides donuts jumps or other driving stunts 61 OPERATION Driving with a Passenger 62 Complete the New Operator Driving Procedures outlined on pages 60 61 Perform the pre ride inspection See page 56 Make sure the passenger is at least 12 years of age and is tall enough to comfortably and safely sit in the passenger seat with the seat belt secured put both feet on the floor and grasp the hand holds Make sure the passenger is wearing appropriate riding gear includ ing an approved he
27. concerned for the safety of our customers and for the general public Therefore we design accessories for your vehicle that take into consideration safe vehicle handling and stability Never operate with accessories not approved by Polaris for use on this vehicle Non approved accessories may seriously affect vehicle stability and could cause the vehicle to overturn Do not install on a Polaris vehicle any equipment that may increase the speed or power of the vehicle or make any other modifications to the vehicle for these purposes Any modifications to the original equipment of the vehicle create a substantial safety hazard and increase the risk of bodily injury The warranty on your Polaris vehicle is terminated if any equipment has been added to the vehicle or if any modifications have been made to the vehicle that increase its speed or power NOTE The addition of certain accessories including but not limited to mow ers 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 13 SAFETY Safe Riding Gear Always wear appropriate clothing when riding a Polaris vehicle Wear protective clothing for comfort and to reduce the chance of injury Eye Protection Footwear Pants 14 SAFETY Safe Riding Gear Helmet Wearing a helmet can prevent a severe head injury
28. hours at the factory To enable or disable the service interval 1 Enter the diagnostic mode Toggle to the service interval screen 2 Press and hold the mode switch for about seven 7 seconds until either ON or OFF appears in the Rider Information Center depend ing on your preference To reset the service interval 1 Enter the diagnostic mode Toggle to the service interval screen 2 Press and hold the mode switch for 2 3 seconds until the wrench icon flashes Release the switch 3 Press and release the mode switch once to advance the setting by one hour Press and hold the mode switch to advance the hours quickly NOTE If you scroll past the intended number press and hold the switch until the hours cycle back to zero 4 When the desired setting is displayed wait until the wrench icon stops flashing The new service interval is now programmed 51 FEATURES AND CONTROLS Instrument Cluster Rider Information Center Diagnostic Mode Miles Kilometers Toggle The display in the tripmeter and odometer can be changed to display either standard or metric units of measurement 1 Enter the diagnostic mode 2 to the screen that displays either kilometers KM miles MP 3 Press and hold the mode switch until the letters flash then press and release the switch once When the display stops flashing the mode has been set Downloading Codes The EFI diagnostic mode is for informational purposes only
29. injury or death Never operate the vehicle with a spongy feeling brake pedal 105 MAINTENANCE Brakes Brake Fluid Inspect the level of the brake fluid before each operation If the fluid level is low add DOT 4 brake fluid only See page 128 for the part num bers of Polaris products 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 Access the brake fluid reservoir through the left front wheel well 1 Position the vehicle on a level surface Brake Fluid l Reservoir Maximum Minimum 2 Place the transmission in PARK 3 View the brake fluid level in the reservoir The level should be between the maxi mum and minimum level lines 4 Ifthe fluid level is lower than the lower level line add brake fluid to the upper line 5 Apply the brake forcefully for a few seconds and check for fluid leakage around the fittings WARNING After opening a bottle of brake fluid always discard any unused portion Never store or use a partial bottle Brake fluid is hygroscopic meaning it rapidly absorbs moisture from the air The moisture causes the boiling temperature of the brake fluid to drop which can lead to early brake fade and the possibility of accident or severe injury 106 Brakes Brake Inspection 1 2 Steering Wheel Inspection Check th
30. off road use only Never operate on public roads Always avoid paved surfaces e Never consume alcohol or drugs before or while operating this vehi cle e Always inspect your vehicle each time you use it to make sure it s in safe operating condition Always follow the inspection and mainte nance procedures and schedules described in this manual e Always keep both hands on the steering wheel during operation A passenger should always be seated in the passenger seat with both feet on the floor and with both hands securely grasping the hand holds e Always travel slowly and use extra caution when operating on unfa miliar terrain Be alert to changing terrain e Never operate on excessively rough slippery or loose terrain e Always follow proper procedures for turning as described in this manual Practice turning at slow speeds before attempting to turn at faster speeds e Always have this vehicle checked by an authorized Polaris dealer if it has been involved in an accident e Never operate this vehicle on hills too steep for the vehicle or for your abilities Practice on smaller hills before attempting larger hills e Always follow proper procedures for climbing hills as described in this manual Check the terrain carefully before attempting to climb a hill Never climb hills with excessively slippery or loose surfaces Never open the throttle suddenly or make sudden gear changes Never go over the top of a hill at high speed
31. pads apply the brakes lightly several times while driving slowly NOTE After running your vehicle in water it s critical that you perform the ser vices outlined in the Periodic Maintenance Chart beginning on page 75 Give special attention to engine oil transmission oil demand drive fluid rear gearcase oil and all grease fittings CAUTION Immersion can result in major damage if the vehicle isn t serviced correctly and promptly After immersion always take the vehicle to your dealer for 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 113 and take the vehicle to your dealer at the first opportunity 68 OPERATION Driving Over Obstacles 1 Be alert Look ahead and learn to read the terrain you re traveling on Watch for hazards such as logs rocks and low hanging branches 2 Before operating in a new area check for obstacles 3 Avoid operating over large obstacles such as rocks and fallen trees If unavoidable use extreme caution and operate slowly 4 Always have a passenger dismount and move away from the vehicle before operating over an obstacle that could cause an overturn A WARNING Severe injury or death can result if your vehicle suddenly comes in contact with a hidden obstacle Not all obstacles are immediately visible Reduce speed and travel with caution in unfamiliar terrain
32. proper diagnosis Gear Indicator This 3 4 5 6 indicator displays gear shifter position P Park R Reverse N Neutral L Low Gear H High Gear 2 AWD Indicator This indicator illuminates when the AWD switch is in the AWD posi tion Engine Hour Display Indicator Service Interval Diagnostic Mode Indicator Low Battery and 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 and high elec trical load lights cooling fan accessories is applied Drive at a higher RPM or recharge the battery to clear the warning Odometer Tachometer Tripmeter Hour Meter Clock Fuel Gauge The segments of the fuel gauge show the level of fuel in the fuel tank When the last segment clears a low fuel warning is activated All segments will flash FUEL will display in the LCD and the speedometer needle will blink Refuel immediately Check Engine Warning Indicator This indicator serves two pur poses The word HOT displays if the engine overheats It also appears if an EFl related fault occurs Do not operate the vehicle if this warning appears Serious engine damage could result FEATURES AND CONTROLS Instrument Cluster Rider Information Center Standard Modes Use the yellow mode switch located near the instrument gauge to toggle through the mode options See page 42 Odometer Mode The odometer rec
33. speed is not satisfactory please see your Polaris dealer for adjustment Throttle Freeplay Adjustment 1 Remove both seats Remove the rear service panel See page 35 2 Locate the throttle cable adjuster 3 Squeeze the end of the rub T8 ber boot and slide it far Bdot 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 LOCK Nut Adjuster 1 5 3 mm of freeplay is achieved at the throttle pedal See page 103 NOTE 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 cable adjuster to its original position 104 MAINTENANCE Brakes The front and rear brakes are hydraulic disc type brakes activated by the brake pedal See page 45 Always check brake pedal travel and the brake fluid reservoir level before each use of the vehicle When applied the brake pedal should feel firm Any sponginess would indicate a possible fluid leak or low brake fluid level which must be corrected before riding See page 106 for brake fluid information If you discover any irregularities in brake system operation including excessive pedal travel contact your dealer for proper diagnosis and repairs A WARNING Operating the vehicle with a spongv brake pedal can result in loss of braking which could cause an accident resulting in severe
34. the decals on the vehicle carefully If any of the decals depicted in this manual differ from the decals on your vehicle always read and follow the instructions of the decals on the vehicle If any decal becomes illegible or comes off contact your Polaris dealer to purchase a replacement Replacement safety decals are provided by Polaris at no charge The part number is printed on the decal Cargo Box Warning WARNING Passengers be thrown off This can cause serious injury or death e Never carry passengers in cargo box Maximum 4X4 Box Load is 300 Ibs 136 4 kg Tire Pressure Cargo Overload Warning WARNING IMPROPER TIRES TIRE __ Cargo Box Warning PRESSURE OR OVERLOADING can Tire Pressure Cargo Overload cause loss of control resulting in Warning SEVERE INJURY OR DEATH TIRE PRESSURE IN PSI KPa 4X4 FRONT 8 55 2 REAR 8 55 2 MAXIMUM WEIGHT CAPACITY INCLUDING DRIVER PASSENGER CARGO AND ACCESSORIES 4X4 is 740 LBS 336 4 kg Reduce speed and allow greater distance for braking when carrying cargo Overloading or carrying tall off center or unsecured loads will increase your risk of losing control Loads should be centered and carried as low as possible in box For stability on rough or hilly terrain reduce speed and cargo Be careful if load extends over the side of the box Read Owner s Manual for more detailed loading information SAFETY Safety D
35. to 5 7 ft Ibs 7 9 Nm 102 MAINTENANCE Throttle System A WARNING Failure to check or maintain proper operation of the throttle system can result in an accident and lead to serious injury or death if the throttle pedal sticks during operation Never start or operate this vehicle if it has a sticking or improperly operating throttle pedal Immediately contact your dealer for service if throttle problems arise Always check the pedal for free movement and return before starting the engine and occasionally during operation Throttle Freeplay If the throttle pedal has excessive play due to cable stretch or mis adjustment 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 Throttle Periodic Maintenance Chart Pedal beginning on page 75 Adjust the freeplay if necessary Throttle Freeplay Inspection 1 Place the transmission in PARK 2 Apply the brakes Start the engine Allow it to warm up thoroughly 3 Measure the distance the throttle pedal moves before the engine begins to pick up speed Freeplay should be 1 16 to 1 8 inches 1 6 3 2 mm 103 MAINTENANCE Throttle System Throttle Body Idle RPM Idle RPM is preset by the manufacturer If the engine idle
36. ve been loosened for maintenance service 27 37 Nm Cast Aluminum Steel Wheel Type Nut Type Location Nut Torque Cast Aluminum Lug Nut Front and Rear 90 ft Ibs 122 Nm Steel 2 Piece Flange Front and Rear 27 ft lbs 37 Nm Nut Any Hub Retaining Front and Rear 80 ft Ibs 108 Nm Nut NOTE Do not lubricate the stud or the lug nut 109 MAINTENANCE Tires A WARNING Improperly installed wheels can adversely affect tire wear and vehicle handling which can result in serious injury or death Always ensure that all nuts are torqued to specification Do not service axle nuts that have a cotter pin installed See your Polaris dealer Wheel Removal 1 2 3 4 5 Position the vehicle on a level surface Place the transmission in PARK Stop the engine Loosen the wheel nuts slightiv Elevate the side of the vehicle bv placing a suitable stand under the frame Remove the wheel nuts and washers Remove the wheel Wheel Installation 1 2 110 Place the transmis a sion in PARK 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 for ward rotation Attach the wheel nuts and washers gt and finger tighten d Carefully lower the vehicle to the ground Torque the wheel nuts to specification See page 109 MAINTENANCE Lights When servicin
37. 0H 12M 1000 1600 Inspect pipe Ignition timing 100 H 12M 1000 1600 Inspect Wiring 100 H 12M 1000 1600 Inspect for wear routing securitv applv dielectric grease to connectors subjected to water mud etc Clutches drive 100H 12M 1000 1600 jInspect clean replace worn and driven parts Drive belt 100 H 12M 1000 1600 Inspect replace as needed Front wheel 100 H 12M 1000 1600 Inspect replace as needed bearings Brake fluid 200 H 24M 2000 3200 Change every two years Spark arrestor 300 H 36 M 3000 4800 Clean out Idle speed Adjust as needed Toe adjustment Inspect periodically adjust when parts are replaced Headlight aim Adjust as needed gt Perform these procedures more often for vehicles subjected to severe use E Emission Related Service Have an authorized Polaris dealer perform these services 79 MAINTENANCE Lubrication Recommendations Check and lubricate all components at the intervals outlined in the Peri odic Maintenance Chart beginning on page 75 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 Fluid Item Lube Method Engine Oil Polaris Premium 4 Synthetic Add to proper level on dipstick OW40 See page 83 Brake Fluid DOT 4 Maintain level between fill lines See page 106 Transmission Oil Premium AGL Synthetic See page 88 Main Gearcase
38. 1 INDEX Idle Speed ssswiiiaomaa 104 Ignition Switch 43 Indicator Service Interval 51 Inspection Axle Nuts 109 Brakes 2 107 Pre Ridens 56 Seat Belts ad ss 40 41 Steering Wheel 107 Throttle Freeplay 103 Wheel Nuts 109 Installation Battery 116 Installation Wheels 110 Instrument Cluster 47 53 Interference Electromagnetic 74 K L Key Periodic Maintenance Chart 76 Kilometers to Miles Toggle 52 Lamp Replacement Headlight 111 Level Coolant 97 98 Light Switch 43 Lights oss halk es avs 111 113 Lights Brake 113 Loads 73 Lubricant Part Numbers 128 Lubrication for Storage 124 Lubrication Recommendations 80 81 M N Maintenance Log 137 139 Maintenance Periodic 75 79 Miles to Kilometers Toggle 52 Mode Switch 42 13 Nets Cabs asda tie cate ke 38 39 New Operator Driving Procedure 60 61 Noise Emission Control System 74 Obst les n n EEEN 69 49 Oil Demand Drive 90 Engine 82 85 Front Gearcase 90 Main Gearcase 88 89 Rear Gearcase 91 Transfer Case
39. 101 Air Filter Cleaning 101 All Wheel Drive Switch 43 All Wheel Drive System 46 Arrestor Spark Warning 102 Auxiliarv Outlet 43 AWD Diagnostics 51 AWD 43 46 AWD 46 Axle Nut Torque 109 B Battery 114 119 Charging 118 Charging Sealed Battery 118 119 Fluid Replenishment 117 Installation 116 115 Storage yoo ohare 117 Before Riding 56 Belt Burning 129 Belt Lite mai 73 Belt 129 Belts Seats aie 40 41 Blink 52 53 BOOtS Sn a 15 Brake Fluid 106 Brake Inspection 107 Brake 113 Brake Pedal 4 02023 aes00 8a4 45 Brake System Break in 55 Brakes e 105 107 Braking ates 58 Break In Period 54 55 Burning Belts 129 140 Cab Net Interference Driver 38 Cab Net Removal Driver 39 Cab Nets 38 39 Cap sies ead eevee 37 Cargos secs say 72 73 Changing Coolant 95 Changing Gears 44 Chart Periodic Maintenance 75 79 Chrome Wheel Care 122 Cleaning and Storage 1
40. 2 Ifthe voltage is less than 12 8 volts recharge the battery at 1 2 amps or less until battery voltage is 12 8 or greater NOTE When using an automatic charger refer to the charger manufacturer s instructions for recharging When using a constant current charger use the guidelines on the next page for recharging 118 Battery MAINTENANCE Battery Charging Sealed Battery NOTE Always verify battery condition before and 1 2 hours after the end of charging State of l Charge Voltage Action Using constant current Charge charger standard amps specified on top of battery 100 12 8 13 0 volts None check at 3 None required mos from date of manufacture 75 100 12 5 12 8 volts May need slight 3 6 hours charge if no charge given check in 3 months Needs charge 5 11 hours 50 75 12 0 12 5 volts At least 13 hours 25 50 11 5 12 0 volts Needs charge verify state of charge 0 25 11 5 volts or less Needs charge with desulfating charger At least 20 hours 119 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 CAUTION High water pressure may damage components Polaris recommends washing the vehicle by hand or with a garden hose using mild soap Certain products including insect repellents and chemicals will damage plast
41. 20 125 Cleaning the Air Filter 101 Cleaning the Exhaust System 102 Cleaning the Spark Arrestor 102 Clock 50 Clothing iat ce Bee een 15 Component Locations 32 34 Condition Spark Plugs 94 Coolant Level 97 Coolant Level Radiator 98 Coolant Adding or Changing 95 Cooling 96 Cooling System 96 98 Cooling System Operation 95 Corrosion Removal Chrome 122 Cover for Storage 124 Crankcase Emission Control System 74 D Demand Drive Fluid 90 Diagnostic Mode 50 52 Diagnostics AWD 51 Diagnostics EFI Blink Codes 53 Diagnostics Gear Circuit 51 Downloading Blink Codes 52 53 Drive Belt Wear 129 Drivetrain Break In 55 Driving Downhill 67 Driving in Reverse 70 Driving on a Sidehill 66 Driving on Slipperv Surfaces 64 Driving Over Obstacles 69 Driving Procedures 60 61 Driving Through Water 68 Driving 65 Driving with a Passenger 62 63 Driving After Driving in Water 100 Drving the Transmission 100 E EFI Blink Codes 52 53 Electromagnetic Interference 74 Emission Control Crankcase 74 Emission Control Exhaust
42. 23 Starting the Engine 57 Steering Wheel Adjustment 36 Steering Wheel Inspection 107 Stopping the Engine 57 Storage Compartment Front 37 120 125 Battery 117 COVES Ser 124 Fluid Levels 123 Inspections 124 Lubrication 124 Oil and Filter 123 Removal 125 Storage Area 124 S Suspension Adjustment 108 Switches 42 43 AWD Switch 43 46 Ignition Switch 43 Light Switch 43 Mode Switch 42 Work Light Switch 42 T Tachometer 49 50 Throttle Freeplay Adjustment 104 Throttle Freeplay Inspection 103 Throttle Freeplay 103 Throttle Pedal 45 Throttle Svstem 103 Tire Tread Depth 109 TES sotto aioe tne 109 110 Torque Axle Nuts 109 Torque Spark Plug 93 Torque Wheel Nut 109 Towing 73 Towing 73 Trail Etiquette 17 Trailer 34 Transfer Case Qil 86 87 Transmission Oil 88 89 Transmission Operation 99 100 Transmission Drying 100 Transporting the Vehicle 125 Tread Depth
43. AND CONTROLS Switches Ignition Instrument Switch Cluster Mode Switch Work Light Switch 12V Accessory Switch Outlet AWD Switch Mode Switch The yellow switch located near the instrument gauge is used to toggle through mode options available such as odometer trip meter hour meter tachometer and clock See page 49 for operation of the modes Work Light Switch Use the work light switch to turn the work light on or off The work light is located at the rear of the vehicle Turn the light on while loading and unloading cargo in low light situations Turn the work light off when driving 42 FEATURES AND CONTROLS Switches Ignition Switch A WARNING Leaving the keys in the ignition can lead to unauthorized use of the vehicle resulting in serious injury or death Always remove the ignition key when the vehicle is not in use The ignition switch is a three position key operated switch Use the ignition switch to start the engine See page 57 for starting procedures The key can be removed from the switch when it is in the OFF position OFF The engine is off Electrical circuits are off except accessory 12V ON Electrical circuits are on Electrical equipment can be used START Turn the key to the START position to engage the electric starter The key returns to the ON position when released Light Switch Use the headlight switch to turn the lights on and off ON
44. Always remove the ignition key when the vehicle is not in use 30 SAFETY Fuel Safety A WARNING Gasoline is highly flammable and is explosive under certain conditions Always exercise extreme caution whenever handling gasoline Always stop the engine when refueling Always refuel outdoors or in a well ventilated area Remove flammable material containers from the box before filling Do not smoke or allow open flames or sparks in or near the refueling area or where gasoline is stored Never refuel while a person is in the vehicle Do not over fill the tank Do not fill the tank neck If gasoline spills on your skin or clothing immediately wash it off with soap and water and change clothing Never start the engine or let it run in an enclosed area Gasoline powered engine exhaust fumes are poisonous and can cause loss of consciousness and death in a short time 31 FEATURES AND CONTROLS Component Locations Your vehicle is equipped with upper and lower cab nets on both sides of the vehicle Cab nets must be used by both operator and passenger at all times Promptly replace worn or damaged cab nets with new cab nets available from your authorized Polaris dealer NOTE The vehicle illustrated below is shown without cab nets only to allow component identification Seat Belts Cab Frame Passenger Hand Hold 32 FEATURES AND CONTROLS Component Locations Storage Compartment under hood
45. N ONE PASSENGER NEVER RIDE AFTER USING DRUGS OR ALCOHOL To reduce the risk of SEVERE INJURY or DEATH NEVER carry a passenger under age 12 or too small to firmly plant feet on the floor and securely grasp hand holds THE PASSENGER MUST ALWAYS wear seat belt use an approved helmet and protective gear eey grasp hand holds and plant feet firmly on the loor tell operator to slow down or stop if uncomfortable get off and walk if conditions require keep hands and feet inside vehicle at all times e watch for branches brush and other hazards that could enter vehicle SAFETY Safety Decals and Locations Discretionary Warning WARNING ALWAYS USE AN APPROVED HELMET AND PROTECTIVE GEAR FOR OPERATOR AND PASSENGER NEVER USE ON PUBLIC ROADS NEVER USE WITH DRUGS OR ALCOHOL Improper vehicle use can result in SEVERE INJURY or DEATH NEVER operate without first viewing safety video and quick start guide e with more than one passenger on hills steeper than 15 degrees on public roads on paved surfaces pavement may seriously affect handling and control e with non Polaris approved accessories they may seriously affect stability ALWAYS keep hands and feet inside vehicle reduce speed and use extra caution when carrying a passenger operate slowly in reverse avoid sharp turns or sudden braking make sure passenger reads and understands all safety labels w
46. Polaris recommends the use of Polaris Premium 60 40 anti freeze coolant or a 50 50 mixture of high quality aluminum compatible anti freeze coolant and distilled water Polaris Premium 60 40 is already premixed and ready to use Do not dilute with water See page 128 for the part numbers of Polaris prod ucts NOTE Always follow the manufacturer s mixing recommendations for the freeze protection required in your area Any time the cooling system has been drained for maintenance or repair replace the coolant If the recovery bottle has run dry the level in the radiator should be inspected Add coolant as needed 95 MAINTENANCE Cooling System Radiator and Cooling Fan Always check and clean the screen and radiator fins at the intervals out lined in the Periodic Maintenance Chart beginning on page 75 Do not obstruct or deflect air flow through the radiator by installing unautho rized accessories in front of the radiator or behind the cooling fan Inter ference with the radiator air flow can lead to overheating and consequent engine damage CAUTION Washing the vehicle with a high pressure hose could damage the radiator fins and impair the radiator s effectiveness Using a high pressure system is not recommended 96 MAINTENANCE Cooling System Coolant Level Always check and change the coolant at the intervals outlined in the Periodic Maintenance Chart begin ning on page 75 Maintain the coolant level between
47. RANTY POLARIS SHALL HAVE NO LIABILITY TO ANY PERSON FOR INCIDENTAL CONSEQUENTIAL OR SPECIAL DAMAGES OF ANY DESCRIP TION WHETHER ARISING OUT OF EXPRESS OR IMPLIED WARRANTY OR ANY OTHER CONTRACT NEGLIGENCE OR OTHER TORT OR OTHERWISE Some states do not permit the exclusion or limitation of incidental or consequential damages or implied warranties so the above limitations or exclusions may not apply to you if inconsistent with controlling state law 133 WARRANTY LIMITATIONS OF WARRANTIES AND REMEDIES ALL IMPLIED WARRANTIES INCLUDING BUT NOT LIMITED TO THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PAR TICULAR PURPOSE ARE LIMITED IN DURATION TO THE ABOVE SIX MONTH WARRANTY PERIOD POLARIS FURTHER DISCLAIMS ALL EXPRESS WARRANTIES NOT STATED IN THIS WARRANTY Some states do not allow limi tations on how long an implied warranty lasts so the above limitation may not apply to you if inconsistent with controlling state law HOW TO OBTAIN WARRANTY SERVICE If your vehicle requires warranty service you must take it to a Polaris Servicing Dealer When requesting warranty service you must present your copy of the Warranty Registra tion form to the dealer THE COST OF TRANSPORTATION TO AND FROM THE DEALER IS YOUR RESPONSIBILITY Polaris suggests that you use your original selling dealer however you may use any Polaris Servicing Dealer to perform warranty service Please work with your dealer to resolve any warranty issues
48. REATER 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 the vehicle to overturn DO NOT TRAVEL FASTER THAN THE RECOMMENDED SPEEDS Vehicle should never exceed 10 mph 16 kph while towing a load on a level grass surface Vehicle speed should never exceed 5 mph 8 kph when towing loads in rough terrain while cornering or while ascending or descending a hill A WARNING Driving with passengers in the cargo box can result in
49. Ride gt Air filter pre filter Daily Inspect clean often replace E as needed Coolant Daily Check level daily change if applicable coolant every 2 years Headlamp tail Daily Check operation apply lamp dielectric grease if replacing gt Air filter Weekly Inspect replace as needed E main element gt Brake pad wear 10H Monthly 100 160 Inspect periodically a Battery 25H Monthly 250 400 Check terminals clean test gt Demand drive fluid 25 Monthly 250 400 jInspect level change yearly gt Rear gearcase oil 25H Monthly 250 400 Inspect level change yearly gt Main gearcase oil 25H Monthly 250 400 Inspect level change yearly gt Transfer case oil 25H Monthly 250 400 Inspect level change yearly gt Perform these procedures more often for vehicles subjected to severe use E Emission Related Service Have an authorized Polaris dealer perform these services 77 MAINTENANCE Periodic Maintenance Chart Item Maintenance Interval Remarks whichever comes first Hours Calendar Miles Km gt Engine breather 25H Monthly 150 250 Inspect replace if necessary E filter if equipped gt Engine oil change 25H 1M Perform a break in oil and break in filter change at one month E Throttle cable 50 H 6M 300 500 Inspect adjust lubricate E ETC switch replace if necessary E Throttl
50. T CAN HAPPEN Loss of control and accident resulting in serious injury or death HOW TO AVOID THE HAZARD This vehicle s tires are designed for off road use only not for use on pavement Paved surfaces may seriously affect handling and control of the vehicle and may cause the vehicle to go out of control Avoid operating the vehicle on pavement If you must operate on a paved surface travel slowly and do not make sudden turns or stops 4 WARNING POTENTIAL HAZARD Operating this vehicle on public streets roads or highways WHAT CAN HAPPEN Collision with another vehicle HOW TO AVOID THE HAZARD Never operate this vehicle on any public street road or highway including dirt or gravel In many areas it s illegal to operate vehicles of this type on public streets roads and highways 21 SAFETY Rider Safety A WARNING POTENTIAL HAZARD Improperly operating over obstacles WHAT CAN HAPPEN Loss of control or overturn A resulting in serious injury or death HOW TO AVOID THE HAZARD Before operating in a new area check for obstacles Avoid operating over large l obstacles such as rocks and fallen trees when possible If unavoidable use extreme caution and operate slowly A WARNING POTENTIAL HAZARD Skidding or sliding WHAT CAN HAPPEN Loss of control accident or overturn resulting in serious injury or death HOW TO AVOID THE HAZARD Always follow proper procedures for operat
51. Tire 109 Tread Lightly 17 Trip Meter is 49 Vehicle Identification Numbers 4 Vehicle Immersion 113 Vehicle Transport 125 Warning Symbols 5 Washing the Vehicle 120 121 Water Immersion of Vehicle 113 Wear Drive Belt 129 Weight Hitch 73 Wheel Installation 110 Wheel Nut Torque 109 Wheel Removal 110 Work Light Switch 42 143
52. Whenever riding this Polaris vehicle always wear a helmet that meets or exceeds established safety standards Approved helmets in the USA and Canada bear a U S Department of Transportation DOT label Approved helmets in Europe Asia and Oceania bear the ECE 22 05 label The ECE mark consists of a circle surrounding the letter E followed by the distinguishing number of the country which has 051039 granted approval The approval number and serial 0006 31 number will also be displayed on the label Eye Protection Do not depend on eyeglasses or sunglasses for eye protection When ever riding a 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 VESC 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 footwear Do not ride a Polaris vehicle with bare feet Clothing Wear long sleeves and long pants to protect arms and legs 15 SAFETY Rider Safety Age Restrictions This vehicle is ADULT VEHICLE ONLY Operation is prohibited for anyone under 16 years of age or anyone without a valid driver s license Never operate with a passenger under the age of 12 Make sure any passenger is tall enough to comfortably and safely reach the hand holds and place bot
53. a Polaris product from a private citizen outside of the country in which the vehicle was originally purchased all warranty coverage will be denied Notice If your vehicle is registered outside of the country where it was purchased and you have not followed the procedure set out above your vehicle will no longer be eligible for war ranty or service bulletin coverage of any kind Vehicles registered to Government offi cials or military personnel on assignment outside of the country where the vehicle was purchased will continue to be covered by the basic warranty For questions call Polaris Customer Assistance United States 1 763 417 8650 Canada 1 204 925 7100 135 WARRANTY U S A EPA Emissions Limited Warranty This All Terrain Vehicle ATV or Off Road Utility Vehicle ORUV emissions limited warranty is in addition to the Polaris standard limited warranty for this vehicle Polaris warrants that this vehicle is 1 designed built and equipped to conform at the time of initial sale with the requirements of 40 CFR 1051 and 2 free from defects in materials and workmanship that may keep it from meeting these requirements The emissions warranty period for this vehicle begins on the date the vehicle is deliv ered to the original retail purchaser and ends 30 months 2 5 years after that date or after 5000 km 3100 miles or after 500 hours of operation whichever comes first This emission related warranty covers component
54. abled the AWD remains enabled until the AWD switch is turned off If the switch is turned off while the demand drive unit is moving it will not disengage until the rear wheels regain traction Engage the AWD switch before getting into conditions where front wheel drive may be needed If the rear wheels are spinning release the throttle before switching to AWD CAUTION Switching to AWD while the rear wheels are spinning may cause severe drive shaft and gearcase damage Always switch to AWD while the rear wheels have traction or are at rest 46 FEATURES AND CONTROLS Instrument Cluster Your vehicle is equipped with an instrument cluster that senses vehicle speed from the transmission The instrument cluster measures distance in miles as well as time hours of operation and engine RPM Speedometer Speedometer Needle Rider gt Information ay tS Center NOTE In addition to showing vehicle speed the speedometer needle flashes when the fuel level is low 47 FEATURES AND CONTROLS Instrument Cluster Rider Information Center The rider information center is located in the instrument cluster All seg ments will light up for 2 5 seconds at start up NOTE Ifthe instrument cluster fails to illuminate a battery over voltage may 48 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
55. ages 117 119 for storage and charging procedures Storage Area Covers Be sure the storage area is well ventilated Cover the vehicle with a gen uine Polaris cover NOTE Do not use plastic or coated materials They do not allow enough ven tilation to prevent condensation and may promote corrosion and oxi dation 124 MAINTENANCE Cleaning and Storage Removal from Storage 1 Check the battery electrolyte level and charge the battery if neces sary Install it in the vehicle Make sure the battery vent hose is routed properly and that it s not pinched or restricted in any way 2 Make sure the spark plug is tight 3 the fuel tank with fuel 4 Check all the points listed in the Daily Pre Ride Inspection section on page 56 NOTE Tightness of the bolts nuts and other fasteners should be checked by an authorized Polaris dealer 5 Lubricate at the intervals outlined in the Periodic Maintenance Chart beginning on page 75 A WARNING Engine exhaust contains poisonous carbon monoxide and can cause loss of consciousness or death Never run an engine in an enclosed area Transporting the Vehicle Follow these procedures when transporting the vehicle 1 Place the transmission in PARK Stop the engine 2 Remove the key to prevent loss during transporting 3 Secure the fuel cap and seats 4 Always tie the frame of the Polaris vehicle to the transporting unit securely with suitable straps or rope Do not
56. ant gal 2871534 60 40 Coolant qt Grease Specialized Lubricants 2871312 Grease Gun Kit Premium All Season 3 oz 2871322 Premium All Season Grease 3 oz cartridge 2871423 Premium All Season Grease 14 oz cartridge 2871460 Starter Drive Grease 2 oz 2871515 Premium U Joint Lube 3 oz 2871551 Premium U Joint Lube 14 oz 2871329 Dielectric Grease Nyogel Additives Miscellaneous 2871326 Carbon Clean Plus 12 oz 2870652 Fuel Stabilizer 16 oz 2872189 DOT 4 Brake Fluid 2871956 Loctite 565 Thread Sealant 2859044 Polaris Battery Tender Charger 128 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 65 Driving at low RPM or ground speed 3 7 MPH Drive ata higher speed or use low range more frequentiv See page 44 Insufficient warm up at low ambient tempera tures 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 flex ible and prevent belt burning Slow easv clutch engage ment 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
57. aration and set up of your vehicle is very important in ensuring trou ble free operation Purchasing a machine in the crate or without proper dealer set up will void your warranty coverage WARRANTY COVERAGE AND EXCLUSIONS LIMITATIONS OF WARRANTIES AND REMEDIES The Polaris limited warranty excludes any failures that are not caused by a defect in material or workmanship This warranty does not cover accidental damage normal wear and tear abuse or improper handling This warranty also does not cover any vehicle that has been altered structurally modified neglected improperly maintained used for rac ing or used for purposes other than for which it was manufactured or for any damages which occur during trailer transit or as a result of unauthorized service or the use of unauthorized parts In addition this warranty does not cover physical damage to paint or finish stress cracks tearing or puncturing of upholstery material corrosion or defects in parts components or the vehicle due to fire explosions or any other cause beyond Polaris control This warranty does not cover the use of unauthorized lubricants chemicals or fuels that are not compatible with the vehicle The exclusive remedy for breach of this warranty shall be at Polaris exclusive option repair or replacement of any defective materials or components or products THE REMEDIES SET FORTH IN THIS WARRANTY ARE THE ONLY REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF THIS WAR
58. aris recommends the use of common household aerosol furniture polish for polishing the finish on your Polaris vehicle Follow the instructions on the container Polishing Tips e Avoid the use of automotive products some of which can scratch the finish of your vehicle Always use clean cloths and pads for cleaning and polishing Old or reused cloths and pads may contain dirt particles that will scratch the finish 121 MAINTENANCE Cleaning and Storage Chrome Wheel Care if equipped Proper maintenance will protect chrome wheels from corrosion pre serve wheel life and ensure a like new appearance for many years NOTE 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 pol ished chrome wheel Choose a product suitable for chrome finishes Read and follow the product labels and instructions Removing Corrosion If light rust is found on the chrome finish use steel wool 0000 OTT
59. ark or contaminated e Coolant test strength fill 123 MAINTENANCE Cleaning and Storage Storage Tips Inspect and Lubricate Inspect all cables and lubricate all areas of the vehicle as recommended in the Periodic Maintenance Chart beginning on page 75 Fog the Engine 1 Treat the fuel system with Polaris Carbon Clean Follow the instruc tions on the container Start the engine Allow it to idle for several minutes so the Carbon Clean reaches the injectors Stop the engine 2 Remove the spark plugs and add 2 3 tablespoons of Premium 4 Syn thetic OW40 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 NOTE 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 94 Apply dielectric grease to the inside of each spark plug cap Do not reinstall the caps onto the plugs at this step 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 protec tive 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 7 Reinstall the spark plug caps to the spark plugs Battery Maintenance See p
60. assignment outside the country of the selling dealer s authorized location This policy does not apply to Safety Recalls How to Get Service In the Country where your vehicle was purchased Warranty or Service Bulletin repairs must be done by an authorized Polaris dealer If you move or are traveling within the country where your vehicle was purchased Warranty or Service Bulletin repairs may be requested from any authorized Polaris dealer who sells the same line as your vehicle Outside the Country where your vehicle was purchased If you are traveling temporarily outside the country where your vehicle was purchased you should take your vehicle to an authorized Polaris dealer You must show the dealer photo identification from the country of the selling dealer s authorized location as proof of residence Upon residence verification the servicing dealer will be authorized to per form the warranty repair If You Move If you move to another country be sure to contact Polaris Customer Assistance and the customs department of the destination country before you move Vehicles importation rules vary considerably from country to country You may be required to present docu mentation of your move to Polaris Industries in order to continue your warranty cover age You may also be required to obtain documentation from Polaris Industries in order to register your vehicle in your new country If Purchased From A Private Party If you purchase
61. atch for branches or other hazards that could enter vehicle LOCATE AND READ OWNER S MANUAL FOLLOW ALL INSTRUCTIONS AND WARNINGS IF OWNER S MANUAL IS MISSING CONTACT A POLARIS DEALER FOR A REPLACEMENT SAFETY Rider Safety A WARNING Failure to follow the warnings contained in this manual can result in severe injury or death Your Polaris vehicle is not a toy and can be hazardous to operate This vehicle handles differently than cars trucks or other off road vehicles A collision or rollover can occur quickly even during routine maneuvers like turning or driving on hills or over obstacles if you fail to take proper precautions Read and understand your owner s manual and all warnings before operating the vehicle Always heed the following instructions and procedures which are outlined in further detail within your owner s manual e Read this manual and all labels carefully Follow the operating proce dures described e Never carry a passenger until you have operated this vehicle for at least two hours and have completed the New Operator Driving Proce dures outlined on pages 60 61 Operation is prohibited for anyone under 16 years of age or anyone without a valid driver s license Never operate with a passenger under the age of 12 Make sure any passenger is tall enough to comfortably and safely reach the hand holds and place both feet on the floor Riders should wear seat belts at all time
62. ate to oncoming operators by signaling the number of vehi cles in your group When stopping move your vehicle to the edge of the trail as far as possible to allow others to pass safely 17 SAFETY Rider Safety A WARNING POTENTIAL HAZARD Operating this vehicle without proper instruction WHAT CAN HAPPEN Loss of control and accident resulting in serious injury or death HOW TO AVOID THE HAZARD The risk of an accident is greatly increased if the operator does not know how to operate the vehicle properly in different situations and on different types of terrain All operators must read and understand the owner s manual and all warning and instruction labels before operating the vehicle A WARNING POTENTIAL HAZARD Turning improperly WHAT CAN HAPPEN Loss of control accident or overturn resulting in serious injury or death HOW TO AVOID THE HAZARD Avoid sharp turns Never turn while applying heavy throttle Never make abrupt steering maneuvers Operate at speeds appropriate for your skills the conditions and the terrain DO NOT do power slides donuts jumps or other driving stunts Practice turning at slow speeds before attempting to turn at faster speeds A WARNING POTENTIAL HAZARD Riding in this vehicle without wearing the seat belt WHAT CAN HAPPEN Serious injury or death in the event of an accident or sudden stop HOW TO AVOID THE HAZARD Always make sure the seat belts are se
63. attach tie straps to the front control arm bolt pockets 125 SPECIFICATIONS RANGER RZR Gross Vehicle Weight 1727 Ibs 783 kg Dry Weight 945 Ibs 429 kg Fuel Capacity 7 gal 26 5 1 Engine Oil Capacitv 2 qts 1 9 1 Coolant Capacitv 4 8 qts 4 5 1 Rear Gearcase Oil Capacitv 18 oz 532 ml Demand Drive Fluid Capacitv 6 75 oz 200 ml Transmission Oil Capacitv 24 oz 710 ml Transfer Case Oil Capacity 14 oz 414 ml Front Storage Capacity 25 Ibs 11 3 kg Rear Cargo Box Capacity 300 Ibs 136 kg Maximum Weight Capacity Payload 740 Ibs 336 4 kg riders cargo accessories Receiver Hitch Tongue Capacity 150 165 68 kg Receiver Hitch Towing Capacity 1500 165 680 kg Overall Length 102 in 259 cm Overall Width 50 in 127 cm Overall Height 68 5 in 174 cm Wheelbase 77 in 196 cm Ground Clearance 10 in 25 4 cm Engine 4 valve 4 stroke twin cylinder with counterbalance Displacement 760 cc Bore x Stroke 80mm x 76mm Alternator Output 500 W 3000 RPM Compression Ratio 10 1 Starting System Electric Fuel System Electronic fuel injection Ignition System ECU Spark Plug Gap RC7YC 035 in 0 9 mm Front Suspension Independent double a arm w 9 in 23 cm of travel Rear Suspension Independent double a arm w 9 5 in 24 cm of travel 126
64. cifications Drain Plug Fluid Check The fill plug and level check plug are located on the left side of the transfer case The fluid level is sufficient when fluid flows out of the check plug hole at step 4 1 Position the vehicle on a level surface 2 Remove the fill plug 3 Remove the level check plug 4 Add the recommended fluid to the fill plug hole until it begins to flow out of the check plug hole Reinstall the level check plug Torque to specification 6 Reinstall the fill plug Torque to specification 86 MAINTENANCE Gearcases Transfer Case Fluid Change The drain plug is located on the bottom of the transfer case Access the drain plug through the drain hole in the skid plate 1 i ti 8 9 Remove the fill plug Place a drain pan under the drain plug Remove the drain plug Allow the fluid to drain completelv Clean the drain plug Reinstall the drain plug with a new o ring Torque to specification Remove the level check plug Add the recommended fluid to the fill plug hole until it begins to flow out of the check plug hole Reinstall the level check plug Torque to specification Reinstall the fill plug Torque to specification 10 Check for leaks Discard used fluid properly 87 MAINTENANCE Gearcases Transmission Main Gearcase Always check and change the fluid at the intervals outlined in the Peri odic Maintenance Chart beginning on page 75 Refer to th
65. cities and torque specifications Fluid Check The fill plug is located on the bottom right side of the demand Fill Plug drive unit Maintain the fluid level even with the bottom thread of the fill plug hole 1 Position the vehicle on a level surface 2 Remove the fill plug Check the fluid level 3 Add the recommended fluid as needed 4 Reinstall the fill plug l Torque to specification Drain Plug Fluid Change The drain plug is located on the bottom of the gearcase Remove the fill plug Place a drain pan under the drain plug Remove the drain plug Allow the fluid to drain completelv Clean the drain plug If the o ring is damaged install a new o ring Reinstall the drain plug Torque to specification Add the recommended fluid Maintain the fluid level even with the bottom thread of the fill plug hole Reinstall the fill plug Torque to specification Check for leaks Discard used fluid properlv QAS Ara 90 MAINTENANCE Gearcases Rear Gearcase Always check and change the fluid at the intervals outlined in the Peri odic Maintenance Chart beginning on page 75 Refer to the Gearcase Specifications Chart on page 92 for recommended lubricants capacities and torque specifications Fluid Check The fill plug is located on the right side of the rear gearcase Maintain the fluid level even with the bottom thread of the fill plug hole 1 Position the vehicle on a level surface 2 Re
66. ctions Check all connections and tighten Low batterv voltage Recharge the batterv to 12 8 VDC Incorrect fuel Replace 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 132 WARRANTY LIMITED WARRANTY Polaris Sales Inc 2100 Highway 55 Medina MN 55340 gives a SIX MONTH LIM ITED WARRANTY on all components of your Polaris vehicle against defects in mate rial or workmanship This warranty covers the parts and labor charges for repair or replacement of defective parts which are covered by this warranty This warranty begins on the date of purchase This warranty is transferable to another consumer during the warranty period through a Polaris dealer REGISTRATION At the time of sale the Warranty Registration Form must be completed by your dealer and submitted to Polaris within ten days Upon receipt of this registration Polaris will record the registration for warranty No verification of registration will be sent to the purchaser as the copy of the Warranty Registration Form will be the warranty entitle ment If you have not signed the original registration and received the customer copy please contact your dealer immediately NO WARRANTY COVERAGE WILL BE ALLOWED UNLESS YOUR VEHICLE IS REGISTERED WITH POLARIS Initial dealer prep
67. cured for both the operator and passenger before riding 18 SAFETY Rider Safety A WARNING POTENTIAL HAZARD Riding in this vehicle without using the cab nets WHAT CAN HAPPEN Serious injury or death in the event of an accident or overturn HOW TO AVOID THE HAZARD Always use the cab nets while operating the vehicle A WARNING POTENTIAL HAZARD Failure to follow the minimum age recommendations for this vehicle WHAT CAN HAPPEN Serious injury or death the child or others HOW TO AVOID THE HAZARD Operation is prohibited for anyone under 16 years of age or anyone without a valid driver s license Never operate with a passenger under the age of 12 Make sure any passenger is tall enough to comfortably and safely reach the hand holds and place both feet on the floor A WARNING POTENTIAL HAZARD Riding this vehicle without wearing an approved helmet and eye protection WHAT CAN HAPPEN Head injury eye injury or death in the event of an accident HOW TO AVOID THE HAZARD Operator and passenger Always wear an approved helmet that fits properly Always wear eye protection goggles or face shield 19 SAFETY Rider Safety A WARNING POTENTIAL HAZARD Riding this vehicle after consuming alcohol or drugs WHAT CAN HAPPEN Accident resulting in serious injury or death due to affected judgment balance and perception and slower reaction time HOW TO AVOID THE
68. defect in material or workman ship This limited warranty does not cover damage due to accidents abuse or improper handling maintenance or use This limited warranty also does not cover any engine that has been structurally altered or any engine that has been used in racing competition This limited warranty also does not cover physical damage corrosion or defects caused by fire explosions or other similar causes beyond the control of Polaris If you have any questions regarding your warranty rights and responsibilities you should contact the Polaris Warranty Department at 1 763 417 8650 136 MAINTENANCE LOG Use the following chart to record periodic maintenance DATE MILES KM OR HOURS TECHNICIAN SERVICE PERFORMED COMMENTS 137 MAINTENANCE LOG DATE MILES KM OR HOURS TECHNICIAN SERVICE PERFORMED COMMENTS 138 MAINTENANCE LOG DATE MILES KM OR HOURS TECHNICIAN SERVICE PERFORMED COMMENTS 139 INDEX A Accessory Outlet 43 Adding Coolant 95 Adjustment Headlight Beam 112 Seati ss fe sures 35 Steering Wheel 36 Suspension 108 Throttle Freeplay 104 Age Restrictions 16 Air Filter
69. e Fluid 532 ml 54 68 Nm 3 5 Nm 92 MAINTENANCE Spark Plugs CAUTION Using non recommended spark plugs can result in serious engine damage Always use Polaris recommended spark plugs Refer to the specifications section beginning on page 126 Spark Plug Gap Torque Model Electrode Gap New Plug Torque Used Plug Torque RANGER 035 9 mm 18 ft Ibs 18 ft Ibs RZR 24 Nm 24 Nm 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 See page 94 A WARNING A hot exhaust system and engine can cause serious burns Wear protective gloves when removing a spark plug for inspection 93 MAINTENANCE Spark Plugs Spark Plug Condition 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 indi cates the proper type and heat range for the engine and the service NOTE The tip should not be white A white insulator tip indicates overheating caused by use of an improper spark plug or incorrect 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
70. e Gearcase Specifications Chart on page 92 for recommended lubricants capacities and torque specifications Fluid Check The fill plug is located on the left side of the gearcase Maintain the fluid level at the bottom of the fill plug hole 1 Position the vehicle on a level surface Remove the fill plug 3 Check the fluid level Add the recommended fluid as needed 5 Reinstall the fill plug Torque to specification 88 MAINTENANCE Gearcases Transmission Main Gearcase Fluid Change The drain plug is located on the bottom of the gearcase Access the drain plug through the drain hole in the skid plate 1 Remove the fill plug Place a drain pan under the drain plug Remove the drain plug Allow the fluid to drain completely Clean the drain plug Reinstall the drain plug with a new o ring Torque to specification Add the recommended fluid to the fill hole Maintain the fluid level at the bottom of the fill plug hole Do not overfill Reinstall the fill plug Torque to specification OY ey 8 Check for leaks Discard used fluid properly Transfer Case Drain Plug Main Gearcase Drain Plug Rear Drain Plug 89 MAINTENANCE Gearcases Demand Drive Unit Front Gearcase Always check and change the fluid at the intervals outlined in the Peri odic Maintenance Chart beginning on page 75 Refer to the Gearcase Specifications Chart on page 92 for recommended lubricants capa
71. e body air 50 H 6M 300 500 Inspect duct for proper seal intake ducts flange ing air leaks gt General 50 H 3M 500 800 Lubricate all fittings pivots lubrication cables etc Shift Linkage 50 H 6M 500 800 Inspect lubricate adjust E Steering 50H 6M 500 800 Lubricate gt Front Suspension 50H 6M 500 800 JLubricate gt Rear Suspension 50H 6M 500 800 Lubricate Cooling system 50H 6M 500 800 Inspect coolant strength if applicable seasonally pressure test system yearly E Fuel system 100 H 12M 600 1000 Check for leaks at tank cap E lines filter pump throttle body replace lines every two years gt Spark plug 100 H 12M 600 1000 Inspect replace as needed E gt Engine oil change 100 H 6M 1000 1600 Perform a break in oil change at one month gt Oil filter change 100 H 6M 1000 1600 JReplace with oil change gt Perform these procedures more often for vehicles subjected to severe use E Emission Related Service Have an authorized Polaris dealer perform these services 78 Periodic Maintenance Chart MAINTENANCE Item Maintenance Interval Remarks whichever comes first Hours Calendar Miles Km Radiator 100 H 12M 1000 1600 Inspect clean external if equipped surfaces Cooling Hoses 100 H 12M 1000 1600 Inspect for leaks Engine mounts 100 H 12M 1000 1600 Inspect Exhaust muffler 10
72. e 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 Inspect the brake pad wear surface for excessive wear Change pads when worn to 3 64 1 mm MAINTENANCE 3 64 1mm Check the steering wheel for specified freeplay and smooth operation at the intervals outlined in the Periodic Maintenance Chart beginning on page 75 1 2 3 4 Position the vehicle on level ground Lightly turn the steering wheel left and right There should be 0 8 1 0 20 25 mm of freeplay If there is excessive freeplay or strange noises or the steering feels rough or catchy have the steering system inspected by an autho rized Polaris dealer 107 MAINTENANCE Suspension Adjustment The front and rear suspensions are preload adjustable with five settings on each axle Adjustment Cam Highest Stiffest Lowest Softest Setting i Setting The suspensions are set on the lowest softest setting at the factory This setting is appropriate for nearly all riding conditions Since the vehicle is equipped with full skid plates suspension adjustment is not necessary If desired the suspension may be adjusted to maintain vehicle clearance height when carrying loads Please see your Polaris dealer for the tool required to make suspension adjustments Elevate the vehicle slightly for easier adjustment
73. e hill A WARNING POTENTIAL HAZARD Traveling downhill improperly WHAT CAN HAPPEN Loss of control or overturn resulting in serious injury or death HOW TO AVOID THE HAZARD Always follow proper procedures for traveling down hills as described in the owner s manual Always descend a hill with the transmission in forward gear Never descend a hill with the transmission in neutral Always check the terrain carefully before descending a hill Never travel down a hill at high speed Avoid traveling down a hill at an angle which would cause the vehicle to lean sharply to one side Travel straight downhill 25 SAFETY Rider Safety A WARNING POTENTIAL HAZARD Crossing hills and turning on hills WHAT CAN HAPPEN Loss of control or overturn resulting in serious injury or death HOW TO AVOID THE HAZARD Avoid operating on steep hills 15 maximum Avoid crossing the side of a hill A WARNING POTENTIAL HAZARD Stalling rolling backwards while climbing a hill WHAT CAN HAPPEN Loss of control or overturn resulting in serious injury or death HOW TO AVOID THE HAZARD Maintain a steady speed when climbing a hill If you lose all forward speed 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 26 Rider Safety SAFETY
74. e seat to engage the rear latch 35 FEATURES AND CONTROLS Steering Wheel The steering wheel can L S be tilted upward or A cert downward for rider pref padu gt tm EN erence 2 QN Lift and hold the steering wheel adjustment lever while moving the steer ing wheel upward or downward Release the lever when the steering wheel is at the desired position Passenger Hand Hold Always adjust the hand hold to a comfortable position for your passen ger before operating Make sure the adjustment pin and retainer are securely installed after making adjustments 1 Remove the retainer from the end of the adjustment pin 2 Remove the pin from the post 3 Slide the post inward or outward to the desired position 4 Reinstall the pin through the mounting bracket hole through both post adjustment holes and through the remaining bracket hole 5 Reinstall the retainer to the pin Adjustment Pin Mounting Bracket Holes 36 FEATURES AND CONTROLS Storage Compartment Remove the hood to access the front storage compartment Refer to the specifications section beginning on page 126 for storage compartment capacity Hood Remove the hood to access the front storage compartment the radiator and the coolant overflow bottle 1 If your model is equipped with remov able fasteners at the upper hood edge remove the fasteners 2 Grasp the upper hood edge and pull upward to disengage the hood from the v
75. ecals and Locations Cab Frame Seat Belt Warning WARNING Age Overturn e ALWAYS WEAR YOUR SEAT BELT Warning Warning and make sure passenger wears seat belt ALWAYS SECURE CAB NETS VEHICLE OVERTURN could cause severe injury or death The cab frame is not designed or intended to provide rollover protection Shift Caution CAUTION To avoid transmission damage shift only when vehicle is stationary and at idle When vehicle is stopped place shift in the parked position Cab Frame Seat APPLY BRAKE TO START Belt Warning sit Age Warning Caution WARNING Operating this vehicle if vou are under the age of 16 increases vour chance of severe injurv or death NEVER operate this vehicle if vou are under age 16 or without a valid driver s license Overturn Warning WARNING Improper operation can cause this vehicle to overturn and lead to serious injurv or death This vehicle handles differentiv than cars trucks or other off road vehicles In order to avoid overturns avoid sharp turns never turn while applying heavy throttle never make abrupt steering maneuvers operate at speeds appropriate for your skills the conditions and the terrain DO NOT do power slides donuts jumps or other driving stunts SAFETY Safety Decals and Locations Discretionary Passenger Safety Warning Warning Passenger Safety Warning WARNING NEVER CARRY A PASSENGER UNDER AGE 12 NEVER CARRY MORE THA
76. econds Stop the engine 4 Remove both seats Remove the rear service panel See page 35 5 Lift the lever lock to remove the dipstick Wipe it dry with a clean cloth 6 Reinstall the dipstick completely but do not lock it The dipstick must be inserted completely in to keep the angle and depth of the stick consistent 7 Remove the dipstick and check the oil level Maintain the oil level in the safe range Do not overfill NOTE 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 Check Level the dipstick on Top Side 8 Reinstall the dipstick Seat the lever lock Dipstick Range 83 MAINTENANCE Engine Oil Oil and Filter Change CAUTION Hot oil can cause serious burns to skin Do not allow hot oil to come into contact with skin Always change the oil and filter at the intervals outlined in the Periodic Maintenance Chart beginning on page 75 Always change the oil filter whenever changing oil The engine drain plug is located on the bottom of the crankcase 1 Position the vehicle on a level surface Place the transmission in PARK Apply the brakes 2 Start the engine Allow it to idle for two to three minutes Stop the engine 3 Clean the area around the drain plug 4 Place a drain pan beneath engine crankcase and remove the drain plug 5 Allow the oil
77. ecurely attached Reduce speed and fol low the instructions in this manual for hauling cargo or pulling a trailer Allow a greater distance for braking e Always turn off the engine before refueling Make sure the refueling area is well ventilated and free of any source of flame or sparks Gas oline is extremely flammable See page 31 for fuel safety warnings e Remove flammable material containers from the box before filling e Always remove the ignition key when the vehicle is not in use to pre vent unauthorized use or accidental starting FOR MORE INFORMATION ABOUT SAFETY call Polaris at 1 800 342 3764 12 SAFETY Rider Safety A WARNING Modifications to your vehicle may negatively impact vehicle stability and result in serious injury or death Failure of critical machine components may result from operation with any modifications especially those that increase speed or power This vehicle may become less stable at speeds higher than those for which it is designed Loss of control may occur at higher speeds Your Polaris vehicle is designed to provide safe operation when used as directed Do not make any modifications to this Polaris vehicle Never operate with accessories not approved by Polaris for use on this vehicle The operator must check all safety components before each ride Make sure your vehicle is in excellent operating condition at all times Equipment Modifications We are
78. ehicle 3 Continue pulling the hood upward to dis engage the lower hood fasteners 4 Lift the hood away from the vehicle 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 gaso line with a minimum pump octane number of 87 R M 2 octane Do not use E 85 fuel Remove flammable material containers from the box before filling 37 FEATURES AND CONTROLS Cab Nets WARNING Riding in this vehicle without using the cab nets can result in serious injury or death in the event of an accident or overturn Always use the cab nets while operating the vehicle Your vehicle is equipped Latches with upper and lower cab nets on both sides of the vehicle Cab nets must be used by both operator and passenger at all times Make sure all latches are secure before operating the vehicle Always inspect cab nets for tightness wear and damage before each use of the vehi cle Use the strap adjusters to tighten any loose straps Promptly replace worn or damaged cab nets with new Lower Cab Net Upper Cab Net cab nets available from your authorized Polaris dealer Upper Cab Net Interference Driver The upper cab net on the driver s side may interfere with vehicle opera tion for some operators due to operator body type driving style or r
79. el A rise in oil level during cold weather can indicate contaminants collecting in the oil sump or crank case Change oil immediately if the oil level begins to rise Monitor the oil level and if it continues to rise discontinue use and determine the cause or see your dealer 75 MAINTENANCE Periodic Maintenance Chart Maintenance Chart Key gt Perform these operations more often for vehicles subjected to severe use Emission related service Failure to conduct this maintenance will not void the emissions warranty but may affect emissions Have an authorized Polaris dealer perform these services A WARNING Improperly performing the procedures marked with a could result in component failure and lead to serious injury or death Have an authorized Polaris dealer perform these services 76 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 E Steering Pre Ride Make anusiments as need 7 ed See Pre Ride Checklist gt Front suspension Pre Ride on page 56 gt Rear suspension Pre Ride Tires Pre Ride gt Brake fluid level Pre Ride gt Brake pedal travel Brake system Pre Ride Wheels fasteners Pre Ride Frame fasteners Pre Ride gt Engine oil level Pre
80. en operating on unfamiliar terrain Always be alert to changing terrain conditions A WARNING POTENTIAL HAZARD Carrying a passenger in the cargo box WHAT CAN HAPPEN Serious injury or death due to a fall from the vehicle or contact with moving components HOW TO AVOID THE HAZARD Never allow a passenger to ride in the cargo box A WARNING POTENTIAL HAZARD Operating with more than one passenger WHAT CAN HAPPEN Loss of control and accident resulting in serious injury or death HOW TO AVOID THE HAZARD Never carry more than one passenger Additional passengers can affect the operator s ability to steer and operate the controls 29 SAFETY Rider Safety A WARNING Operating a damaged vehicle can result in an accident with serious injury or death After any overturn or accident have a qualified service dealer inspect the entire vehicle for possible damage including but not limited to brakes throttle and steering systems A WARNING Exhaust system components are very hot during and after use of the vehicle Hot components can cause serious 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 A WARNING Leaving the keys in the ignition can lead to unauthorized use of the vehicle resulting in serious injury or death
81. ep 5 Ifadjustment is necessary turn the headlight adjustment screw to adjust the beam 6 Repeat steps 4 5 until the beam is properly adjusted 112 MAINTENANCE Lights Brake Lights When the brake pedal is depressed the brake light comes on Check the brake light before each ride 1 Turn the ignition switch to the ON position 2 Apply the brakes The brake light should come on after about 10 mm 0 4 in of pedal travel If the light doesn t come on check the bulb Vehicle Immersion CAUTION 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 vehicle to a dealer before starting it fol low the steps outlined below 1 Move the vehicle to dry land 2 Check the air box If water is present dry the air box and replace the filter with a new filter Thoroughly dry the air pre filter See page 101 3 Remove the spark plugs 4 Turn the engine over several times 5 Dry the spark plugs and reinstall them or install new plugs NOTE Attempt to start the engine If necessary repeat the drying procedure 6 Take the vehicle to your dealer for service as soon as possible whether you succeed in starting it or not NOTE If water has been ingested into the PVT follow the procedure on page 100 for drying 113 MAINTENANCE Battery Your vehicle
82. filter if needed Do not attempt to clean the main air 6 filter Reinstall the pre filter over the main filter NOTE Apply a small amount of general purpose grease to the sealing edges 7 of the filter before installing Inspect the air box for oil or water deposits If present drain them into a suitable container 101 MAINTENANCE Spark Arrestor A WARNING Failure to heed the following warnings while servicing the spark arrestor could result in serious injury or death Do not perform clean out immediately after the engine has been run as the exhaust system becomes very hot Serious burns could result from contact with the exhaust components Allow components to cool sufficiently before proceeding Wear eye protection and gloves Never run the engine in an enclosed area Exhaust contains poisonous carbon monoxide gas that can cause loss of consciousness or death ina very short time Periodically clean the spark arrestor to remove accumulated carbon 1 Remove the retaining screw and remove the Arrestor arrestor from the end of the muffler Screen 2 Use anon synthetic brush to clean the arrestor screen A syn thetic brush may melt if components are B x If necessary blow Muffler debris from the Retaining screen with com Screw pressed air 3 Inspect the screen for wear and damage Replace a worn or damaged screen 4 Reinstall the arrestor Torque screws
83. g 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 A WARNING Poor lighting while driving can result in severe injury or death Headlight and taillight lenses become dirty during normal operation Wash the headlights frequently to maintain lighting quality Hot components can cause serious burns to skin Do not service the headlamps until they ve cooled sufficiently Headlight Lamp Replacement 1 Unplug the headlamp from the wiring harness Be sure to pull on the connector not on the wiring 2 Turn the lamp counter clockwise to remove it 3 Install the new lamp NOTE Make sure the tab on the lamp locates properly in the housing 4 Reinstall the harness assembly into the head light assembly Harness 111 MAINTENANCE Lights Headlight Beam Adjustment 1 Place the vehicle on a level surface with the headlight approxi mately 25 ft 7 6 m from a wall Place the transmission in PARK 2 Measure the distance from the floor to the center of the headlight and make a mark on the wall at the same height 3 Apply the brakes Start the engine Turn on the headlights 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 in step 2 NOTE Include the weight of a rider on the seat while performing this st
84. h feet on the floor Know Your Vehicle As the operator of the vehicle you are responsible for your personal safety the safety of others including your passenger and the protec tion of our environment Read and understand your owner s manual which includes valuable information about all aspects of your vehicle including safe operating procedures We strongly advise you to strictly follow the recommended maintenance program outlined in your owner s manual This preventive maintenance program is designed to ensure that all critical components on your vehi cle are thoroughly inspected at specific intervals 16 SAFETY Rider Safety Know Your Riding Area Tread Lightly Your Polaris vehicle is an off road vehicle Familiarize yourself with all laws and regulations concerning the operation of this vehicle in your area Respect the environment in which you ride your vehicle Find out where the designated riding areas are by contacting your Polaris dealer a local riding club or local officials Help keep our trails open for recreational vehicle use As an off road enthusiast you represent the sport and can set a good example or a poor example for others to follow Tread lightly Operate with respect for the terrain avoid littering and always stay on the designated trails Trail Etiquette Always practice good etiquette when riding Allow a safe distance between your vehicle and other vehicles operating in the same area Communic
85. he PVT housing is securely in place during operation 99 MAINTENANCE Polaris Variable Transmission PVT System PVT Drying There may be some instances when water is accidently ingested into the PVT system Use the following instructions to dry it out before operat ing FIELD ee ey Nai 9 10 100 Remove the seats See page 35 Loosen the lower screws that secure the clutch cover Allow the water to drain Tighten the screws Place the transmission in PARK Apply the brakes Start the engine 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 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 Take the vehicle to your dealer for service as soon as possible MAINTENANCE Filter Systems Air Filter Always change the air filter at the intervals outlined in the Periodic Maintenance Chart beginning on page 75 1 from behind the left rear wheel Remove the air box Gasket cover and inspect the gasket It should adhere tightly to the cover around the entire edge Air Filter Remove the air filter Pre Filter Remove the pre filter from the main air filter Wash the pre filter in soapy water then rinse and let dry NOTE Install a new main
86. ic surfaces Do not allow these types of products to contact the vehicle The best and safest way to clean your Polaris vehicle is with a garden hose and a pail of mild soap and water 1 Use a professional type washing cloth cleaning the upper body first and the lower parts last 2 Rinse with clean water frequently 3 Dry surfaces with a chamois to prevent water spots Washing Tips e 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 e 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 120 MAINTENANCE Cleaning and Storage Washing the Vehicle If a high pressure water system is used for cleaning not recommended exercise extreme caution The water may damage components and could remove paint and decals Avoid directing the water stream at the follow ing items e Wheel bearings e Radiator Transmission seals e Brakes Cab and body panels e Labels and decals e Electrical components and wiring NOTE If warning and safety labels are damaged contact your Polaris dealer for free replacement 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 Polishing the Vehicle Pol
87. iding apparel Each operator must check for upper cab net interference before operating the vehicle 1 Complete the New Operator Driving Procedures outlined on pages 60 61 2 Test for upper cab net interference by making slow speed turns to the left and right If the net interferes with operation it should be removed from the vehicle for this operator only All other cab nets must remain on the vehicle during operation See page 39 38 FEATURES AND CONTROLS Cab Nets Upper Cab Net Removal Driver The upper cab net on the driver s side may be removed only if it inter feres with operation of the vehicle All other cab nets must remain installed 1 Using a T 25 torx bit and 7 16 open end wrench remove the mounting screw and washers secur ing the upper and lower cab nets to the floor of the vehicle on the driver s side Reinstall the lower net with the screw and all washers Tighten the screw securely Unclip the four latches that secure and the upper net to the chassis and lower net See the photo on the pre vious page Clip the free upper latch of the lower cab net to the free latch on the shoulder net adjusting strap length as needed Tighten the strap Washers Reverse all steps to reinstall the cab net NOTE Always reinstall the upper cab net for any other operator of the vehicle 39 FEATURES AND CONTROLS Seat Belts This Polaris vehicle is equipped with three point lap and diago
88. ing on slippery surfaces as described in the owner s manual 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 22 SAFETY Rider Safety A WARNING POTENTIAL HAZARD Operating through deep or fast flowing water WHAT CAN HAPPEN Loss of traction loss of control overturn or accident resulting in serious injury or death HOW TO AVOID THE HAZARD Always follow proper procedures for operating in water as described in the owner s manual Never operate in fast flowing water or in water that exceeds the recommended maximum depth A WARNING POTENTIAL HAZARD Improperly operating in reverse WHAT CAN HAPPEN Collision with an obstacle or person resulting in severe injury or death HOW TO AVOID THE HAZARD Always follow proper procedures for operating in reverse as described in the owner s manual Before shifting into reverse gear always check for obstacles or people behind the vehicle When it s safe to proceed back slowly Avoid making sharp turns in reverse 23 SAFETY Rider Safety A WARNING POTENTIAL HAZARD Overloading the vehicle or carrying towing cargo improperly WHAT CAN HAPPEN Loss of control accident due to instability and changes in vehicle handling HOW TO AVOID THE HAZARD Always follow the in
89. llow additional braking distance when towing or hauling cargo 58 OPERATION Parking the Vehicle A WARNING Gasoline is extremely flammable and can be explosive under certain conditions When parking inside a garage or other structure be sure that the structure is well ventilated and that the vehicle is not close to any source of flame or sparks including any appliance with pilot lights A WARNING A rolling vehicle can cause property damage and serious injury Always place the transmission in PARK when stopping the engine 1 Stop the vehicle on a level surface Place the transmission in PARK 2 Turn the engine off 3 Remove the ignition switch key to prevent unauthorized use 59 OPERATION New Operator Driving Procedures A WARNING Operating improperly can cause an accident or overturn which could result in severe injury or death This vehicle handles differently than cars trucks or other off road vehicles Operators of this vehicle must become familiar with vehicle handling at slow speeds before operating at faster speeds Do not carry a passenger until you have at least two hours of driving experience with this vehicle 1 Do not carry a passenger until you have at least two hours of driving experience with this vehicle Do not tow or carry cargo during this period 3 Select an open area that allows room to familiarize yourself with vehicle operation
90. lmet and eye protection See page 14 Make sure the passenger secures the seat belt Make sure all cab nets are properly secured OPERATION Driving with a Passenger 7 8 9 10 11 Allow a passenger to ride only in the passenger seat Do not carry more than one passenger Additional passengers can affect the operator s ability to steer and operate the controls Slow down Always travel at a speed appropriate for your skills your passenger s 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 Always follow all operating guidelines as outlined on safety labels and in this manual 63 OPERATION Driving on Slippery Surfaces When driving on slip pery surfaces such as wet trails loose gravel or ice be alert for the possibility of skidding and sliding Under these conditions fol low these precautions 1 Slow down when entering slippery areas 2 Maintain a high level of alertness reading the trail and avoiding quick sharp turns which can cause skids 3 Engage all wheel drive before wheels begin to lose traction Correct a skid by turning the steering wheel in the direction of the skid CAUTION Severe damage to the drive train may occur if the AWD is engaged while the wheels are s
91. may have either a sealed battery which requires little maintenance or a conventional battery A sealed battery can be identi fied by its flat covers on the top of the battery 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 solution or tap water into a conventional battery A WARNING Battery electrolyte is poisonous It contains sulfuric acid Serious burns can result from contact with skin eyes or clothing Antidote External Flush with water Internal Drink large quantities of water or milk Follow with milk of magnesia beaten egg or vegetable oil Call physician immediately Eyes Flush with water for 15 minutes and get prompt medical attention Batteries produce explosive gases Keep sparks flame cigarettes etc away Ventilate when charging or using in an enclosed space Always shield eyes when working near batteries KEEP OUT OF REACH OF CHILDREN 114 MAINTENANCE Battery A WARNING Improperly connecting or disconnecting battery cables can result in an explosion and cause serious injury or death When removing the batter
92. move the fill plug Check the fluid level 3 Add the recommended fluid as needed 4 Reinstall the fill plug Torque to specification Fluid Change The drain plug is located on the bottom right side of the rear gearcase Fill Plug Drain Plug 1 Remove the fill plug 2 Place a drain pan under the drain plug Remove the drain plug 3 Allow the fluid to drain completely 4 Clean the drain plug Reinstall the drain plug with a new o ring Torque to specification 5 Add the recommended fluid Maintain the fluid level even with the bottom thread of the fill plug hole 6 Reinstall the fill plug Torque to specification 7 Check for leaks Discard used fluid properly 91 MAINTENANCE Gearcases Gearcase Specification Chart Use of other fluids may result in improper operation of components See page 128 for the part numbers of Polaris products Gearcase Lubricant Capacity Fill Plug Drain Plug Torque Level Check Plug Torque Transmission Premium AGL 24 oz 40 50 ft Ibs 30 45 in Ibs Main Gearcase Synthetic 710 ml 54 68 Nm 3 5 Nm Gearcase Fluid Transmission Premium AGL 14 oz 40 50 ft Ibs 30 45 in Ibs Transfer Case Synthetic 414 ml 54 68 Nm 3 5 Nm Gearcase Fluid Demand Drive Unit Demand Drive LT 6 75 oz 8 10 ft Ibs 11 ft Ibs Front Gearcase Premium Fluid 200 ml 11 13 6 Nm 15 Nm Rear Gearcase Premium ATV 18 oz 40 50 ft Ibs 30 45 in Ibs Angle Driv
93. n carefully Engine and Drivetrain Break in 1 Fill the fuel tank with gasoline See page 37 2 Check the oil level See page 83 Add the recommended oil as needed to maintain the oil level in the safe operating range 3 Complete the New Operator Driving Procedures outlined on pages 60 61 NOTE Avoid aggressive use of the brakes See Brake System Break in 4 Vary throttle positions Do not operate at sustained idle 5 Perform regular checks on fluid levels controls and areas outlined on the daily pre ride inspection checklist See page 56 6 Pull only light loads 7 During the break in period change both the oil and the filter at 25 hours or one month Brake System Break in Apply only moderate braking force for the first 50 stops Aggressive or overly forceful braking when the brake system is new could damage brake pads and rotors PVT Break in Clutches Belt A proper break in of the clutches and drive belt will ensure a longer life and better performance Break in the clutches and belt by operating at slower speeds during the break in period as recommended Pull only light loads Avoid aggressive acceleration and high speed operation dur ing the break in period 55 OPERATION Pre Ride Inspection A WARNING proper operating condition If a proper inspection is not done before each use severe injury or death could result Always inspect the vehicle before each use to ensure it s in
94. nal seat belts for the operator and passenger A WARNING Riding in this vehicle without wearing the seat belt can result in serious injury or death in the event of an accident or sudden stop Always make sure the seat belts are secured for both the operator and passenger before riding To wear the seat belt properly follow this procedure 1 Pull the seat belt latch down Seat Belt ward and across your chest Seat Belt Buckles toward the buckle at the inner Latches edge of the seat The belt should fit snugly across your hips and diagonally across your chest Make sure the belt is not twisted 2 Push the latch plate into the buckle until it clicks 3 Release the strap it will self tighten NOTE Press the red release latch on the buckle to release the seat belt 40 FEATURES AND CONTROLS Seat Belts Seat Belt Inspection Inspect all seat belts for proper operation before each use of the vehicle 1 Push the latch plate into the buckle until it clicks The latch plate must slide smoothly into the buckle A click indicates that it s securely latched 2 Push the red release latch in the middle of the buckle to make sure it releases freely 3 Pull each seat belt completely out and inspect the full length for any damage including cuts wear fraying dirt debris or stiffness If any damage is found have the seat belt system checked and or replaced by an authorized Polaris dealer 41 FEATURES
95. ng procedures outlined in the owner s manual Never climb hills with excessively slippery or loose surfaces Never open the throttle suddenly Never go over the crest of a hill at high speed An obstacle a sharp drop or another vehicle or person could be on the other side of the hill 65 OPERATION Driving on a Sidehill Sidehilling Avoid driving across the side of a hill Control becomes difficult and there is an increased chance of vehicle overturn when driving on a hill side If crossing a hill is unavoidable follow these precautions 1 2 3 Engage all wheel drive Drive slowlv and use extreme caution If the vehicle begins to overturn or if it feels as if it may overturn immediately turn downhill Avoid obstacles and changes in terrain that may lower or raise one side of the vehicle or cause the vehicle to slide If the vehicle begins to slide downhill immediately turn downhill to stop the slide or stop the vehicle and maneuver slowly and care fully until the vehicle can be driven straight downhill A WARNING Crossing hillsides or turning on hills can result in loss of control or vehicle overturn resulting in severe injury or death Avoid crossing the side of a hill Avoid operating on steep hills 15 maximum 66 OPERATION Driving Downhill Whenever descending a hill follow these precautions 1 2 Slow down Always descend a hill with the transmission in fo
96. or over obstacles Low Loading the vehicle onto a trailer Low Towing heavy loads Low Operating at speeds greater than 7 MPH 11 km h High 44 FEATURES AND CONTROLS Brake Pedal Depress the brake pedal to slow or stop the vehicle Apply the brakes while start ing the engine Throttle Pedal Push the pedal down to increase engine speed Spring pressure returns the pedal to the rest position when released Always check that the throttle pedal returns normally before start ing the engine Make sure there s adequate throttle pedal freeplay See page 104 for throttle pedal adjustment procedures 45 FEATURES AND CONTROLS All Wheel Drive AWD System The All Wheel Drive system is con trolled by the AWD switch When T T the switch is on 2X4 the vehicle is N in two wheel drive at all times 1 9 5 When the switch is on AWD the 4 vehicle is in all wheel drive and the AWD indicator light will be on When in AWD the demand drive c unit will automatically engage any time the rear wheels lose traction 2 When the rear wheels regain trac tion the demand drive unit will automatically disengage There is no limit to the length of time the vehicle may remain in AWD Engaging AWD The AWD switch may be turned on or off while the vehicle is moving Initially the vehicle s electronic system will not enable the AWD until the engine RPM is below 3100 Once en
97. ords the miles traveled by the vehicle Trip Meter Mode The trip meter records the miles traveled by the vehicle on each trip if it s reset before each trip To reset the trip meter select the trip meter mode Press and hold the mode switch until the total changes to 0 NOTE In the Rider Information Center the trip meter display contains a deci mal point but the odometer 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 NOTE Small fluctuations in the RPM from day to day may be normal because of changes in humidity temperature and elevation Clock Mode The clock displays time in a 12 hour format To reset the clock see page 50 49 FEATURES AND CONTROLS Instrument Cluster Rider Information Center Diagnostic Mode The wrench icon will display when the gauge is in the diagnostic mode To exit the diagnostic mode turn the key switch off and on Any move ment of the tires will also cause the gauge to exit the diagnostic mode To enter the diagnostics mode 1 Turn the key switch off and wait 10 seconds 2 Place the transmission in neutral 3 Hold the mode switch and turn the key switch on Release the switch as soon as the display is activated 4 Use the mode switch to toggle through the diagnostic screens Clock Screen To reset the clock 1 Enter the diagnostic mode Toggle to the clock sc
98. overflow bottle has run dry the level in the radiator should also be inspected NOTE Use of a non standard pressure will not allow the recovery system to function properly See your dealer for the correct replacement part 98 MAINTENANCE Polaris Variable Transmission PVT System 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 A WARNING Failure to comply with the instructions in this warning can result in severe injury or death Do not modify any component of the PVT system Doing so may reduce its strength so that a failure may occur at a high speed The PVT system has been precision balanced Any modification will cause the system to be out of balance creating vibration and additional loads on components The PVT system rotates at high speeds creating large amounts of force on clutch components Extensive engineering and testing has been conducted to ensure the safety of this product However as the owner you have the following responsibilities to make sure this system remains safe e Always follow all recommended maintenance procedures See your dealer as outlined in the owner s manual e This PVT system is intended for use on Polaris products only Do not install it in any other product e Always make sure t
99. own in ambi ent temperatures from 40 to 120 F 40 to 49 C Its exceptional frictional properties result in more efficient operation more power out put and lower fuel consumption Although Polaris Premium 4 is the only oil recommended for use in this engine use of any API certified SH oil is allowable as long as it s OW 40 Oil may need to be changed more frequently if Polaris Premium 4 is not used Follow the manufacturer s recommendations for ambient tem perature operation CAUTION Mixing brands or using a non recommended oil may cause serious engine damage We recommend the use of Polaris Premium 4 All Season synthetic oil or API certified SH oil OW 40 Never substitute or mix oil brands Use only OW 40 WARNING Vehicle operation with insufficient deteriorated or contaminated engine oil will cause accelerated wear and may result in engine seizure accident and injury Always perform the maintenance procedures as outlined in the Periodic Maintenance Chart 82 MAINTENANCE Engine Oil Always check and change the oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 75 Always use the recommended engine oil Oil Check The oil dipstick and fill tube is located on the engine behind the passenger seat 1 Position the vehicle on a level surface 2 Place the transmission in PARK Apply the brakes 3 Start the engine Allow it to idle for 20 30 s
100. pinning Always allow the wheels to stop spinning before engaging AWD A WARNING Failure to exercise care when operating on slippery surfaces can result in loss of tire traction and cause loss of control accident and serious injury or death Never apply the brakes during a skid Do not operate on excessively slippery surfaces Always reduce speed and use additional caution when operating on slippery surfaces 64 OPERATION Driving Uphill Whenever traveling uphill follow these precautions 1 Drive straight uphill 2 Proceed at a steady rate of speed and throttle opening Avoid unnecessary changes in speed or direction 3 Avoid steep hills 15 maximum NOTE If ascending a steeper grade is unavoidable engage all wheel drive before ascending 4 Ifthe vehicle stalls while climbing a hill 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 A WARNING Climbing hills improperly can cause loss of control or vehicle overturn Always check the terrain carefully before climbing a hill Braking and handling are greatly affected when operating in hilly terrain Improper operating procedures could cause loss of control or overturn and result in serious injury or death Avoid climbing steep hills 15 maximum Use extreme caution when operating on hills and follow proper operati
101. rcase 92 Fluid Battery 117 Fluid Brake 106 Fogging the Engine 124 Fouled 1 94 Freeplay Adjustment Throttle 104 Freeplay Steering Wheel 107 Freeplay Throttle 103 Ruel thease 37 Fuel Safety 31 Fuel Stabilizer 123 Fuel Tank Filler Cap 37 G Gap Spark Plug 93 Gear Circuit Diagnostics 51 Gear Selector 44 Gearcase Capacities 92 Gearcase Oil Demand Drive Unit 90 Front Gearcase 90 Main Gearcase 88 89 Rear Gearcase 91 Transfer Case 86 87 Gearcase Specifications 92 Gear CASCS 86 92 Demand Drive Unit 90 Front Gearcase 90 Main Gearcase 88 89 Rear Gearcase 91 Specification Chart 92 Transfer Case 86 87 Transmission 88 89 Gears shifting 44 GLOVES be es 15 H Hand Hold Passenger 36 Hauling a Load 72 73 Hauling Cargo 72 73 Headlight Beam Adjustment 112 Headlight Lamp Replacement 111 se etna ij 15 ot hart d iet sera eae 34 Hitch 1 73 Hood Removal 37 Hour bus a gid arsar 49 14
102. re not adjustable The emissions label is located on the lower frame behind the driver s seat Electromagnetic Interference This spark ignition system complies with Canadian ICES 002 This vehicle complies with European directives 97 24 EC and 89 336 EEC 74 MAINTENANCE Periodic Maintenance Chart Careful periodic maintenance will help keep your vehicle in the safest most reliable condition Inspection adjustment and lubrication of important components are explained in the periodic maintenance chart Inspect clean lubricate adjust and replace parts as necessary When inspection reveals the need for replacement parts use genuine Polaris parts available from your Polaris dealer Record maintenance and service in the Maintenance Log beginning on page 137 NOTE Service and adjustments are important for proper vehicle operation If you re not familiar with safe service and adjustment procedures have a qualified dealer perform these operations Maintenance intervals in the following chart are based upon average riding conditions and an average vehicle speed of approximately ten 10 miles per hour Vehicles subjected to severe use must be inspected and serviced more frequently Severe Use Definition e Frequent immersion in mud water or sand Racing or race style high RPM use Prolonged low speed heavy load operation Extended idle Short trip cold weather operation Pav special attention to the oil lev
103. reen 2 Press and hold the mode switch until the hour display flashes Release the switch 3 Press and release the mode switch once to advance the setting by one hour Press and hold the mode switch to advance the hours quickly 4 When the desired hour is displayed wait approximately four sec onds until the minute display flashes 5 When the display stops flashing the mode has been set 6 Use the same procedure to reset the minutes Battery Voltage Screen View this screen to check battery voltage level Tachometer Screen View the tachometer to check engine speed 50 FEATURES AND CONTROLS Instrument Cluster Rider Information Center Diagnostic Mode AWD Diagnostic Screen The gauge indicates whether or not current is flowing through the AWD coil only on models with switchable AWD This screen is for informa tional purposes only Please see your dealer for all major repairs Gear Circuit Diagnostic Screen This screen displays the resistance value in ohms being read at the gear switch input of the gauge This screen is for informational purposes only Please see your dealer for all major repairs 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
104. rward gear Never descend a hill with the transmission in neutral Travel straight downhill Apply the brakes lightly to aid in slowing A WARNING Traveling downhill improperly could cause loss of control or vehicle overturn Always check the terrain carefully before descending a hill Never descend a hill at high speed Excessive speed may result in loss of vehicle control and lead to serious injury or death Always operate slowly when traveling downhill Avoid descending a hill at an angle which would cause the vehicle to lean sharply to one side Travel straight downhill 67 OPERATION Driving Through Water A WARNING The large tires on your vehicle may cause the vehicle to float in deep or fast flowing water which could result in loss of control and lead to serious injury or death Never cross deep or fast flowing water with your vehicle Your vehicle can operate through water with a maximum recommended depth equal to floor level Follow these procedures when operating through water 1 Determine water depths and current before crossing 9 ee S 2 Saw lt 2 Never operate in water Floor Level 5 5 wae C that exceeds the i maximum I recommended depth 3 Choose a crossing where both banks have gradual inclines 4 Proceed slowly avoiding rocks and obstacles 5 Wet brakes may have reduced stopping ability To dry out the
105. s sories available through our online store at www purepolaris com Have your accessories and clothing delivered right to your door POLARIS The Way Out POLARIS and POLARIS THE WAY OUT are registered trademarks of Polaris Indus tries Inc Copyright 2007 Polaris Sales Inc All information contained within this publication is based on the latest product information at the time of publication Due to constant improvements in the design and quality of production components some minor discrep ancies may result between the actual vehicle and the information presented in this publi cation Depictions and or procedures in this publication are intended for reference use only No liability can be accepted for omissions or inaccuracies Any reprinting or reuse of the depictions and or procedures contained within whether whole or in part is expressly prohibited Printed in U S A 2008 RANGER RZR Owner s Manual P N 9921181 2 TABLE OF CONTENTS Vehicle Identification Numbers 5 DalCly LA i ii ii se SSS BIEB ost a 6 Features and 32 Operation is s Ou ees 54 Emission Control Systems 74 75 126 Polaris Products 128 Troubleshooting 129 Warranty 133 Maintenance Log
106. s Seat belts reduce the sever ity of injury in the event of a sudden stop or accident e Always use the cab nets while operating the vehicle e Helmets and eye protection are required for both operator and passen ger at all times e Always keep hands and feet inside the vehicle at all times e Never allow a passenger to ride in the cargo box Never carry more than one passenger e Never permit a guest to operate this vehicle unless the guest has read this manual and all product labels and has completed the New Opera tor Driving Procedures outlined on pages 60 61 To reduce tipover risk be especially careful when encountering obstacles and slopes and when braking on hills or during turns e Never operate with accessories not approved by Polaris for use on this vehicle Non approved accessories may seriously affect vehicle stability and could cause the vehicle to overturn 10 SAFETY Rider Safety e This vehicle handles differently than cars trucks or other off road vehicles Turning improperly can result in an overturn Avoid sharp turns Never turn while applying heavy throttle Never make abrupt steering maneuvers Operate at speeds appropriate for your skills the conditions and the terrain Do not do power slides donuts jumps or other driving stunts e Never operate at excessive speeds Always travel at a speed appropri ate for your skills your passenger s skills and operating conditions This vehicle is for
107. s whose failure would increase an engine s emissions including electronic controls fuel injection exhaust gas recircula tion aftertreatment or any other system utilized in this vehicle to control emissions Replacing or repairing other components not covered by this emissions warranty or the standard warranty is the responsibility of the owner including the parts labor and other costs associated with recommended maintenance The exclusive remedy for breach of this limited warranty shall be at the exclusive option of Polaris repair or replacement of any defective materials components or prod ucts THE REMEDIES SET FORTH IN THIS LIMITED WARRANTY ARE THE ONLY REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF THIS WAR RANTY POLARIS SHALL HAVE NO LIABILITY TO ANY PERSON FOR INCI DENTAL CONSEQUENTIAL OR SPECIAL DAMAGES OF ANY DESCRIPTION WHETHER ARISING OUT OF EXPRESS OR IMPLIED WAR RANTY OR ANY OTHER CONTRACT NEGLIGENCE OR OTHER TORT OR OTHERWISE ALL IMPLIED WARRANTIES INCLUDING BUT NOT LIMITED TO ANY IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PAR TICULAR PURPOSE ARE LIMITED IN DURATION TO THE WARRANTY PERIOD DESCRIBED HEREIN POLARIS DISCLAIMS ALL EXPRESS WARRAN TIES 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 incon sistent with the controlling state law This limited warranty excludes failures not caused by a
108. se Oil Change 91 Receiver 34 Removal Batterv 115 Removal 35 Removal Wheels 110 R Removing the Vehicle from Storage 125 Replacement Headlight Lamp 111 Reverses 5 70 Rider Information Center 48 53 Rider Safety 5 30 Riding 17 Riding 14 15 RPM Idle Throttle Bodv 104 S Safety Decals 6 9 Safety 5 Seat Adjustment 35 Seat Belt Inspection 40 41 Seat 40 41 Seat Removal 35 Selector 44 Service Interval Indicator 51 Service Panel Rear 35 Severe Use Definition 75 Shifting 44 Signal Words 5 Spark Arrestor Cleaning 102 Spark Arrestor Warning 102 Spark 1 93 94 Condition 94 GAP a 93 94 TOTQU s siwi i 93 ig gees 94 Specifications 126 127 Specifications Gearcase 92 Speed fags bare use aes 104 Speed Towing 73 47 Spring Preload Adjustment 108 Stabilizing the Fuel 1
109. severe injury or death Never allow a passenger to ride in the cargo box A passenger must always ride in the passenger seat with the seat belt fastened securely 72 OPERATION Hauling Cargo Your Polaris vehicle has been designed to carry or tow specific capaci ties Reduce speed and allow a greater distance for braking when carry ing cargo Loads should be centered and carried as low as possible in the box For stability on rough or hilly terrain reduce both speed and cargo Exercise caution if the cargo load extends over the side of the box Always read and understand the load distribution warnings listed on warning labels and in this manual Never exceed the maximum capaci ties specified for your vehicle See page 126 Belt Life To extend belt life use low gear when hauling or towing heavy cargo Towing Loads A WARNING Towing improperly can alter vehicle handling and may cause loss of control or brake instability which can result in serious injury or death Always follow these precautions when towing Never load more than 150 Ibs 68 1 kg tongue weight on the towing bracket Do not operate the vehicle faster than 10 mph 16 km h when towing Towing a trailer increases braking distance Do not tow more than the recommended weight for the vehicle Attach a trailer to the trailer hitch bracket only Do not attach a trailer to any other location which could result in loss of control of the vehicle
110. structions in the owner s manual for carrying cargo or pulling a trailer Never exceed the stated load capacity for this vehicle Cargo should be properly distributed and securely attached Reduce speed when carrying cargo or pulling a trailer Allow a greater distance for braking A WARNING POTENTIAL HAZARD Operating this vehicle with improper tires NI aga or with improper or uneven tire pressure LS ZL WHAT CAN HAPPEN l Loss of control accident or overturn N mA resulting in serious injurv or death la k HOW TO AVOID THE HAZARD Always use the size and type of tires specified for your vehicle Always maintain proper tire pressure 24 SAFETY Rider Safety A WARNING POTENTIAL HAZARD Climbing hills improperly WHAT CAN HAPPEN Loss of control or overturn resulting in serious injury or death HOW TO AVOID THE HAZARD 3 4 Always follow proper procedures for 15 climbing hills as described in the owner s 5 manual Always check the terrain carefully before ascending a hill Avoid climbing steep hills 15 maximum Use extreme caution when operating on hills and follow proper operating procedures outlined in the owner s manual Never climb hills with excessively slippery or loose surfaces Never open the throttle suddenly Never go over the crest of a hill at high speed An obstacle a sharp drop or another vehicle or person could be on the other side of th
111. the transmission to low range and carefully use fast aggressive throttle application to engage clutch WARNING Excessive throttle may cause loss of control and vehicle overturn 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 overturn Belt slippage from water or snow ingestion into the PVT system Dry out the PVT See page 100 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 gas 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 54 and 44 129 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
112. to drain completely Drain Plug 6 Reinstall the sealing washer on the drain plug NOTE The sealing surfaces on drain plug and crankcase should be clean and free of burrs nicks or scratches 7 Reinstall the drain plug Torque to 16 ft 165 22 Nm 84 MAINTENANCE Engine Oil Oil and Filter Change 8 9 10 11 12 13 14 15 16 17 Using a cap style oil filter wrench turn the filter counter clockwise to remove it Using a clean dry cloth clean the filter sealing surface on the crank case 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 Install the new filter and turn by hand until the filter gasket contacts the sealing surface then turn and additional 1 2 turn Remove the dipstick and fill the sump with two quarts 1 9 1 of rec ommended oil Place the transmission in PARK Apply the brakes Start the engine Allow it to idle for one to two minutes Stop the engine Inspect for leaks Re check the oil level on the dipstick and add oil as necessary to bring the level to the upper mark on the dipstick Dispose of used filter and oil properly 85 MAINTENANCE Gearcases Transfer Case Always check and change the fluid at the intervals outlined in the Peri odic Maintenance Chart beginning on page 75 Refer to the Gearcase Specifications Chart on page 92 for recommended lubricants capacities and torque spe
113. uns Irregularly Stalls or Misfires Possible Cause Fouled or defective spark plugs Solution Inspect clean and or replace spark plugs Worn or defective spark plug wires See vour 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 batterv voltage Recharge batterv to 12 8 VDC Kinked or plugged fuel tank vent line Inspect and replace Incorrect fuel Replace with recommended fuel Clogged air filter Other mechanical failure Possible Lean Fuel Cause Low or contaminated fuel Inspect and clean or replace See vour dealer Solution Add or change fuel clean the fuel system Low octane fuel Replace with recommended fuel Clogged fuel filter See your Polaris dealer Possible Rich Fuel Cause Fuel is very high octane Solution Replace with lower octane fuel 131 TROUBLESHOOTING Engine Stops or Loses Power Possible Cause Solution Out of fuel Refuel Kinked or plugged fuel vent line Inspect and replace Water is present in fuel Replace with new fuel Fouled or defective spark plugs Inspect clean and or replace spark plug Worn or defective spark plug wires See vour dealer Incorrect spark plug gap or heat range Set gap to specs or replace plug Loose ignition conne
114. us injury or death Always ensure that the vent tube is free of obstructions and is securely installed as recommended Coat the terminals with dielectric grease or petroleum jelly Connect and tighten the red positive cable first Connect and tighten the black negative cable last Verify that cables are properly routed Reinstall the driver s seat 116 MAINTENANCE Battery 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 118 NOTE Battery charge can be maintained by using a Polaris Battery Tender charger or by charging about once a month to make up for normal self discharge Battery Tender can be left connected during the storage period and will automatically charge the battery if the voltage drops below a pre determined point See page 128 for the part numbers of Polaris products Battery Fluid Conventional Battery A poorly maintained battery will Lower Upper deteriorate rapidly Check the bat Mark Mark tery 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 117 MAINTENANCE Battery Battery Charging
115. y always disconnect the negative black cable first When reinstalling the battery always connect the negative black cable last Battery Removal 1 Remove the driver s seat See page 35 2 On conventional batteries remove the battery vent tube 3 Disconnect the black negative battery cable first 4 Disconnect the red positive battery cable last 5 Lift the battery out of the vehicle Be careful not to tip a conven tional battery sideways which could spill electrolyte CAUTION If electrolyte spills immediately wash it off with a solution of one tablespoon baking soda and one cup water to prevent damage to the vehicle 115 MAINTENANCE Battery Battery Installation Using a new battery that has not been fully charged can damage the bat tery and result in a shorter life It can also hinder vehicle performance Follow the battery charging instructions on page 118 before installing the battery 1 Ensure that the battery is fully charged 2 Place the battery in the battery holder 3 On conventional batteries install the battery vent tube sealed bat teries do not have a vent tube NOTE The vent tube must be free of obstructions and securely installed Route the tube away from the frame and vehicle body to prevent con tact with electrolyte A WARNING Battery gases could accumulate in an improperly installed vent tube and cause an explosion resulting in serio

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