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2014 RANGER XP 900 with Crew.fm

1. 6 Apply the brake forcefully for a few seconds and check for fluid leakage around the fittings Minimum 76 MAINTENANCE Brakes Brake Inspection 1 Check the brake system for fluid leaks 2 Check the brake pedal for excessive travel or a spongy feel 3 Check the friction pads for wear damage and looseness Check brake discs for signs of cracks excessive corro sion warping or other damage Clean any grease using an approved brake cleaner or alcohol WARNING Do not apply WD 40 or any petroleum product to brake discs These types of products are flammable and may also reduce the friction between the brake pad and caliper 5 Inspect the brake disc spline and pad wear surface for excessive wear Change pads when worn to 3 64 1 mm Steering Wheel Inspection Check the steering wheel for specified freeplay and smooth operation at the intervals out lined in the Periodic Maintenance Chart beginning on page 59 1 Position the vehicle on a level surface 2 Place the transmission in PARK 3 Lightly turn the steering wheel left and right There should be 0 8 1 0 20 25 mm of freeplay 4 If there is excessive freeplay or strange noises or the steering feels rough or catchy have the steering system inspected by an authorized POLARIS dealer 77 MAINTENANCE Suspension Adjustments The front and rear suspensions can be adjusted to provide a stiffer suspension if necessary 1 Remove the top sh
2. 00 65 Speed TOWIDE aede mt eet het 46 Speedometer sss os obs ere prr e Ee ve 30 Spring Shock Adjustment 78 Stabilizing the Fuel s scs isss encasta iiss 87 Starting the Engine 0 00 37 Steering Wheel Inspection 77 Steering Wheel Adjustment 24 Stopping the Engine T Nor M PC 86 88 Storage ATCA e i eiaei at k tette 88 Storage Compartment Under Seat 25 Storage Battery lisse ee t ess 84 Storage COVeIS i c isse hme mea 88 Storage Fluid Levels 04 88 Storage Oil and Filter 0 87 Storage Removal eco yes 89 108 S Suspension Adjustment Rear 78 Switches AWD Switch 64 23 Differential Lock Switch 23 Igrition emper eet MU DUO 23 Eight iue opas ded ads tye 23 Mode Button 0000 23 T Tachometer 222 Leve x eR pornasi ieii 33 Throttle Pedal 1 2 er pee 24 Tilt Steering i ette ewe re DaeER Ies 24 Tire Tread Depth 2 iore ee RR 79 Tires s cos dre e encre d AR det qae th 79 80 Torque Axle Nuts sees eee 79 Torque Spark Plug erum mre 67 Torque Wheel Nut 00 0 0000 79 Towing Loads ir ER Rene 46 Towing Speed iis esae re nee veda ete 46 Trailer Hitch ehe LESS n wack 27 EPANSTMUSSION ee nase ee ge dient ha ede ee 65 Transmission Operation 70 73 Transmission System 04 7
3. Air induction system Ignition system Fuel system Exhaust gas recirculation systems The following parts are also considered emission related components for exhaust emissions Aftertreatment devices Sensors Crankcase ventilation valves Electronic control units The following parts are considered emission related components for evaporative emissions Fuel Tank Vacuum Control Diaphragms Fuel Cap Control Cables Fuel Line Control Linkages FuelLine Fittings Purge Valves Clamps Vapor Hoses Pressure Relief Valves Liquid Vapor Separator Control Valves Carbon Canister Control Solenoids Canister Mounting Brackets Electronic Controls e Carburetor Purge Port Connector As related to the evaporative emission control system 102 WARRANTY U S A EPA Emissions Limited Warranty The exclusive remedy for breach of this limited warranty shall be at the exclusive option of POLARIS repair or replacement of any defective materials components or products THE REMEDIES SET FORTH IN THIS LIMITED WARRANTY ARE THE ONLY REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF THIS WARRANTY POLARIS SHALL HAVE NO LIABILITY TO ANY PERSON FOR INCIDENTAL CONSEQUENTIAL OR SPECIAL DAMAGES OF ANY DESCRIPTION WHETHER ARISING OUT OF EXPRESS OR IMPLIED WARRANTY OR ANY OTHER CONTRACT NEGLIGENCE OR OTHER TORT OR OTHERWISE THIS EXCLUSION OF CONSEQUENTIAL INCIDENTAL AND SPECIAL DAMAGES IS INDEPENDENT FROM AND SHAL
4. The warranty on your POLARIS vehicle will be terminated if any non POLARIS approved equipment and or modifications have been added to the vehicle that increase speed or power The addition of certain accessories including but not limited to mowers blades tires sprayers or large racks may change the handling characteristics of the vehicle Use only POLARIS approved accessories and familiarize yourself with their function and effect on the vehicle SAFETY Operator Safety AWARNING Failure to operate the RANGER properly can result in a collision loss of control accident or rollover which may result in serious injury or death Heed all safety warnings outlined in this section of the owner s manual See the OPERATION section of the owner s manual for proper operating procedures Age Restrictions This vehicle is an ADULT VEHICLE ONLY NEVER operate this vehicle if you are under age 16 and NEVER operate without a valid driver s license Never operate with a passenger under the age of 12 All riders must be able to sit with backs against the seat both feet flat on the floor and both hands on the steering wheel if driving or on a passenger hand hold Operating Without Instruction Operating this vehicle without proper instruction increases the risk of an accident The operator must understand how to operate the vehicle properly in different situations and on different types of terrain All operators must read and unde
5. _ LN RANGER XP 900 RANGER CREW 900 Owner s Manual for Maintenance and Safety A WARNING Read understand and follow all of the instructions and safety precautions in this manual and on all product labels Failure to follow the safety precautions could result in serious injury or death A WARNING The engine exhaust from this product contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm WELCOME Thank you for purchasing a POLARIS vehicle and welcome to our world wide family of POLARIS enthusiasts Be sure to visit us online at www polaris com for the latest news new product introductions upcoming events career opportunities and more Here at POLARIS we proudly produce an exciting line of utility and recreational products Snowmobiles All terrain vehicles ATVs Low emission vehicles LEVs RANGERQ utility vehicles RZR sport vehicles VICTORY motorcycles e GEMQ electric vehicles We believe POLARIS sets a standard of excellence for all utility and recreational vehicles manufactured in the world today Many years of experience have gone into the engineering design and development of your POLARIS vehicle making it the finest machine we ve ever produced For safe and enjoyable operation of your vehicle be sure to follow the instructions and rec ommendations in this owner s manual Your manual contains ins
6. 3 Allow the engine to run for 15 20 minutes to allow the stabilizer to disperse through the entire fuel delivery system Cil and Filter Change the oil and filter See page 63 Air Filter Air Box 1 Replace the air filter See page 74 2 Clean the air box 87 MAINTENANCE Cleaning and Storage Storage Tips Inspect and Lubricate Inspect all cables and lubricate all areas of the vehicle as recommended in the Periodic Main tenance Chart beginning on page 59 Battery Maintenance See page 84 for storage and charging procedures Fluid Levels Inspect the fluid levels Add or change fluids as recommended in the Periodic Maintenance Chart beginning on page 59 Front gearcase fluid Transmission fluid Brake fluid change every two years and any time the fluid looks dark or contaminated Coolant test strength fill Fog the Engine 1 Treat the fuel system with POLARIS Carbon Clean Follow the instructions on the con tainer Start the engine Allow it to idle for several minutes so the Carbon Clean reaches the injectors Stop the engine 2 Remove the spark plugs and add 2 3 tablespoons of engine oil To access the plug holes use a section of clear 1 4 hose and a small plastic squeeze bottle filled with the pre measured amount of oil Do this carefully If you miss the plug holes oil will drain from the spark plug cavities into the hole at the front of the cylinder head and appear to be an oil leak 3 Reinstall
7. Oil Fill Filter Oil Cap Dipstick Access Crankcase Hole Drain Plug Bottom View of Skid Plate Remove the oil fill cap and add oil as needed to bring the level to the upper mark on the dipstick Do not overfill Reinstall the fill cap Reinstall the dipstick Lower the cargo box and push down securely to latch Dispose of used filter and oil properly MAINTENANCE Gearcases Gearcase Specification Chart RANGER XP 900 RANGER CREW 900 Gearcase Specifications Gearcase Lubricant Capacity Fill Plug Torque Drain Plug Torque Main Gearcase AGL Gearcase 40 6 oz 12 ft Ibs 12 ft Ibs Transmission Lubricant amp 1200 ml 16 3 Nm 16 3 Nm Transmission Fluid Front Gearcase Demand Drive Fluid 6 76 7 6 oz 8 10 ft Ibs 8 10 ft Ibs 200 225 ml 11 13 6 Nm 11 13 6 Nm Transmission Main Gearcase Always check and change the transmission oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 59 Refer to the Gearcase Specifications Chart for recommended lubricants capacities and torque specifications See page 94 for the part numbers of POLARIS products Oil Check The level check fill plug is located on the rear of the gearcase Maintain the oil level even with the bot Level E Peo tom of the level check fill plug hole threads Check Fill s Jae d 7 CU 7 i gt 1 Position the vehicle on a level surface Plug 9 gt 2 Place the transmission in
8. Place the transmission in PARK 3 Ensure that the cargo is positioned evenly or toward the front of the cargo box 4 Release the tailgate by pulling up on the tail gate latch WARNING If the weight distribution on the box is located toward the rear of the box when the release lever is pulled forward the box may dump unexpectedly and cause serious injury to the operator or bystanders Never operate the dump lever without ensuring that the load is positioned evenly or at the front of the box 5 Stand clear and pull up on the cargo box release lever Lift the front of the cargo box to dump the cargo 6 Lower the cargo box and push down securely to latch WARNING Operating the vehicle while the cargo box is raised could result in severe injury The box could close unexpectedly and cause injury to the driver or passenger The rear tires could also catch the rear of a raised box damaging the vehicle and creating hazardous driving conditions Never operate this vehicle with the cargo box in the raised position 47 OPERATION All Wheel Drive AWD Engaging AWD Press the top of the switch to engage All Wheel Drive AWD The 4X4 indicator illuminates in the rider information center to indicate that the vehicle is in AWD See page 31 When the AWD switch is on the front wheels will Differential Lock automatically engage any time the rear wheels lose traction When the rear wheels regain traction the Differential Unlock fro
9. WARNING A WARNING indicates a hazardous situation that if not avoided could result in death or serious injury CAUTION A CAUTION indicates a hazardous situation that if not avoided could result in minor or moderate injury NOTICE A NOTICE indicates a situation that could result in property damage The Prohibition Safety Sign indicates an action NOT to take in order to avoid a hazard O The Mandatory Action Sign indicates an action that NEEDS to be taken to avoid a hazard INTRODUCTION 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 Key Number Engine Serial Number Vehicle Model Number Frame VIN Engine Serial Number Key Number INTRODUCTION European Vibration and Noise The driver perceived noise and hand arm and whole body vibration levels of this machinery is measured per prEN 15997 The operating conditions of the machinery during testing The vehicles were in like new condition The environment was controlled as indicated by the test procedure s The uncertainty of vibration exposure measurement is dependent on many factors including nstrument and calibration
10. shock loading Shock loading may tension a winch cable beyond its strength and cause the cable to break The end of a broken winch cable under such high loading can cause SEVERE INJURY or DEATH to you and other bystanders Winch cables are designed to NOT absorb energy This is true of both wire rope and syn thetic rope winch cables 1 Never attempt to jerk a load with the winch For example never take up slack in the winch cable by moving the winching vehicle in an attempt to move an object This is a dangerous practice It generates high winch cable loads that may exceed the strength of the cable Even a slowly moving vehicle can create large shock loads in a winch cable WARNING SEVERE INJURY or DEATH can result from a broken winch cable 2 Never quickly turn the winch ON and OFF repeatedly jogging This puts extra load on the winch winch cable and generates excessive heat from the motor This is a form of shock loading 3 Never tow a vehicle or other object with your winch Towing an object with a winch produces shock loading of the cable even when towing at slow speeds Towing from a winch also positions the towing force high on the vehicle This can cause instability of the vehicle and possibly lead to an accident 4 Never use recovery straps with your winch Recovery straps are designed to stretch and can store energy This stored energy in the recovery strap is released if a winch cable fails making the event even
11. 712 kg Test GVW Rollover Protection System ROPS 3600 Ibs 1633 kg per OSHA 29 CFR 1928 53 Fuel Capacity 10 gal 37 8 1 Engine Oil Capacity 2 5 qts 3 4 I Coolant Capacity 5 qts 4 751 Towing Capacity 2000 Ibs 907 kg Hitch Tongue Capacity 150 Ibs 68 kg Max Cargo Box Load 1000 Ibs 454 kg 600 Ibs 272 kg Models sold in California Overall Length 148 in 376 cm Overall Width box 60 in 152 4 cm Overall Width tires 58 in 147 3 cm Overall Height 76 in 193 cm Wheelbase 113 in 287 cm Cargo Box Dimensions Inside 36 5 x 54 x 11 5 in 93 x 137 x 29 cm Ground Clearance 12 in 30 5 cm Min Turning Radius 214 in 543 5 cm Engine 4 Stroke DOHC Twin Cylinder Displacement 875 cc Bore x Stroke 93mm x 64 4mm Alternator Output 575 W 3000 RPM Compression Ratio 10 5 1 Starting System Electric Fuel System Electronic fuel injection Ignition System Electronic Spark Plug Gap XG4YCX 0 7 0 8 mm Front Suspension Dual A arm w 10 in 25 4 cm of travel Rear Suspension Independent w 10 in 25 4 cm of travel Lubrication System Wet Sump 92 SPECIFICATIONS RANGER CREW 900 Driving System Type PVT 4 wheel independent shaft lockable differential Shift Type Single Lever H L N R P Transmission Gear Ra
12. Cap i eee cares ole ERE dae AR EUN 26 Fuel Safety ise eee Sis ctae waa nubs sian 18 Fuel Stabili Zer 5 saepe gis eden 87 Fuel Tank Fillet Cap esee attesa 26 lr ELS 83 G Gap Spark Plug isrener nee Rem 67 Gasoline Handling 04 18 Gear Selector orsa xr Sh ahaa eae 22 Gearcase Specification Chart 65 Gearcase FONE onsite e dur Dat vectes 66 GEarcases esss eae ego ee eee EAS 65 66 G ars Shifting 3 4 esee RI x rre EE 22 GIOVES i eere eR ORA ORO nene dare 9 H Hauling Cargo e036 aee ch beh hebreo pev 45 Headlight Beam Adjustment 82 Headlight Lamp Replacement 81 Jin PCR PUR eon 8 Hitchin unce RLeRRe9 ex ESPERE EIE 27 Hitch Weight 2 6e rense eer ve 46 Hood L tches esses che er ere ee 26 l Ieration Switch eee ee tmr ctt 23 Indicator Lamps sibs gh iano hae hi 30 Inspection Pre Ride 005 36 Instrument Cluster 00 30 34 Intake Screens v em RR IR EXER VS 74 Interference Electromagnetic 58 K Key Periodic Maintenance Chart 59 L Lamp Replacement Headlight 81 Light Switeh ssec vita bb Ere rn 23 E38his 1e orden Rura ER tO 81 82 Load Capacity sodes suem ducos tou re aas 45 Lubrication Recommendations 62 M Maintenance Log 00005 104 Maintenance Periodic 4 59 61 Metric Display e m etn cen 32 Mode Button A ore
13. ERR ERSTES 35 PVT Drying 2h ve X v eed es RS 73 PVT SyStem ici rhr brem re 70 73 PVT Warning esc in penny es aaah os 70 PVT Cleaning Debris 71 72 107 INDEX R Radiator ici pester cists EDER DESEAS eas 68 Radiator Coolant Level 0 0 69 Rear Suspension Adjustment 78 Receiver Hitch is ep ea RED Eee 27 Removing the Vehicle from Storage 89 Reverse Operation cece nena Rhen 43 Rider Information Center 31 34 Riding G ar osi te cotta Ix nee ease 8 9 Rollover Protective Structure 21 ROPS Cab Frame eee meb eee dies 27 S Safety Labels ene EE XR bs 10 12 Safety Symbols essit ea ck eR RE 5 Safety Winch Maintenance 57 Sedat BEIS emean MP Eq 29 Seat Removalos is vire ewe rte 25 Severe Use Definition 59 Shiliet eee ree are Ur kreisen RE ca 22 Shifting Gears cols a ea oa EROS nS 22 Shock Loading the Winch lusus 56 Shock Spring Adjustment 78 Signal WoOrdS visi sire y e REP Re 5 Spark Arrester Warning llus lesus 75 Spark Plug Gap tis err Eee 67 Spark Plug Inspection 67 Spark Plug Recommendations 67 Spark Plug Torque ien mme 67 Spark Plugs tuss aito 0 eee eee eee eee eee 67 Spark Plugs Fouled 67 Specifications wi isis wae RR Rees 90 91 Specifications Gearcase
14. Lug Nut Tapered fr I Front and Rear 60 ft lbs 81 Nm Spindle Nut Front 75 ft Ibs 102 Nm Hub Retaining Nuts Rear 110 ft Ibs 150 Nm 79 MAINTENANCE Tires Wheel Removal Position the vehicle on a level surface Place the transmission in PARK Stop the engine Loosen the wheel nuts slightly Elevate the side of the vehicle by placing a suitable stand under the frame Uns Be Qe Remove the wheel nuts and washers Remove the wheel Wheel Installation 1 Place the transmission in PARK 2 Place the wheel in the correct position on the at wheel hub Be sure the valve stem is toward Con the outside and rotation arrows on the tire e point toward forward rotation WARNING Improperly installed wheels can adversely affect tire wear and vehicle handling which can result in serious injury or death Always ensure that all nuts are torqued to specification Do not service axle nuts that have a cotter pin installed See your POLARIS dealer 3 Attach the wheel nuts and washers and fin lt ger tighten 8 4 Carefully lower the vehicle to the ground 5 Torque the wheel nuts to specification See page 79 Power Steering Unit If your model is equipped with power steering fre quently clean the areas around and on the power steering unit to allow proper cooling Clean these areas thoroughly Clean Often 80 MAINTENANCE Lights Poor lighting can result in reduced visibility
15. PARK 3 Remove the level check fill plug Check the oil level 4 Add the recommended oil as needed gt Ey 5 Reinstall the fill plug Torque to specification Oil Change Level The drain plug is located near the bottom of the gearcase Remove the level check fill plug Drain Plug Place a drain pan under the gearcase Remove the drain plug Allow the oil to drain completely Clean and reinstall the drain plug Torque to specification Add the recommended oil Reinstall the fill plug Torque to specification SA OW Re ONS Check for leaks Dispose of used oil properly 65 MAINTENANCE Gearcases Front Gearcase Always check and change the front gearcase oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 59 Maintain the oil level even with the bottom thread of the fill plug hole Refer to the Gearcase Specifications Chart on page 65 for recommended lubricants capaci ties and torque specifications See page 94 for the part numbers of POLARIS products Oil Check The front gearcase fill plug is located on the right side of the front gearcase 1 Position the vehicle on a level surface 2 Place the transmission in PARK 3 Remove the fill plug Check the oil level 4 Add the recommended oil as needed 5 Reinstall the fill plug Torque to specification Oil Change 1 Support the vehicle securely with a jackstand 2 Remove the fill plug 3 Place a drain pan under the dr
16. Parking on an Incline Avoid parking on an incline if possible If it s unavoidable follow these precautions 1 2 B 4 Apply the brakes Place the transmission in PARK Turn the engine off Block the rear wheels on the downhill side OPERATION Hauling Cargo AWARNING Hauling cargo improperly can alter vehicle handling and may cause loss of control or brake instability which can result in serious injury or death Always follow these precautions when hauling cargo Never exceed the maximum weight capacity of the vehicle When determining the weight you are adding to the vehicle include the weight of the operator passenger accessories loads in the rack or box and the load on the trailer tongue The combined weight of these items must not exceed the maximum weight capacity REDUCE SPEED AND ALLOW GREATER DISTANCES FOR BRAKING WHEN HAULING CARGO Always load the cargo box with the load as far forward and as low as possible When operating over rough or hilly terrain reduce speed and cargo to maintain stable driving conditions Always operate the vehicle with extreme care when hauling or towing loads Slow down and drive in the lowest gear available Always use LOW gear when towing or hauling heavy loads 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 handli
17. Responsibly Shift Caution Warning Proper Use Warning XP 900 Require Proper Use of Your Vehicle Do your part to prevent injuries Do not allow careless or reckless driving Make sure operators are 16 or older with a valid driver s license Do not let people drive or ride after using alcohol or drugs Do not allow operation on public roads unless designated for off highway vehicle access collisions with cars and trucks can occur Do not exceed seating capacity 3 occupants 7179979 Proper Use Warning CREW 900 Require Proper Use of Your Vehicle Do your part to prevent injuries Do not allow careless or reckless driving Make sure operators are 16 or older with a valid driver s license Do not let people drive or ride after using alcohol or drugs Do not allow operation on public roads unless designated for off highway vehicle access collisions with cars and trucks can occur Do not exceed seating capacity 5 occupants 7179990 10 SAFETY Safety Labels and Locations Payload Warning Shift Caution WARNING XP 900 Never exceed 40 MPH 64 km h if total payload is greater than 550 Ibs 250 kg Never exceed 25 MPH 40 km h if total payload is greater than 1050 Ibs 476 kg XP 900 CA Never exceed 40 MPH 64 km h if total payload is greater than 550 Ibs 250 kg CREW 900 Never exceed 35 MPH 56 km h if total payload is greater than 1280 Ibs 582 kg CREW 900 CA Never exceed 43 MPH
18. Steering 24 Emission Control Crankcase 58 Emission Control Exhaust 58 Emission Control Noise 0 00 58 Emissions Limited Warranty 102 103 Engaging AWD oriens reb qn 48 Engine Break In cete Re 35 Engine Fogging leeeeeeee eese 88 Engine Oil zi sss Rr met ELSE D 3a 62 64 Engine Starting 0 0 eee eee eee eee 37 Engine Stopping 0 0 eee ee eee ee 37 EPS orense eee enia Sooo Eades meager Deus 24 Equipment Modifications 15 Error Codes Engine 0 000005 34 Exhaust Emission Control System 58 Exhaust System Warning 75 Ey Protection 5 eob e eR e RES 9 F Fan Cooling i osse hb RR RC GREPR EE 68 Filter Cleaning Air eese 74 Filter Systems osseo ear penp EOR UN UA 74 Filter Aif ssec serere hes 74 Fluid Brake 4 ue ace eere nre teria 76 Fluid Change Engine Oily cs cse RR hEReh 63 64 Front Gearc se essere ct Ree 66 Main Gearcase 4 65 Transmission exe sd 65 F Fluid Level Engine Oll uere eb eR 63 Front Gieatcase c ioo cas wen enero 66 Main Gearcase 04 65 Transmission 2x rk cae ae Case 65 Fluid Levels During Storage 88 Fluid Part Numbers 2 00 0 000 94 Fogging the Engine 0 0 88 Fouled Plugs e amor ere ee emen 67 Front Gearcase ecce beret I Rees 66 Fuel
19. WITH POLARIS Initial dealer preparation and set up of your vehicle is very important in ensuring trouble free operation Purchasing a machine in the crate or without proper dealer set up will void your warranty coverage WARRANTY COVERAGE AND EXCLUSIONS LIMITATIONS OF WARRANTIES AND REMEDIES This POLARIS limited warranty excludes any failures that are not caused by a defect in material or workmanship THIS WARRANTY DOES NOT COVER CLAIMS OF DEFECTIVE DESIGN This warranty also does not cover acts of God accidental damage normal wear and tear abuse or improper handling This warranty also does not cover any vehicle component or part that has been altered structurally modified neglected improperly maintained or used for purposes other than for which it was designed This warranty excludes damages or failures resulting from improper lubrication improper engine timing improper fuel surface imperfections caused by external stress heat cold or contamination operator error or abuse improper component alignment tension adjustment or altitude compensation snow water dirt or other foreign substance ingestion contamination improper maintenance modified components use of aftermarket or unapproved components accessories or attachments unauthorized repairs or repairs made after the warranty period expires or by an unauthorized repair center 98 WARRANTY LIMITATIONS OF WARRANTIES AND REMEDIES This warranty excludes damages or fai
20. and hook when operating winch Never attempt to jerk a load attached to the winch with a moving vehicle See the Shock Loading section on page 56 Always keep the area around the vehicle winch winch cable and load clear of people especially children and distractions while operating the winch Always turn the vehicle ignition power OFF when it and the winch are not being used Always be sure that at least five 5 full turns of winch cable are wrapped around the winch drum at all times The friction provided by this wrapped cable allows the drum to pull on the winch cable and move the load Always apply your vehicle s park brake and or park mechanism to hold the vehicle in place during winching Use wheel chocks if needed Always align the vehicle and winch with the load directly in front of the vehicle as much as possible Avoid winching with the winch cable at an angle to the winching vehicle s centerline whenever possible If winching at an angle is unavoidable follow these precautions A Look at the winch drum occasionally Never let the winch cable stack or accumulate at one end of the winch drum Too much winch cable at one end of the winch drum can damage the winch and the winch cable B If stacking occurs stop winching Follow step 15 on page 55 to feed and rewind the cable evenly before continuing the winch operation WINCH GUIDE Winch Safety Precautions 13 14 15 16 17 18 19 2
21. coverage of any kind other than safety bulletins Products registered to Government officials or military personnel on assignment outside of the country where the product was purchased will continue to be covered by the Limited Warranty Please work with your dealer to resolve any warranty issues Should your dealer require any additional assistance they will contact the appropriate person at POLARIS This warranty gives you specific legal rights and you may also have other rights which vary from state to state or in different countries If any of the above terms are void because of federal state local law all other warranty terms will remain in effect For questions call POLARIS Customer Assistance United States amp Canada 1 800 POLARIS 1 800 765 2747 French 1 800 268 6334 101 WARRANTY U S A EPA Emissions Limited Warranty This emissions limited warranty is in addition to the POLARIS standard limited warranty for your vehicle POLARIS Industries Inc warrants that at the time it is first purchased this emissions certified vehicle is designed built and equipped so it conforms with applicable U S Environmental Protection Agency emission regulations POLARIS warrants that the vehicle is free from defects in materials and workmanship that would cause it to fail to meet these regulations The warranty period for off road vehicles 100cc or greater emissions certified vehicles starts on the date of purchase by original retail purch
22. for differential lock operating instructions Ignition Switch HIGH LOW OFF AWD Differential Lock Differential Unlock Mode Button 23 FEATURES AND CONTROLS Brake Pedal Throttle Depress the brake pedal to slow or stop the vehicle Apply the brakes while starting the engine Prae Pagal Throttle Pedal Push the throttle pedal down to increase engine speed Spring pressure returns the pedal to the rest position when released Always check that the throttle pedal returns normally before starting the engine Tip If the throttle pedal and brake pedal are applied simultaneously engine power may be limited Adjustable Steering Wheel The steering wheel can be tilted upward or downward Adjuster for rider preference Lift and hold the adjustment lever toward you while moving the steering wheel upward or downward Release the lever when the steering wheel is at the desired position Electronic Power Steering EPS Electronic power steering if equipped engages when the ignition key is turned to the ON position EPS remains engaged whether the vehicle is moving or idle To conserve battery power the EPS will shut down 5 minutes after the engine is stopped if the key remains in the ON position The EPS warning indicator will illuminate to indicate the EPS has shut down Turn the key off and on to reset the unit See page 30 for EPS
23. hardware store Although they may look similar they are NOT alike A polymer rope not designed for winch use will stretch and store excessive energy when winching WARNING Failure of a stretched rope under winching conditions will release all of the stored energy This will increase the chances of SEVERE INJURY or DEATH 57 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 require ments Operation on Public Lands in the U S A Your POLARIS vehicle has a spark arrester that was tested and qualified to be in accordance with the USFS standard 5100 1c Federal law requires that this spark arrester be installed and functional when the vehicle is operated on public lands Operation of off road vehicles on public lands in the U S A is regulated by 43 CFR 420 Violations are subject to monetary penalties Federal regulations can be viewed online at www gpoaccess gov 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 an electronic fuel injection EFI system The engine and EFI components are set at the factory for optimal pe
24. more fre quently Severe Use Definition Frequent immersion in mud water or sand Frequent or prolonged operation in dusty environments Racing or race style high RPM use Prolonged low speed heavy load operation Extended idle Frequent short trip operation in cold weather engine frequently does not operate long enough to reach full operating temperature Pay special attention to the oil level A rise in oil level during cold weather can indicate con taminants collecting in the oil sump or crankcase Change oil 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 Maintenance Chart Key Perform these operations more often for vehicles subjected to severe use E Emission related service Failure to conduct this maintenance will not void the emis sions warranty but may affect emissions D Have an authorized POLARIS dealer perform these services WARNING Improperly performing the procedures marked with a D could result in component failure and lead to serious injury or death Have an authorized POLARIS dealer perform these services 59 MAINTENANCE Periodic Maintenance Chart Perform all services at whichever maintenance interval is reached first Item Maintenance Interval Remarks whichever comes first H
25. more hazardous Similarly never use elastic bungie cords for winching 5 Neveruse the winch to tie down a vehicle to a trailer or other transportation vehicle This type of use also causes shock loading that can cause damage to the winch winch cable or vehicles used Your winch cable is designed and tested to withstand the loads produced by the winch motor when operated from a stationary vehicle Always remember that the winch and winch cable are NOT designed for shock loading 56 WINCH GUIDE Winch Maintenance and Service Safety WARNING Improper or lack of winch maintenance and service could lead to SEVERE INJURY or DEATH Always follow all winch instructions and warnings in this manual 1 Always inspect your winch before each use Inspect for worn or kinked winch cable Also inspect for worn or loose parts including mounting hardware Permit your winch motor to cool down prior to servicing your winch 3 Never work on your winch without first disconnecting the battery connections to prevent accidental activation of the winch 4 For your safety always replace POLARIS winch parts including the cable with genuine POLARIS replacement parts available at your authorized POLARIS dealer 5 Some winch models use wire rope as the winch cable Other winches use a specially designed synthetic rope as the winch cable 6 Never replace a synthetic rope winch cable with a consumer grade polymer rope such as can be purchased in a
26. recharge the battery to clear the warning Clock The clock displays time in a 12 hour or 24 hour format See page 32 for reset ting instructions Service Indicator A flashing wrench symbol alerts the operator that the preset service interval has been reached The vehicle should be brought to your dealer for scheduled maintenance See page 32 for resetting instructions 4X4 Indicator This indicator illuminates when the 4X4 system is engaged switch is on 4X4 Turf Mode Indicator This indicator illuminates when the operator unlocks the differ ential See page 49 31 FEATURES AND CONTROLS Instrument Cluster Rider Information Center Use the MODE button to toggle through the information area options Display Units Standard Metric The display can be changed to display either standard or metric units of measurement Tip To exit the set up mode at any time wait 10 seconds The display automatically exits and returns to the odometer display Standard Display Metric Display Distance Miles Kilometers Fuel U S Gallons Liters Imperial Gallons Temperature Fahrenheit Celsius Time 12 Hour Clock 24 Hour Clock 1 Turn the key to the OFF position 2 Press and hold the MODE button while turning the key to the ON position 3 When the display flashes the distance setting tap the MODE button to advance to the desired setting 4 Press and hold the MODE button to save the setting and advance to the
27. that the vehicle is in safe operating condition before operating increases the risk of an accident Always perform the pre ride inspection before each use of your RANGER to make sure it s in safe operating condition See page 36 Always follow all inspection and maintenance procedures and schedules described in this owner s manual See page 59 Operating With a Load on the Vehicle The weight of both cargo and passengers impacts vehicle operation For your safety and the safety of others carefully consider how your vehicle is loaded and how to safely operate the vehicle Follow the instructions in this manual for loading tire pressure gear selection and speed Do not exceed vehicle weight capacities The vehicle s maximum weight capacity is listed in the specifications section of this manual and on a label on the vehicle When more passenger weight is added cargo weight may need to be reduced accordingly The recommended tire pressures are listed in the specifications section of this manual and on a label on the vehicle Always follow these guidelines Under ANY of these conditions Do ALL of these steps Passenger and or cargo exceeds half the maximum weight capacity 1 Slow down Operating in rough terrain 2 Verify tire pressure 3 Use extra caution when Operating over obstacles operating Climbing an incline Towing 17 SAFETY Operator Safety Handling Gasoline Gasoline is highly flammab
28. the following items Wheel bearings Brakes Switches and controls Radiator Cab and body panels Electrical components and wiring Transmission seals Labels and decals If an informational or graphic label becomes illegible or comes off contact your POLARIS dealer to purchase a replacement Replacement safety labels are provided by POLARIS at no charge Polishing the Vehicle POLARIS recommends the use of common household aerosol furniture polish for polishing the finish on your POLARIS vehicle Follow the instructions on the container Avoid the use of automotive products some of which can scratch the finish of your vehi cle Always use clean cloths and pads for cleaning and polishing Old or reused cloths and pads may contain dirt particles that will scratch the finish 86 MAINTENANCE Cleaning and Storage Storage Tips NOTICE Starting the engine during the storage period will disturb the protective film created by fogging and damage could occur Never start the engine during the storage period Clean the Exterior Make any necessary repairs and clean the vehicle as recommended See page 86 Stabilize the Fuel 1 Hill the fuel tank 2 Add POLARIS Carbon Clean Fuel Treatment or POLARIS Fuel Stabilizer Follow the instructions on the container for the recommended amount Carbon Clean removes water from fuel systems stabilizes fuel and removes carbon deposits from pistons rings valves and exhaust systems
29. the seat belt Always use the cab nets or doors while riding in this vehicle Place the transmission in PARK Start the engine Apply the service brakes and shift the transmission into gear Check your surroundings and determine your path of travel Keeping both hands on the steering wheel slowly release the brakes and slowly depress the throttle with your right foot to begin driving 10 Drive slowly Practice maneuvering and using the throttle and brakes on level surfaces 11 Do not carry a passenger until you have at least two hours of driving experience with this 38 vehicle OPERATION Driving with a Passenger 1 2 9 ig Perform the pre ride inspection See page 36 Make sure all passengers are at least 12 years of age and tall enough to comfortably and safely sit in a passenger seat with the seat belt secured put both feet on the floor and grasp the hand hold Make sure all passengers are wearing helmet eye protection gloves long sleeve shirt long pants and over the ankle boots Make sure all passengers secure their seat belt Make sure all cab nets or doors are properly secured Do not carry more than the recommended number of passengers for your vehicle See page 12 Allow a passenger to ride only in a passenger seat Slow down Always travel at a speed appropriate for your skills your passengers skills and operating conditions Avoid unexpected or aggressive maneuvers that could cau
30. up If the instrument WE T S F cluster fails to illuminate a battery Trip 1 PM over voltage may have occurred WW NA WAIN WANA IN and the instrument cluster may have VN shut off to protect the electronic speedometer If this occurs take the vehicle to your POLARIS dealer for proper diagnosis VN ANTAN UNTEN EN The information center is set to dis play standard units of measurement and a 12 hour clock at the factory To change to metric and or a 24 hour clock see page 32 1 Gear Indicator This indicator displays gear shifter position H High Gear L Low Gear N Neutral R Reverse Gear P Park Tip Gear Signal Error or shifter between gears Fuel Gauge The segments of the fuel gauge show the level of fuel in the fuel tank When the last segment clears a low fuel warning is activated All segments including the fuel icon will flash Refuel immediately If the fuel icon fails to display an open or short circuit has occurred in the fuel sensor circuit See your dealer Information Display Area This area displays odometer trip meter tachometer engine temperature meter engine hour meter and programmable service hour interval Under Over Voltage This warning usually indicates that the vehicle is operating at an RPM too low to keep the battery charged It may also occur when the engine is at idle and high electrical load lights cooling fan accessories is applied Drive at a higher RPM or
31. 0 21 22 23 24 25 Never winch up or down at sharp angles This can destabilize the winching vehicle and possibly cause it to move without warning Never attempt to winch loads that weigh more than the winch s rated capacity The winch motor may become hot during winch use If you winch for more than 45 seconds or if the winch stalls during operation stop winching and permit the winch to cool down for 10 minutes before using it again Never touch push pull or straddle the winch cable while winching a load Never let the winch cable run through your hands even if wearing heavy gloves Never release the clutch on the winch when the winch cable is under load ai Never use the winch for lifting or transporting people Never use the winch to hoist or suspend a vertical load Never immerse or submerse your winch in water Take your winch to your dealer for service if this occurs Always inspect your winch and winch cable before each use Never winch the hook fully into the winch This can cause damage to winch components Unplug the remote control from the vehicle when the winch is not in use to prevent inadvertent activation and use by unauthorized persons Never grease or oil the winch cable This will cause the winch cable to collect debris that will shorten the life of the cable 51 WINCH GUIDE Winch Operation Read the Winch Safety Precautions in the preceding pages before using your winch Ti
32. 0 73 Transmission Warming 00 70 Transmission Drying 00 73 Transporting the Vehicle 89 Tread Deptt is iue Deve e Eu RR 79 U Under Seat Storage eese 25 V Vehicle Identification Numbers 6 Vehicle Immersion lese eeesss 73 Vehicle Transport 00 0 000005 89 W Warning Symbols 0 000000 eee eee 5 Washing the Vehicle 0 86 Water Immersion of Vehicle T3 Wheel Installation 00 0 0000 80 Wheel Nut Inspection 04 79 Wheel Nut Torque meme rm RES 79 Wheel Removal os se ERR 80 Winch Cable Cate sis cca aise ere es 55 Winch Maintenance and Service Safety 5I Winch Operation 00005 52 55 Winch Safety Precautions 50 51 Winch Shock Loading lusus 56 PMS 419 AWARNING Improper vehicle use can result in SEVERE INJURY or DEATH NEVER Operate If you are under age 16 and without a valid driver s license Without first viewing safety video and taking a ROHVA training course at www rohva org On excessively steep hills On public roads unless designated for off road use With a passenger who is not seated in a passenger seat or with passengers under age 12 or who cannot comfortably reach the floor and hand holds On paved surfaces pavement may seriously affect handling and cont
33. 20A 10A ECM tears FUEL PUMP B Nec 20A 10A 10A 7177866 Power Steering Fuse if equipped 83 MAINTENANCE Battery Your vehicle has a sealed battery which requires little maintenance Always keep battery ter minals 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 dielec tric grease or petroleum jelly Battery Removal AWARNING Improperly connecting or disconnecting battery cables can result in an explosion and cause serious injury or death When removing the battery always disconnect the negative black cable first When reinstalling the battery always connect the negative black cable last 1 Remove the storage bin under the passenger seat to access the battery 2 Disconnect the black battery cable first Disconnect the red battery cable last 3 Lift the battery out of the vehicle Battery Installation Using a new battery that has not been fully charged can damage the battery and result in a shorter life It can also hinder vehicle performance Follow the battery charging instructions on page 85 before installing the battery 1 Ensure that the battery is fully charged 2 Place the fully charged battery in the battery holder Make sure the positive terminal is toward the driver s side of the
34. 47 Chart Gearcase Specifications 65 Periodic Maintenance 59 61 Check Engine Indicator 34 Cleaning and Storage 86 88 ClOn oeste tres D RDRUO aspe G 9 iuuirennrpr cc 91 Component Locations 04 2 Console csse ry rr nex eee 22 Coolant Level Overflow Bottle Coolant 69 Coolant Level Radiator 4 69 Coolant Adding or Changing 68 Cooling Fa Jess mmc 68 Cooling System oie esurire renes 68 69 Crankcase Emission Control System 58 106 D Differential Lock Switch suuuus 23 Differential Locking 04 49 Disengaging AWD eseeeesee 48 Display Units Standard Metric 32 Drive Belt Wear b aes EUM 95 Drivetrain Break In 00000 35 Driving Downhill 000 002 0005 41 Driving in Reverse crece cia Rr metere 43 Driving on a Sidehill seeuuus 41 Driving on Slippery Surfaces 40 Driving Over Obstacles 0 39 Driving Procedure lt i csc ceo dote e ks 38 Driving Through Water 0005 42 Driving Uphill i ort br teresa 41 Driving with a Passenger 39 Driving After Driving in Water 73 Drying the Transmission 00 73 Dumping the Cargo Box 47 E Electromagnetic Interference 58 Electronic Power
35. 70 km h if total payload is greater than 1280 Ibs 582 kg CAUTION To avoid transmission damage shift only when vehicle is stationary and at idle When vehicle is stopped place shift in parked position Seat Belt Drive Responsibly Warning WARNING Improper vehicle use can result in SEVERE INJURY or DEATH Be Prepared Fasten seat belts Wear an approved helmet and protective gear ALWAYS use cab nets and or doors Each rider must be able to sit with back against seat feet flat on the floor and hands on steering wheel or hand holds Stay completely inside the vehi cle Drive Responsibly Avoid loss of control and rollovers Avoid abrupt maneuvers sideways sliding skidding or fishtailing and never do donuts Slow down before entering a turn Avoid hard acceleration when turning even from a stop Plan for hills rough terrain ruts and other changes in traction and terrain Avoid paved surfaces S e Avoid sidehilling riding across slopes Rollovers have caused severe injuries and death Be Sure Riders Pay Attention and Plan Ahead even on flat open areas If you think or feel the vehicle may tip or roll reduce your risk of injury Keep a firm grip on the steering wheel or hand holds and brace yourself Do not put any part of your body outside of the vehicle for any reason LOCATE AND READ OWNER S MANUAL FOLLOW ALL INSTRUCTIONS AND WARNINGS ALWAYS REVIEW SAFETY VIDEO
36. AND TAKE ROHVA TRAINING rohva org 7179983 SAFETY Safety Labels and Locations Load Passenger Tire Pressure Warning WARNING Never carry passengers in cargo box Passengers can be thrown off This can cause serious injury or death f total payload is greater than 500 Ibs the vehicle must be operated in LOW range IMPROPER TIRE PRESSURE OR OVERLOADING CAN CAUSE LOSS OF CONTROL RESULTING IN SERIOUS INJURY OR DEATH Reduce speed and allow greater distance for braking when carrying cargo Overloading or carrying tall off center or unsecured loads will increase your risk of losing control Loads should be centered and carried as low as possible in box For stability on rough or hilly terrain reduce speed and cargo RANGER XP 4x4 4x4 CA CREW CA CREW MAXIMUM CARGO BOX LOAD 1000 Ibs 600 Ibs 1000 Ibs 600 Ibs 454 kg 272 kg 454 kg 272 kg TIRE PRESSURE IN PSI KPa FRONT 10 69 FRONT 10 69 FRONT 14 96 FRONT 14 96 REAR 12 83 REAR 12 83 REAR 16 110 REAR 16 110 MAXIMUM WEIGHT CAPACITY 1500 Ibs 1100 Ibs 1750 lbs 1350 lbs INCLUDES WEIGHT OF 682 kg 499 kg 795 kg 612 kg OPERATOR PASSENGER CARGO AND ACCESSORIES Read Operation and Maintenance Manual for more detailed loading information 7180135 Clutch Cover Warning WARNING Improper service or maintenance of this
37. ED WARRANTY POLARIS Sales Inc 2100 Highway 55 Medina MN 55340 POLARIS gives a SIX MONTH LIMITED WARRANTY on all components of your POLARIS vehicle against defects in material or workmanship POLARIS further warrants that the spark arrestor in this product will meet the efficiency requirements of USFS standard 5100 1C for at least 1000 hours when subjected to normal use and when maintenance and installation are in accordance with POLARIS recommendations This warranty covers parts and labor charges for repair or replacement of defective parts and begins on the date of purchase by the original retail purchaser This warranty is transferable to another owner during the warranty period through a POLARIS dealer but any such transfer will not extend the original term of the warranty The duration of this warranty may vary by international region based upon local laws and regulations REGISTRATION At the time of sale the Warranty Registration Form must be completed by your dealer and submitted to POLARIS within ten days of purchase Upon receipt of this registration POLARIS will record the registration for warranty No verification of registration will be sent to the purchaser as the copy of the Warranty Registration Form will be your proof of warranty coverage If you have not signed the original registration and received the customer copy please contact your dealer immediately NO WARRANTY COVERAGE WILL BE ALLOWED UNLESS YOUR VEHICLE IS REGISTERED
38. Front Control Arm Pivot Grease 3 fittings on each side of the Bushings All Season Grease or grease vehicle Rear Control Arm Pivot CONfOrming to NLGI No 2 Grease 4 fittings on each side of the Bushings vehicle Rear Stabilizer Bar Grease one fitting on each side of the Bushings vehicle Engine Oil Always check and change the engine oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 59 Always change the oil filter whenever changing oil WARNING Vehicle operation with insufficient deteriorated or contaminated engine oil will cause accelerated wear and may result in engine seizure accident and injury Always perform the maintenance procedures as outlined in the Periodic Maintenance Chart Oil Recommendations POLARIS recommends the use of POLARIS PS 4 5W 50 4 Cycle Oil or a similar oil Refer to the specifications section beginning on page 90 for capacities See page 94 for the part numbers of POLARIS products NOTICE Mixing brands or using a non recommended oil may cause serious engine damage Always use the recommended oil Never substitute or mix oil brands Always check and change the oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 59 Always use the recommended engine oil 62 MAINTENANCE Engine Oil Oil Check Always check the oil when the engine is cold If the engine is hot when the oil is checked the level will appear to be overfull CAUTI
39. ICE PERFORMED COMMENTS 105 INDEX A Accessory Outlets 0 0 0 00 0000000 22 Aat PIHET v ede pROx ER EET rre Eve 74 Air Filter Cleaning 2 005 74 All Wheel Drive eere 48 49 Disengaging AWD 48 Engaging AWD 48 Locking the Differential 49 All Wheel Drive Switch 0 23 Arrester Spark Warning 75 Auxiliary Outlets sesse sa aasian neisa 22 Axle Nut Inspection 00 79 Axle Nut Torque is csseezoe e Rem Remy 79 B Battery c oucrexexe bx saan nux REUS 84 85 CAP OIG 1i itr RAIL Dh tools 85 Installation euuuess 84 Removal eese e RAE 84 LOLA BE ies eese e pee QM Io ER e 84 Beam Adjustment Headlight 82 Belt Burm ge iet eecbeCERPY RE eR CRY 95 BeltEHe ts uei enel uccide oerte ire us 46 Belt Replacement ovr e eR s 71 72 Belt Waf ocra eva le ER E ae 95 Lp CE 9 Brake Fluid 2 ree eer 76 Brake Inspection i cx ate re seed eR ES 77 Brake Light Inspection 81 Brake Ped l ere p aee 24 Brakes 5229 3a ev REED EES E iud 76 77 Braking ica nsise ages tise tansausemiacded 37 Break In Period dieer eer egre eme 35 C Cab Frame ROPS o 5 6 cece cese eee essi 27 Cab NES aee A hot ee as NODUM qe 28 Car SO isc cies o oo Hoek uon RA reda di ee uie 45 Cargo Box Dumping
40. Instrument Cluster Rider Information Center Engine Error Codes The error screen displays only when the CHECK ENGINE light is on or when it goes on and off during one ignition cycle Error codes are not stored When the key is turned OFF the code and message is lost but will reappear if the fault reoccurs after restarting the engine If the CHECK ENGINE light illuminates retrieve the error codes from the display 1 Ifthe error codes are not displayed use the MODE button to toggle until Ck ENG displays on the main line of the display 2 Press and hold the MODE button to enter the diagnostics code menu Nw Pw 34 Suspect Parameter Number SPN Error Code Number 0 9 Failure Mode Indicator FMI Record the three numbers displayed in the gear position clock and odometer displays Press the MODE button to advance to the next error code Press and hold the MODE button to exit the diagnostics code menu See an authorized POLARIS dealer for code details and diagnosis OPERATION Failure to operate the vehicle properly can result in a collision loss of control accident or rollover which may result in serious injury or death Read and understand all warnings outlined in the safety section of this manual Break In Period The break in period for your new RANGER is the first 25 hours of operation or the time it takes to use the first two tanks full of fuel No single action on your part is as important as a p
41. L SURVIVE ANY FINDING THAT THE EXCLUSIVE REMEDY FAILED OF ITS ESSENTIAL PURPOSE ALL IMPLIED WARRANTIES INCLUDING BUT NOT LIMITED TO ANY IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE ARE LIMITED IN DURATION TO THE WARRANTY PERIOD DESCRIBED HEREIN POLARIS DISCLAIMS ALL EXPRESS WARRANTIES NOT STATED IN THIS WARRANTY Some states do not allow limitations on how long an implied warranty lasts so the above limitation may not apply if it is inconsistent with the controlling state law This limited warranty excludes failures not caused by a defect in material or workmanship This limited warranty does not cover damage due to accidents abuse or improper handling maintenance or use This limited warranty also does not cover any engine that has been structurally altered or when the vehicle has been used in racing competition This limited warranty also does not cover physical damage corrosion or defects caused by fire explosions or other similar causes beyond the control of POLARIS Owners are responsible for performing the scheduled maintenance identified in the owner s manual POLARIS may deny warranty claims for failures that have been caused by the owner s or operator s improper maintenance or use by accidents for which POLARIS has no responsibility or by acts of God Any qualified repair shop or person may maintain replace or repair the emission control devices or systems on your vehicle POLARIS recommends that you
42. LS Switches Ignition Switch The ignition switch is a three position key operated switch The key can be removed from the switch when it is in the OFF position OFF The engine is off Electrical circuits are off except Acc 12V ON Electrical circuits are on Electrical equip ment can be used START Turn the key to the START postion to engage the electric starter The key returns to the ON position when released Mode Button The MODE button is located on the instrument cluster Use the MODE button to toggle through mode options available in the instrument cluster See pages 30 34 Light Switch The ignition switch key must be in the ON RUN position to operate the headlights Press the top of the rocker switch toward the dash to place the headlights on high beam Move the rocker switch to the center position to place the headlights on low beam Press the bottom of the rocker switch to turn off the headlights AWD Differential Lock Switch The AWD Differential Switch has three positions All Wheel Drive AWD Differential Lock 2WD Differential Unlock Press the top of the rocker switch to engage All Wheel Drive AWD See page 48 for operating instructions Move the rocker switch to the center position to lock the differential and operate in rear wheel drive Press the bot tom of the switch to unlock the differential and allow the two rear drive wheels to operate independently See page 49
43. ON Always remove all cargo from the cargo box before lifting the box to access engine components Access the oil fill cap dipstick and filter under the cargo box 1 Remove all cargo from the cargo box See page 47 Position the vehicle on a level surface Place the transmission in PARK Stop the engine d E Stand clear and pull up on the cargo box release lever Lift the front of the cargo box 6 Remove the dipstick Wipe it dry with a clean cloth Oil Fill Oil Oil 7 Reinstall the dipstick completely Remove Cap Filter Dipstick the dipstick and check the oil level 8 Remove the oil fill cap to add the recommended oil as needed Maintain the oil level between the minimum and maximum marks on the dipstick Do not overfill 9 Reinstall the fill cap Reinstall the dipstick 10 Lower the cargo box and push down securely to latch Oil and Filter Change Always change the oil and filter at the intervals outlined in the Periodic Maintenance Chart beginning on page 59 Always change the oil filter whenever changing oil The crankcase drain plug is located on the bottom of the crankcase Access the drain plug through the access hole in the skid plate under the crankcase see next page CAUTION Always remove all cargo from the cargo box before lifting the box to access engine components Access the oil fill cap dipstick and filter under the cargo box 1 Remove all cargo from the cargo box See page 47 2 Position
44. PVT system can result in vehicle damage SEVERE INJURY or DEATH Always look for and remove debris inside and around clutch and vent system when replacing belt Read owner s manual or see authorized POLARIS dealer 7177469 Clutch Cover Warning 12 SAFETY Operator Safety AWARNING Serious injury or death can result if you do not follow these instructions and procedures which are outlined in further detail within your owner s manual Read this entire manual and all labels carefully Follow the operating procedures described Never allow anyone under the age of 16 to operate this vehicle and never allow anyone without a valid driver s license to operate this vehicle Do not carry a passenger until you have at least two hours of driving experience with this vehicle No person under the age of 12 may ride as a passenger in this vehicle All riders must be able to sit with backs against the seat both feet flat on the floor and both hands on the steering wheel if driving or on a passenger hand hold The driver and all passengers must wear helmet eye protection gloves long sleeve shirt long pants over the ankle boots and seat belt at all times Always use the cab nets or doors while riding in this vehicle Always keep hands and feet inside the vehicle at all times Always keep both hands on the steering wheel and both feet on the floorboards of the vehicle during operation Never permit a guest t
45. RERBA 23 Modifications to Vehicle luus 15 N Noise Emission Control System 58 O ObstacleS eese opp E EEES 39 Oil Engine unde hh ES e oboe a 62 64 Transmission 0 00 eee ee 65 Oil and Filter Care During Storage 87 Oil Change Engine cs scd ise eb pate en 63 64 Front Gearcase eee 66 Main Gearcase ioc apes ees 65 Transmission 0 0 eee ee 65 Oil Level Egne 12 6 4 pp eX EX Spas 63 Front Gearcase cessere epa 66 Main Gearcase 00 65 Transmission 0 00 eee 65 Oil Recommendation Engine 62 Operation on Public Lands 58 Operator Safety s ce ceita lesse 13 20 Outlets Auxiliary i c a Exe was 22 P Parking on an Incline 00 44 Parking the Vehicle 0 00 0005 44 Part N mbets soiree t Sata ERR Y REX 94 Periodic Maintenance Chart 59 61 Plug G pii euet che toe SRSA eee Cede 67 Plug TOrque 24 2o te trm o ec nose 67 Plug Accessory i yg Re OR RE RENS 22 Plugs Fouled penenie doeet miens 67 Plugs Spark 42 pidieron enean ics 67 Polaris Products lsslssees esses 94 Polishing the Vehicle 0 86 Power Steering eri eae SAG ee Erde n reme 24 Power Steering Unit Cleaning 80 Pre Ride Inspection 0000 36 Product Part Numbers 000005 94 P blic Wands seen este topo tme tmdiod 58 PVT Break In i ovo et
46. RPM Compression Ratio 10 5 1 Starting System Electric Fuel System Electronic fuel injection Ignition System Electronic Spark Plug Gap XG4YCX 0 7 0 8 mm Front Suspension Dual A arm w 10 in 25 4 cm of travel Rear Suspension Independent w 10 in 25 4 cm of travel Lubrication System Wet Sump 90 SPECIFICATIONS RANGER XP 900 Driving System Type PVT 4 wheel independent shaft lockable differential Shift Type Single Lever H L N R P Transmission Gear Ratio High Front 3 48 1 Rear 10 4 1 Transmission Gear Ratio Low Front 8 56 1 Rear 25 59 1 Transmission Gear Ratio Reverse Front 7 67 1 Rear 22 92 1 Front Drive Ratio Tire Size Front 3 818 1 25 x 10 12 26 x 9 12 for select models Tire Size Rear 25 x 11 12 26x 11 12 for select models Tire Pressure Front 10 psi 69 kPa Tire Pressure Rear 12 psi 83 kPa Brakes Front Rear Foot Activated 4 wheel hydraulic disc Hood Headlight 2 single beam 50W quartz halogen Taillights 10 L E D 28W Brake Light 10 L E D 3 1W Clutching See your POLARIS dealer for clutching specifications 91 SPECIFICATIONS Maximum Weight Capacity RANGER CREW 900 1750 lbs 795 kg including operator passengers cargo accessories 1350 Ibs 612 kg Models sold in California Dry Weight 1570 Ibs
47. Side View Bight Tee tom to expose the air filter 3 Remove the air filter 4 Inspect the air box for oil or water deposits Wipe away any deposits with a clean cloth 5 Install a new filter if needed Do not attempt to clean the air filter Intake Screens An engine intake screen is located on the driver s side of the vehicle A clutch intake screen is located on the passenger side of the vehicle Intake Screens both sides Inspect the screens before each use of the vehicle Remove the screens and clean them frequently with warm soapy water to ensure adequate air flow 74 MAINTENANCE Spark Arrester Failure to heed the following warnings while servicing the spark arrester 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 in a very short time Never operate without the spark arrestor Periodically clean the spark arrestor to remove accumulated carbon 1 2 Place the transmission in PARK Remove the retaining screw and remove the arrester from the end of the muffler Screen Use a non synthet
48. Vehicle operators assume all risk associated with ice conditions on frozen bodies of water Unauthorized Use of the Vehicle Leaving the keys in the ignition can lead to unauthorized use of the vehicle by someone under the age of 16 without a drivers license or without proper training This could result in an accident or rollover Always remove the ignition key when the vehicle is not in use Hot Exhaust Systems Exhaust system components are very hot during and after use of the vehicle Hot components can cause burns and fire Do not touch hot exhaust system components Always keep combustible materials away from the exhaust system Use caution when traveling through tall grass especially dry grass to avoid debris build up around the exhaust system 20 FEATURES AND CONTROLS Component Locations Your vehicle is equipped with cab nets on both sides of the vehicle Cab nets or doors if equipped must be used by both operator and passengers at all times Any illustrations with out cab nets are only to allow component identification Always use the cab nets or doors Not all models come with all features Refer to the specifications section on page 90 Console Headlights J sees Es sz D yum X Receiver CV Boot Rear Hitch Caliper Muffler Spark Arrester Radiator Front Bumper Brush Guard ROPS Cab Frame Intake Scre
49. Y DEFECTIVE MATERIALS COMPONENTS OR PRODUCTS THE REMEDIES SET FORTH IN THIS WARRANTY ARE THE ONLY REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF THIS WARRANTY POLARIS SHALL HAVE NO LIABILITY TO ANY PERSON FOR INCIDENTAL CONSEQUENTIAL OR SPECIAL DAMAGES OF ANY DESCRIPTION WHETHER ARISING OUT OF EXPRESS OR IMPLIED WARRANTY OR ANY OTHER CONTRACT NEGLIGENCE OR OTHER TORT OR OTHERWISE THIS EXCLUSION OF CONSEQUENTAL INCIDENTAL AND SPECIAL DAMAGES IS INDEPENDENT FROM AND SHALL SURVIVE ANY FINDING THAT THE EXCLUSIVE REMEDY FAILED OF ITS ESSENTIAL PURPOSE THE IMPLIED WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE IS EXCLUDED FROM THIS LIMITED WARRANTY ALL OTHER IMPLIED WARRANTIES INCLUDING BUT NOT LIMITED TO THE IMPLIED WARRANTY OF MERCHANTABILITY ARE LIMITED IN DURATION TO THE ABOVE SIX MONTH WARRANTY PERIOD POLARIS DISCLAIMS ALL EXPRESS WARRANTIES NOT STATED IN THIS WARRANTY SOME STATES DO NOT PERMIT THE EXCLUSION OR LIMITATION OF INCIDENTAL OR CONSEQUENTIAL DAMAGES OR ALLOW LIMITATIONS ON THE DURATION OF IMPLIED WARRANTIES SO THE ABOVE LIMITATIONS MAY NOT APPLY TO YOU IF INCONSISTENT WITH CONTROLLING STATE LAW 99 WARRANTY HOW TO OBTAIN WARRANTY SERVICE If your vehicle requires warranty service you must take it to a POLARIS Servicing Dealer When requesting warranty service you must present your copy of the Warranty Registration From to the dealer THE COST OF TRANSPORTATION TO AND FROM THE DEALER IS YOUR RESPONSIBILITY POLARIS sugge
50. a non standard pressure cap will not allow the recov ery system to function properly See your dealer for the correct replacement part 69 MAINTENANCE POLARIS Variable Transmission PVT System AWARNING Failure to comply with the instructions in this warning can result in severe injury or death Do not modify any component of the PVT system Doing so may reduce its strength so that a failure may occur at a high speed The PVT system has been precision balanced Any modification will cause the system to be out of balance creating vibration and additional loads on components The PVT system rotates at high speeds creating large amounts of force on clutch components As the owner you have the following responsibilities for your own safety and the safety of others Always follow all recommended maintenance procedures Always look for and remove debris inside and around the clutch and vent system when replacing the belt See your dealer as outlined in the owner s manual This PVT system is intended for use on POLARIS products only Do not install it in any other product Always make sure the PVT housing is securely in place during operation 70 MAINTENANCE POLARIS Variable Transmission PVT System Belt Replacement Debris Removal If a belt fails always clean any debris from the duct and from the clutch and engine compart ments when replacing the belt WARNING Failure to remove ALL debris when replacing the belt could re
51. ain plug 4 Remove the drain plug Allow the oil to drain completely 5 Clean and reinstall the drain plug Torque to specification 6 Add the recommended oil 7 Reinstall the fill plug Torque to specification 8 Check for leaks Dispose of used oil properly 66 Recessed Drain Plug MAINTENANCE Spark Plugs Spark Plug Recommendations Refer to the specifications section beginning on page 90 for the recommended spark plug type for your vehicle Always torque spark plugs to specification NOTICE Using non recommended spark plugs can result in serious engine damage Always use POLARIS recommended spark plugs Spark Plug Gap Torque Model Electrode Gap New Plug Torque Used Plug Torque RANGER XP 0 7 0 8 mm 10 ft Ibs 13 5 Nm 10 ft lbs 13 5 Nm Spark Plug Inspection Spark plug condition is indicative of engine operation The spark plug firing end condition should be read after the engine is warmed up and the vehicle is driven at higher speeds Immediately check the spark plug for correct color CAUTION Always remove all cargo from the cargo box before lifting the box to access engine components 1 Lift the cargo box Remove the spark plug cap CAUTION A hot exhaust system and engine can cause burns Wear protective gloves when removing a spark plug for inspection 2 Using the spark plug wrench provided in the tool kit remove the plug by rotating it counter clockwise 3 Revers
52. al See page 41 Check the terrain carefully before attempting to climb a hill Never climb hills with excessively slippery or loose surfaces Never apply throttle suddenly Never make sudden gear changes Never go over the top of a hill at high speed Always follow the proper procedures outlined in this manual for traveling downhill and for braking on hills See page 41 Check the terrain carefully before descending a hill Never travel downhill at high speed Avoid going downhill at an angle which would cause the vehicle to lean sharply to one side Travel straight down the hill where possible Always check for obstacles before operating in a new area Never attempt to operate over large obstacles such as large rocks or fallen trees Always follow the proper procedures outlined in this manual when operating over obstacles See page 39 Always be careful of skidding or sliding On slippery surfaces such as ice travel slowly and exercise caution to reduce the chance of skidding or sliding out of control Never operate your vehicle in fast flowing water or in water deeper than that specified in this manual See page 42 Wet brakes may have reduced stopping ability Test your brakes after leaving water If necessary apply them lightly several times to let friction dry out the pads Always be sure there are no obstacles or people behind your vehicle when operating in reverse When it s safe to proceed in reverse move slowly Avoid turning at sharp
53. angles in reverse SAFETY Operator Safety Always use the proper size and type of tires specified in this manual Always maintain proper tire pressure as specified on safety labels Never modify this vehicle through improper installation or use of non POLARIS approved accessories Never exceed the stated load capacity for this vehicle Cargo should be properly distributed and securely attached Reduce speed and follow the instructions in this manual for hauling cargo or pulling a trailer Allow a greater distance for braking Always place the transmission in PARK before getting out of the vehicle Always stop the engine before refueling Remove flammable material containers from the box before filling them with fuel Make sure the refueling area is well ventilated and free of any source of flame or sparks Gasoline is extremely flammable See page 18 for fuel safety warnings Always remove the ignition key when the vehicle is not in use to prevent unauthorized use by someone under the age of 16 or without a driver s license and proper training or accidental starting FOR MORE INFORMATION ABOUT SAFETY call POLARIS at 1 800 342 3764 Equipment Modifications Do not install any non POLARIS approved accessory or modify the vehicle for the purpose of increasing speed or power Any modifications or installation of non POLARIS approved accessories could create a substantial safety hazard and increase the risk of bodily injury
54. aser and continues for a period of 500 hours of engine operation 5000 kilometers 3100 miles of vehicle travel or 30 calendar months from the date of purchase whichever comes first The warranty period for ATVs less than 100cc emissions certified vehicles starts on the date of purchase by original retail purchaser and continues for a period of 250 hours of engine operation 2500 kilometers 3100 miles of vehicle travel or 30 calendar months from the date of purchase whichever comes first This EPA emissions warranty period is extended for at least as long as the standard factory warranty that Polaris provides on the vehicle as a whole The EPA emissions warranty period does not further extend if you purchase additional warranty coverage in the form of a service contract or other paid warranty extension but emission related parts may be covered subject to the terms of any such paid service contract or paid warranty extension This emissions limited warranty covers components whose failure increases the vehicle s regulated emissions and it covers components of systems whose only purpose is to control emissions Repairing or replacing other components not covered by this warranty is the responsibility of the vehicle owner This emissions limited warranty does not cover components whose failure does not increase the vehicle s regulated emissions For exhaust emissions emission related components include any engine parts related to the following systems
55. ate on excessively rough slippery or loose terrain 2 Slow down before entering slippery areas 3 Maintain a high level of alertness reading the trail and avoiding quick sharp turns which can cause skids 4 Engage all wheel drive before wheels begin to lose traction NOTICE Severe damage to the drive train may occur if the AWD is engaged while the wheels are spinning Always allow the wheels to stop spinning before engaging AWD 5 Correct a skid by turning the steering wheel in the direction of the skid Never apply the brakes during a skid Sideways Turn in skid direction of COC D C 2C D LA Sy ITIS o lt gt T4 C C Co C BY s C C y 40 OPERATION Driving Uphill Whenever traveling uphill follow these precautions 1 Always travel straight uphill 2 Avoid excessively steep hills 3 Keep both feet on the floor 4 Always check the terrain carefully before ascending any hill Never climb hills with excessively slippery or loose surfaces 5 Proceed at a steady rate of speed and throttle pedal position Never apply throttle suddenly 6 Never go over the crest of a hill at high speed An obstacle a sharp drop or another vehicle or person could be on the other side of the hill Driving on a Sidehill Sidehilling Driving on a sidehill is not recommended Improper procedure could cause loss of control or rollover Avoid crossing the side of any hill unless absolutely necessary If cr
56. ation and high speed operation during the break in period If a belt fails always clean any debris from the duct and from the engine compartment See page 71 35 OPERATION Pre Ride Inspection Failure to inspect and verify that the vehicle is in safe operating condition before operating increases the risk of an accident Always inspect the vehicle before each use to make sure it s in safe operating condition Item Remarks Page Brake system pedal travel Ensure proper operation ae Brake fluid Ensure proper level 76 Front suspension Inspect lubricate if necessary 62 Rear suspension Inspect lubricate if necessary 62 Steering Ensure free operation 77 Tires Inspect condition and pressure 79 Wheels fasteners Inspect ensure fastener tightness 79 Frame nuts bolts fasteners Inspect ensure tightness Fuel and oil Ensure proper levels 31 63 Coolant level Ensure proper level 69 Coolant hoses Inspect for leaks Throttle Pedal Ensure proper operation Indicator lights switches Ensure operation 23 Intake Screens 2 Inspect clean 74 Air filter Inspect clean 74 Headlamp Verify proper operation Brake light tail lamp Verify proper operation Seat Belts Check length of belt for damage check latches for 29 proper operation Cab Nets Check for wear or damage ensure proper installation 28 36 OPERATION Starting the Engine Always start the engine outdoors or in a
57. brake insta bility Always follow these precautions when towing 1 Never load more than 150 Ibs 68 1 kg tongue weight on the towing bracket 2 Always shift to low gear for towing 3 When towing a disabled RANGER vehicle place the disabled vehicle s transmission in neutral Do not operate the vehicle faster than 10 MPH 16 km h when towing 4 Do not operate the vehicle faster than 10 MPH 16 km h when towing See page 45 Towing a trailer increases braking distance 5 Do not tow more than the recommended weight for the vehicle See the towing capacity chart below and the specifications charts beginning on page 90 6 Attach a trailer to the trailer hitch bracket only Do not attach a trailer to any other loca tion or you may lose control of the vehicle 7 Never tow a trailer on a grade steeper than 15 Model Total Towed Total Towed Total Hitch Maximum Load Weight Load Weight Vertical Towin Level Ground 15 grade Weight Spee RANGER XP 900 2000 Ibs 850 Ibs 150 Ibs 10 MPH 907 kg 386 kg 68 1 kg 16 km h RANGER CREW 900 2000 Ibs 850 Ibs 150 Ibs 10 MPH 907 kg 386 kg 68 1 kg 16 km h Belt Life To extend belt life use the lowest gear possible when hauling or towing heavy cargo 46 OPERATION Dumping the Cargo Box 1 Select a level site to dump the cargo box Do Release Lever not attempt to dump or unload the vehicle while parked on an incline 2 Apply the brakes
58. clutch covers to fail Switch to low range while operating at slower speeds to extend the life of the PVT components belt cover etc To install a belt place one end of the belt over the driving clutch Route the belt over the top of the driven clutch and down into the groove of the clutch to allow slack in the belt Rotate the driven clutch by hand until the belt falls into place Reinstall the clutch cover in the reverse order of removal fitting the top of the cover into place then working the bottom of the cover over the suspension Step 8 or Install all clutch cover screws Torque to 4 5 ft Ibs 5 5 6 5 Nm Step 13 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 operating 1 2 T Position the vehicle on a level surface Place the transmission in PARK Stop the engine Remove the clutch cover drain plug Allow the water to drain completely Reinstall the drain plug Start the engine Apply varying throttle for 10 15 seconds to expel the moisture and air dry the belt and clutches Do not apply heavy throttle 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 Drain PI Test for belt slippage If the belt slips repea
59. contact an authorized POLARIS dealer to perform any service that may be necessary for your vehicle POLARIS also recommends that you use only Pure POLARIS parts It is a potential violation of the Clean Air Act if a part supplied by an aftermarket parts manufacturer reduces the effectiveness of the vehicle s emission controls Tampering with emission controls is prohibited by federal law California Residents Certain POLARIS off road vehicles are available in 49 state and 50 state versions Only the 50 state models are certified for sale in California The 50 state models available for sale in California are identified by the letter C in the model name e g R13UH88A C The POLARIS 50 state models are designed and built with features such as a reduced cargo box capacity Any modifications to these features may be a violation of the applicable California regulations and may void this limited emissions warranty offered by the manufacturer If you have any questions regarding your warranty rights and responsibilities please contact POLARIS Customer Assistance United States amp Canada 1 800 POLARIS 1 800 765 2747 French 1 800 268 6334 103 MAINTENANCE LOG Use the following chart to record periodic maintenance DATE MILES KM OR HOURS TECHNICIAN SERVICE PERFORMED COMMENTS 104 MAINTENANCE LOG DATE MILES KM OR HOURS TECHNICIAN SERV
60. drive and driven 100 H 12M 1000 1600 Inspect clean replace worn parts D Front wheel bearings 100 H 12M 1000 1600 Inspect replace as needed D Brake fluid 200 H 24M 2000 3200 Change every two years Spark arrester 300 H 36 M 3000 4800 Clean out E Valve clearance 5000 8000 Inspect adjust as needed D Toe adjustment Inspect periodically adjust when parts are replaced vo Auxiliary brake if equipped Inspect daily adjust as needed Headlight aim Adjust as needed gt Perform these procedures more often for vehicles subjected to severe use E Emission Related Service D Have an authorized POLARIS dealer perform these services 61 MAINTENANCE Lubrication Recommendations Check and lubricate all components at the intervals outlined in the Periodic Maintenance Chart beginning on page 59 or more often under severe use such as wet or dusty conditions Items not listed in the chart should be lubricated at the general lubrication interval Item Lube Method Engine Oil PS 4 5W 50 4 Cycle Oil Add to proper level on dipstick See page 63 Brake Fluid DOT 4 Brake Fluid Maintain level between fill lines See page 76 Main Gearcase Oil AGL Gearcase Lubricant amp See page 65 Transmission Transmission Fluid Front Gearcase Oil Demand Drive Fluid See pages 65 66 Front Prop Shaft Yoke U Joint Grease Locate fittings and grease 3 pumps maximum
61. e Chart MAINTENANCE Item Maintenance Interval Remarks whichever comes first Hours Calendar Miles Km D Throttle pedal 50H 6M 500 800 Inspect for free movement replace E pedal as needed E Maa body air intake ducts 50 H 6M 500 800 Inspect duct for proper sealing air leaks ange Drive belt 50H 6M 500 800 Inspect adjust replace as needed Cooling system if applicable 50 H 6M 500 800 Inspect coolant strength seasonally pressure test system yearly gt Oil lines fasteners 50H 6M 1000 1600 Inspect for leaks and loose fittings gt Engine oil and filter change 100 H 6M 1000 1600 Change the oil and filter gt Front gearcase oil 100 H 12M 1000 1600 Change fluid gt Transmission oil 100 H 12M 1000 1600 Change fluid D Fuel system 100 H 12M 1000 1600 Check for leaks at tank cap lines fuel E valve filter pump throttle body replace lines every two years gt Radiator if applicable 100 H 12M 1000 1600 Inspect clean external surfaces gt Cooling Hoses if applicable 100 H 12M 1000 1600 Inspect for leaks gt Engine mounts 100 H 12M 1000 1600 Inspect Exhaust muffler pipe 100 H 12M 1000 1600 Inspect B Spark plug 100 H 12M 1000 1600 Inspect replace as needed Wiring 100 H 12M 1000 1600 Inspect for wear routing security apply dielectric grease to connectors sub jected to water mud etc D Clutches
62. e the procedure for spark plug installation Apply anti seize compound to the spark plug threads 4 Torque to specification Spark Plugs Normal Plug The normal insulator tip is gray tan or light brown There will be few combustion depos its The electrodes are not burned or eroded This indicates the proper type and heat range for the engine and the service The tip should not be white A white insulator tip indicates overheating caused by use of an improper spark plug or incorrect throttle body adjustments Wet Fouled Plug The wet fouled insulator tip is black A damp oil film covers the firing end There may be a carbon layer over the entire nose Generally the electrodes are not worn General causes of fouling are excessive oil use of non recommended oil or poor fuel quality 67 MAINTENANCE Cooling System The engine coolant level is controlled or maintained by the recovery system The recovery system components are the overflow bottle radiator filler neck radiator pressure cap and connecting hose As coolant operating temperature increases the expanding heated excess coolant is forced out of the radiator past the pressure cap and into the overflow bottle As engine coolant tem perature decreases the contracting cooled coolant is drawn back up from the tank past the pressure cap and into the radiator Some coolant level drop on new vehicles is normal as the system is purging itself of trapped air Obse
63. ealing 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 2 If the voltage is less than 12 8 volts recharge the battery at 1 2 amps or less until battery voltage is 12 8 or greater 3 When using an automatic charger refer to the charger manufacturer s instructions for recharging When using a constant current charger use the guidelines below for recharg ing Always verify battery condition before and 1 2 hours after the end of charging State of charge Tima Voltage Action Using constant current Charge charger standard amps specified on top of battery 100 12 8 13 0 volts None check at 3 mos from date of None required manufacture 75 100 12 5 12 8 volts May need slight charge if no charge 3 6 hours given check in 3 months 50 75 12 0 12 5 volts Needs charge 5 11 hours 25 50 11 5 12 0 volts Needs charge At least 13 hours verify state of charge 0 25 11 5 volts or less Needs charge with desulfating charger At least 20 hours 85 MAINTENANCE Cleaning and Sto
64. ens both sides Cargo Box Tailgate 21 FEATURES AND CONTROLS Console Gear Selector Instrument Storage Cluster Shifter Tray Guo Helder 12V Auxiliary Storage Outlets Compartment Auxiliary Outlets The 12 volt receptacles have spade connections on the back that may be used to power an auxiliary light or other optional accessories or lights The connections are behind the console under the dash Gear Selector High Gear Low Gear Neutral Reverse Park Low gear is the primary driving range for the RANGER High gear is intended for use on hard packed surfaces with light loads VEZEH To shift gears brake to a complete stop When the engine is idling move the lever to the desired gear NOTICE Shifting gears with the engine speed above idle or while the vehicle is moving could cause transmission damage Always shift when the vehicle is stationary and the engine is at idle Tip Maintaining shift linkage adjustment is important to assure proper transmission function See your dealer if you experience any shifting problems Using Low Range Always shift into low gear for any of the following conditions e Operating in rough terrain or over obstacles e Loading the vehicle onto a trailer e Towing heavy loads 22 FEATURES AND CONTRO
65. er which could result in loss of control and lead to serious injury or death Never cross deep or fast flowing water with ee Qr ccm deu DS your RANGER a mW Foo 5 After leaving water always dry the brakes by applying light pressure to the pedal repeatedly until braking action is normal Avoid applying brake and throttle at the same time NOTICE After running your vehicle in water it s critical that you perform the services outlined in the Periodic Maintenance Chart beginning on page 59 Give special attention to engine oil transmission oil all gearcase fluids and all grease fittings 42 OPERATION Driving in Reverse Follow these precautions when operating in reverse 1 Aw PWN Always check for obstacles or people behind the vehicle Always inspect left and right fields of vision before backing Always avoid backing downhill Back slowly Apply the brakes lightly for stopping Avoid turning at sharp angles Apply only light throttle Never apply throttle suddenly 43 OPERATION Parking the Vehicle 1 Apply the brakes Stop the vehicle on a level surface 2 When parking inside a garage or other structure be sure that the structure is well venti lated and that the vehicle is not close to any source of flame or sparks including any appliance with pilot lights 3 Place the transmission in PARK 4 Turn the engine off 5 Remove the ignition switch key to prevent unauthorized use
66. er E E E E a E 8 Features and Controls 000c cece eee eee eee 21 Operation cciccceactkiseapesioosteeceeteseseeeeess 35 WINCH GUdG 25 4 oss ccdes ted EE nn aeee a a 50 Emission Control Systems lsl 58 Maintenance senes oe sen es ERE RENE ERR Eun 59 Specifications ceoxcRSRPARAXRRReSPQREREEESRRREERZRREEGeE 90 POLARIS Products epp RRRERIEREERR RE LEER RD Rem 94 Troubleshooting s esce x ERE RRREERERERRE UE ER LEE ERR 95 WaltA dee RR RUE UR RR eed E ee ee ieee eee aerated 98 Maintenance LOG cisco RE kee sees hoes eee ase es Ree Ss 104 Index cas eccecksheehess tease er eeaws eens beeen eee es 106 INTRODUCTION Failure to follow the warnings contained in this manual can result in severe injury or death Your POLARIS RANGER is not a toy and can be hazardous to operate This vehicle handles differently than other vehicles such as cars trucks or other off road vehicles A collision or rollover can occur quickly even during routine maneuvers like turning or driving on hills or over obstacles if you fail to take proper precautions Read this owner s manual and review the safety DVD that came with your vehicle A free extra copy of the DVD can be obtained by contacting your local POLARIS dealer Understand all safety warnings precautions and operating procedures before operating the vehicle Keep this manual with the vehicle Review the safety DVD and take the free online Recreational Off Highway Vehicle As
67. es Wear gloves for comfort and for protection from sun cold weather and other elements Boots Wear sturdy over the ankle boots for support and protection Never ride a POLARIS vehicle with bare feet or sandals Clothing Wear long sleeves and long pants to protect arms and legs Rider Comfort Under certain operating conditions heat generated by the engine and exhaust system can elevate temperatures in the driver and passenger cab area The condition occurs most frequently when a vehicle is being operated in high ambient temperatures at low speeds and or high load conditions for an extended period of time The use of certain windshield roof and or cab systems may contribute to this condition by restricting airflow Any discomfort due to heat buildup in this area can be minimized by wearing proper riding apparel and by varying speeds to increase airflow SAFETY Safety Labels and Locations Warning labels have been placed on the vehicle for your protection Read and follow the instructions of the labels on the vehicle carefully If any of the labels depicted in this manual differ from the labels on your vehicle always read and follow the instructions of the labels on the vehicle If any label becomes illegible or comes off contact your POLARIS dealer to purchase a replacement Replacement safety labels are provided by POLARIS at no charge The part number is printed on the label Proper Use Seat Belt Drive Payload Warning Warning
68. formation MODE Button Lamp Indicates Condition Vehicle Speed When standard mode is selected speed displays in miles per hour When metric mode is selected speed displays in kilometers per hour E Over Temperature This lamp illuminates to indicate an overheated engine If the indicator flashes the overheating condition remains and the system will automatically reduce engine power f EPS Warning if 2 equipped This indicator illuminates briefly when the key is turned to the ON position If the light remains on the EPS system is inoperative See your authorized POLARIS dealer for service Neutral This lamp illuminates when the transmission is in neutral and the ignition key is in the ON position High Beam This lamp illuminates when the headlamp switch is set to high beam Helmet Seat Belt This lamp flashes for several seconds when the key is turned to the ON position The lamp is a reminder to the operator to ensure all riders are wearing helmets and seat belts before operating NI ED Check Engine This indicator appears if an EFI related fault occurs Do not operate the vehicle if this warning appears Serious engine damage could result See your dealer 30 FEATURES AND CONTROLS Instrument Cluster Rider Information Center The rider information center is located in the instrument cluster All segments will light up for one sec ond at start
69. fter you move to continue your warranty coverage and to ensure that you receive information and notices regarding your vehicle If you purchase from a private party If you purchase a POLARIS product from a private party to be kept and used outside of the country in which the product was originally purchased all warranty coverage will be denied You must nonetheless register your product under your name and address with a local POLARIS dealer in your country to ensure that you receive safety information and notices regarding your product 100 WARRANTY EXPORTED PRODUCTS EXCEPT WHERE SPECIFICALLY REQUIRED BY LAW THERE IS NO WARRANTY OR SERVICE BULLETIN COVERAGE ON THIS PRODUCT IF IT IS SOLD OUTSIDE THE COUNTRY OF THE SELLING DEALER S AUTHORIZED LOCATION This policy does not apply to products that have received authorization for export from POLARIS Dealers may not give authorization for export You should consult an authorized dealer to determine this product s warranty or service coverage if you have any questions This policy does not apply to products registered to government officials or military personnel on assignment outside the country of the selling dealer s authorized location This policy does not apply to Safety Bulletins NOTICE If your product is registered outside of the country where it was purchased and you have not followed the procedure set above your product will no longer be eligible for warranty or service bulletin
70. h cable to a suspension component brush guard bumper or cargo rack Vehicle damage may result Instead attach the winch to a strong portion of the vehicle frame or hitch Extensive winching will run down the battery on the winching vehicle Let the winching vehicle s engine run while operating the winch to prevent the battery from running low if winching for long periods WINCH GUIDE Winch Operation 14 The winch motor may become hot during winch use If you winch for more than 45 seconds or if the winch stalls during operation stop winching and permit the winch to cool down for 10 minutes before using it again 15 After winching is complete especially if winching at an angle it may be necessary to re distribute the winch cable across the winch drum You will need an assistant to perform this task Release the clutch on the winch Feed out the winch cable that is unevenly bunched up in one area Re engage the winch clutch Have an assistant pull the winch cable tightly with about 100 Ibs 45 kg of tension using the hook strap Slowly winch the cable in while your assistant moves the end of the winch cable back and forth horizontally to evenly distribute the winch cable on the drum Doing this reduces the chances of the winch cable wedging itself between lower layers of winch cable Winch Cable Care For your safety always replace POLARIS winch parts including the cable with genuine POLARIS replacement parts ava
71. han 10 ethanol Engine damage could occur Hood Latches Remove the hood to access the coolant overflow bottle the radiator cap and the headlight adjustment screws To remove the hood rotate the hood latches 1 4 turn and lift the hood away from the vehicle 26 FEATURES AND CONTROLS Rollover Protective Structure ROPS The Rollover Protective Structure ROPS on this vehicle meets OSHA 1928 53 rollover performance requirements Always have your authorized POLARIS dealer thoroughly inspect the ROPS if it ever becomes damaged in any way No device can assure occupant protection in the event of a rollover Always follow all safe operating practices outlined in this manual to avoid vehicle rollover WARNING Vehicle rollover could cause severe injury or death Always avoid operating in a manner that could result in vehicle rollover ROPS Trailer Hitch Bracket This vehicle is equipped with a receiver hitch bracket for a trailer hitch To avoid injury and property damage always heed the warnings and towing capacities outlined on pages 45 46 27 FEATURES AND CONTROLS Cab Nets Riding in this vehicle without using the cab nets or doors if equipped increases the risk of serious injury or death in the event of an accident or rollover Cab nets or doors must be used by both operator and passengers at all times Make sure all latches are secure before operating the vehicle Always inspect cab nets and
72. hill while applying light brake pressure to control speed 19 SAFETY Operator Safety Improper Tire Maintenance Operating this vehicle with improper tires or with improper or uneven tire pressure could cause loss of control or accident Always use the size and type of tires specified for your vehicle Always maintain proper tire pressure as described in the owner s manual and on safety labels Operating on Slippery Terrain Failure to use extra caution when operating on excessively rough slippery or loose terrain could cause loss of traction loss of control accident or rollover Do not operate on excessively slippery surfaces Always slow down and use additional caution when operating on slippery surfaces Skidding or sliding due to loss of traction can cause loss of control or rollover if tires regain traction unexpectedly Always follow proper procedures for operating on slippery surfaces as described in this owner s manual See page 40 Operating on Frozen Bodies of Water Severe injury or death can result if the vehicle and or the operator fall through the ice Never operate the vehicle on a frozen body of water unless you have first verified that the ice is sufficiently thick to support the weight and moving force of the vehicle you and your passengers and your cargo together with any other vehicles in your party Always check with local authorities and residents to confirm ice conditions and thickness over your entire route
73. hook This could lead to SEVERE INJURY A Attach the hook itself onto the load or use a tow strap or NOT chain to secure the load to the winch cable NO YES Tip A tow strap is NOT intended to stretch A recovery strap is designed to stretch WARNING Never use a recovery strap when winching due to the excessive energy that can be released if the winch cable breaks This can result in SEVERE INJURY or DEATH See the Shock Loading section on page 56 B Never hook the winch cable back onto itself This will damage the winch cable and may result in winch cable failure WARNING Replace the winch cable at the first sign of damage to prevent SEVERE INJURY or DEATH in the event of failure For your safety always replace POLARIS winch parts including the cable with genuine POLARIS replacement parts available at your authorized POLARIS dealer C If possible keep the winch cable aligned with the centerline of the winching vehicle This will help the spooling of the winch cable and reduce the load on the fairlead D If freeing a stuck vehicle by attaching to a tree use an item such as a tow strap to avoid damaging the tree during winch operation Sharp cables and chains can damage and even kill trees Please remember to TreadLightly treadlightly org E Before operating the winch be sure that the safety latch on the winch cable hook is fully seated when the load is attached F Never operate your winch with a damaged hook or la
74. hook the winch cable back onto itself This will damage the winch cable and may result in winch cable failure Never use straps chains or other rigging items that are damaged or worn The ONLY time a winch equipped vehicle should be moving when using the winch is when that vehicle itself is stuck The winch equipped vehicle should NEVER be in motion to shock load the winch cable in an attempt to move a second stuck vehicle See the Shock Loading section on page 56 For your safety always follow these guidelines when winching a vehicle free A Release the winch clutch and spool out the necessary length of winch cable B Align the winch cable as close as possible to the winching vehicle s centerline C Attach the winch cable hook to the anchor point or the stuck vehicle s frame following instructions in this manual D Re engage the clutch on the winch E Slowly winch in the slack in the winch cable F Select the proper vehicle gear to propel the stuck vehicle in the direction of winching G Shiftto the lowest gear available on the stuck vehicle H Slowly and carefully apply vehicle throttle and winch together to free the vehicle I SICH Minching as soon as the stuck vehicle is able to propel itself without the help of the winch J Detach the winch cable hook K Rewind the winch cable evenly back onto the winch drum following the instructions in this manual Never attempt to winch another stuck vehicle by attaching the winc
75. ic brush to clean the arrester screen A synthetic brush may melt a if components are warm If necessary blow debris from the screen with compressed air Arrester Tns Retaining Muffl pect the screen for wear and damage Screw uttter Replace a worn or damaged screen Reinstall the arrester Torque the bolts to 5 7 ft Ibs 7 9 Nm 75 MAINTENANCE Brakes The front and rear brakes are hydraulic disc type brakes activated by the brake pedal See page 24 Brake Fluid Inspect the brake system routinely Inspect the level of the brake fluid before each operation WARNING After opening a bottle of brake fluid always discard any unused portion Never store or use a partial bottle Brake fluid is hygroscopic meaning it rapidly absorbs moisture from the air The moisture causes the boiling temperature of the brake fluid to drop which can lead to early brake fade and the possibility of accident or severe injury Change the brake fluid every two years and any time the fluid becomes contaminated the fluid level is below the minimum or if the type and brand of the fluid in the reservoir are unknown 1 Position the vehicle on a level surface Maximum 2 Place the transmission in PARK 3 View the brake fluid level at the reservoir in the driver s side wheel well 4 The level should be between the upper MAX and lower MIN level lines 5 Ifthe fluid level is lower than the upper level line add brake fluid to the upper MAX line
76. ilable at your authorized POLARIS dealer WARNING Use of worn or damaged cable could lead to sudden failure and SEVERE INJURY 1 Always inspect your winch before each use Inspect for worn or loose parts including mounting hardware Never use the winch if any part needs repair or replacement m oom m 2 Always inspect your winch cable before each use Inspect for worn or kinked winch cable A A kinked winch cable made of wire rope is shown at right Even after being straightened out this cable has already been permanently and severely damaged Promptly discontinue use of a winch cable in this condition B Akinked winch cable made of wire rope that has been straightened out is shown at right Even though it may look usable the cable has been permanently and severely damaged It can no longer transmit the load that it could prior to kinking Promptly discontinue use of a winch cable in this condition C Awinch cable made of synthetic rope should be inspected for signs of fraying Replace the cable if fraying is observed shown at right Promptly discontinue use of a winch cable in this condition D Also replace the winch cable if there are fused or melted fibers Such an area of the synthetic rope will be stiff and appear smooth or glazed Promptly discontinue use of a winch cable in this condition 59 WINCH GUIDE Shock Loading WARNING Your winch cable is very strong but it is NOT designed for dynamic or
77. isplays current temperature of the engine coolant Hour Meter Mode This mode logs the total hours the engine has been in operation Programmable Service Interval When the hours of engine operation equal the programmed service interval setting the wrench icon will flash for 5 seconds each time the engine is started When this feature is enabled it provides a convenient reminder to perform routine maintenance The service interval is programmed at 50 hours at the factory Use the following procedure to change the service interval 1 Press the MODE button until remaining service hours display 2 Press and hold the MODE button 3 When the service hours flash press and release the MODE button to advance the hours to the desired setting including OFF Press and hold the MODE button to set the new service hour interval Diagnostic Display Mode The EFI diagnostic display mode is for informational purposes only Please see your POLARIS dealer for all major repairs The diagnostic mode is accessible only when the check engine warning indicator activates after the key has been turned on Leave the key on if you want to view the active code fail ure code The diagnostic mode becomes inaccessible if the key is turned off and on and the warning indicator is no longer active This allows the determination of persistent as well as intermit tent faults Inactive codes are stored in the history of the unit 33 FEATURES AND CONTROLS
78. latches for tightness wear and damage before each use of the vehicle Use the strap adjusters to tighten any loose straps Promptly replace worn or dam aged cab nets and latches with new cab nets and latches Please see your authorized POLARIS dealer Securing a Net 1 After entering the vehicle insert the lower net rod into the net mount on the floor Make sure the ball at the end of the rod is properly secured in the mount Connect the latch at the top edge of the net to the receiver latch mounted on the front frame Opening a Net 1 2 28 To exit the vehicle release the latch at the top front edge of the cab net Rotate the net rearward and pull upward on the lower net rod to remove it from the mount Allow the net to hang freely outside the vehicle while dismounting Latch Net Mount FEATURES AND CONTROLS Seat Belts This POLARIS vehicle is equipped with three point lap and diagonal seat belts on all seats Always make sure the seat belts are secured for all riders before operating WARNING Falling from a moving vehicle could result in serious injury or death Always fasten your seat belt securely before operating or riding in the RANGER To wear the seat belt properly follow this proce dure 1 For3 point belts pull the seat belt latch down ward and across your chest toward the buckle at the inner edge of the seat The belt should fit snugly across your hips and diagonally across your che
79. le and explosive under certain conditions Always exercise extreme caution whenever handling gasoline Always turn off the engine when refueling Always refuel outdoors or in a well ventilated area free of any source of flame or sparks Always use an approved gasoline container to store fuel and remove the container from the vehicle before filling to avoid fuel ignition due to electrical static discharge Do not smoke or allow open flames or sparks in or near the area where refueling is performed or where gasoline is stored Do not overfill the tank Do not fill the tank neck f gasoline spills on your skin or clothing immediately wash it off with soap and water and change clothing Exposure to Exhaust Engine exhaust fumes are poisonous and can cause loss of consciousness or death in a short time Never start the engine or let it run in an enclosed area The engine exhaust from this product contains chemicals known to cause cancer birth defects or other reproductive harm Operate this vehicle only outdoors or in well ventilated areas Operating a Damaged Vehicle Operating a damaged vehicle can result in an accident After any rollover or other accident have a qualified service dealer inspect the entire machine for possible damage including but not limited to seat belts rollover protection devices brakes throttle and steering systems Operating at Excessive Speeds Operating this vehicle at excessive speeds inc
80. lures caused by abuse accident fire or any other cause other than a defect in materials or workmanship and provides no coverage for consumable components general wear items or any parts exposed to friction surfaces stresses environmental conditions and or contamination for which they were not designed or not intended including but not limited to the following items Wheels and tires Finished and unfinished surfaces Suspension components Carburetor Throttle body components Brake components Engine components Seat components Drive belts Clutches and components Hydraulic components and fluids Steering components Circuit breakers Fuses Batteries Electronic components Light bulbs Sealed beam lamps Spark plugs Filter Sealants Lubricants Coolants Bushings Bearings Lubricants and Fluids 1 Mixing oil brands or using non recommended oil may cause engine damage We recommend the use of POLARIS engine oil 2 Damage or failure resulting from the use of non recommended lubricants or fluids is not covered by this warranty This warranty provides no coverage for personal loss or expense including mileage transportation costs hotels meals shipping or handling fees product pick up or delivery replacement rentals loss of product use loss of profits or loss of vacation or personal time THE EXCLUSIVE REMEDY FOR BREACH OF THIS WARRANTY SHALL BE AT POLARIS OPTION REPAIR OR REPLACEMENT OF AN
81. ly Stuck in mud or snow Shift 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 rollover 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 rollover Belt slippage from water or snow ingestion into the PVT system Dry out the PVT See page 73 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 35 and 70 95 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 clea
82. n reinstall connectors Engine Turns Over Fails to Start Possible Cause Out of fuel Solution Refuel Water is present in fuel Drain the fuel system and refuel Old or non recommended fuel Replace with fresh recommended fuel Fouled or defective spark plugs Inspect plugs and replace if necessary No spark to spark plug Inspect plugs and replace if necessary Water or fuel in crankcase Immediately see your POLARIS dealer Low battery voltage Recharge the battery to 12 8 VDC Mechanical failure See your dealer Engine Backfires Possible Cause Weak spark from spark plug Solution Inspect clean and or replace spark plugs Incorrect spark plug gap or heat range Set gap to specs or replace plugs Old or non recommended fuel Replace with fresh recommended fuel Incorrectly installed spark plug wires See your dealer Mechanical failure See your dealer Loose ignition connections Check all connections and tighten Water present in fuel Replace with fresh recommended fuel Engine Pings or Knocks Possible Cause Poor quality or low octane fuel Solution Replace with recommended fuel Incorrect spark plug gap or heat range Set gap to specs or replace plugs TROUBLESHOOTING Engine Runs Irregularly Stalls or Misfires Possible Cause Solution Fouled or defec
83. next display option 5 Repeat the procedure to change remaining display settings Clock Mode Tip The clock must be reset any time the battery has been disconnected or discharged 1 Turn the key to the ON position Use the MODE button to toggle to the odometer dis play Press and hold the MODE button until the hour segment flashes Release the button With the segment flashing tap the MODE button to advance to the desired setting Press and hold the MODE button until the next segment flashes Release the button Repeat steps 3 4 twice to set the 10 minute and 1 minute segments After completing the 1 minute segment step 4 will save the new settings and exit the clock mode 6 Turn the key to the OFF position wae wn 32 FEATURES AND CONTROLS Instrument Cluster Rider Information Center Odometer Mode The odometer records and displays the distance traveled by the vehicle Trip Meter Mode The trip meter records the distance traveled by the vehicle if reset before each trip To reset select the trip meter mode Press and hold the MODE button until the meter resets to zero In the Rider Information Center the trip meter display contains a decimal point but the odome ter displays without a decimal point Tachometer Mode The engine RPM is displayed digitally Tip Small fluctuations in the RPM from day to day may be normal because of changes in humidity temperature and elevation Engine Temperature Mode This mode d
84. ng off centered loads that cannot be centered securely fasten the load and operate with extra caution Always attach the tow load to the hitch point designated for your vehicle HEAVY LOADS CAN CAUSE BRAKING AND CONTROL PROBLEMS Use extreme caution when applying brakes with a loaded vehicle Avoid terrain or situations that may require backing downhill USE EXTREME CAUTION when operating with loads that extend over the rack sides Stability and maneuverability may be adversely affected causing a rollover DO NOT TRAVEL FASTER THAN THE RECOMMENDED SPEEDS Vehicle should never exceed 10 MPH 16 km h while towing a load on a level grass surface Vehicle speed should never exceed 5 MPH 8 km h when towing loads in rough terrain while cornering or while ascending or descending a hill Load Capacity The RANGER has been designed to carry or tow specific capacities Always read and under stand the load distribution warnings listed on the warning labels The total load operator passenger accessories cargo and weight on hitch must not exceed the maximum weight capacity of the vehicle See page 12 WARNING Driving with passengers in the cargo box can result in severe injury or death Never allow passengers to ride in the cargo box Passengers must always ride in the cab with seat belts fastened securely 45 OPERATION Towing Loads Towing improperly can alter vehicle handling and may cause loss of control or
85. nt wheels will automatically disengage There is no limit to the length of time the vehicle may remain in AWD Tip The AWD switch may be turned on or off while the vehicle is moving Engage the AWD before getting into conditions where front wheel drive may be needed If the rear wheels are spinning release the throttle before switching to AWD NOTICE Switching to AWD while the rear wheels are spinning may cause severe drive shaft and clutch damage Always switch to AWD while the rear wheels have traction or are at rest AWD Disengaging AWD Move the AWD switch to the center or bottom position to disengage AWD If the switch is turned off while the front hubs are driving they will not release until the rear wheels regain traction In some situations the front gearcase may remain locked after turning the AWD switch off If this occurs you may notice increased steering effort and some vehicle speed restriction Perform the following procedure to unlock the front gearcase 1 Stop the vehicle Operate in reverse for at least 10 feet 3 m Stop completely Shift into low gear and drive forward Sie ee IS If the front gearcase remains locked after following these instructions see your dealer for service 48 OPERATION All Wheel Drive AWD Locking the Differential NOTICE Damage to the differential can occur if it is engaged while the vehicle is traveling a
86. o operate this vehicle unless the guest has read this manual and all product labels To reduce rollover risk be especially careful when encountering obstacles and slopes and when braking on hills or during turns This vehicle is for off road use only Never operate on public roads unless marked for off road use Always avoid paved surfaces Never consume alcohol or drugs before or while operating this vehicle Never operate at excessive speeds Always travel at a speed proper for the terrain visibility and operating conditions and your experience Never attempt jumps or other stunts Always inspect the vehicle before each use to make sure it s in safe operating condition Always follow the inspection procedures described in this manual SAFETY O 14 perator Safety Always travel slowly and use extra caution when operating on unfamiliar terrain Be alert to changing terrain Never operate on excessively rough slippery or loose terrain Always follow proper procedures for turning Practice turning at slow speeds before attempting to turn at faster speeds Never turn at excessive speeds Always have this vehicle checked by an authorized POLARIS dealer if it has been involved in an accident Never operate this vehicle on hills too steep for the vehicle or for your abilities Practice on smaller hills before attempting larger hills Always follow proper procedures for climbing hills as described in this manu
87. ock mounting bolts from the inside mounting positions 2 Reposition the shocks to the outside mounting holes 3 Reinstall the shock mounting bolts Torque to 40 ft Ibs 54 2 Nm Outside Mounting Position Inside Mounting Position C uS gam 7 Li TAS Q HH zi Ja cle Rear Suspension Sh SE Adjustment is similar for Front Suspension Spring Adjustment Adjust the front and rear shock absorber springs by rotating the adjustment cam either clockwise or counter clockwise to increase or decrease spring tension 78 MAINTENANCE Tires AWARNING Operating your vehicle with worn tires improperly inflated tires non standard tires or improperly installed tires will affect vehicle handling and could cause an accident resulting in serious injury or death Always follow all tire maintenance procedures as outlined in this manual and on the labels on the vehicle Always use POLARIS approved size and type of tires for this vehicle when replacing tires Tire Tread Depth i Always replace tires when tread depth is 1 8 3 mm Z worn to 1 8 3 mm or less Axle and Wheel Nut Torque DP SS Specifications Inspect the following items occasionally for tightness and if they ve been loosened for main tenance service Do not lubricate the stud or the lug nut Nut Type Location Nut Torque Lug Nut Front and Rear 120 ft lbs 163 Nm Aluminum Wheels
88. ossing a sidehill is unavoidable follow these precautions 1 Slow down 2 Exercise extreme caution 3 Avoid crossing the side of a steep hill Driving Downhill When driving downhill follow these precautions 1 Avoid excessively steep hills 2 Drive straight downhill Avoid descending a hill at an angle which would cause the vehicle to lean sharply to one side Travel straight downhill when possible Slow down 4 Apply the brakes slightly to aid in slowing g 41 OPERATION Driving Through Water Your POLARIS RANGER can operate through water up to a maximum recommended depth equal to the floorboards NOTICE Immersion can result in major damage if the vehicle isn t serviced correctly and promptly After immersion always take the vehicle to your dealer service Do not start the engine If it s impossible to bring the vehicle to your dealer before starting the engine perform the service outlined on page 73 and take the vehicle to your dealer at the first opportunity Follow these procedures when operating through water 1 Determine water depths and current before entering water 2 Choose a crossing where both banks have gradual inclines 3 Proceed slowly avoiding rocks and obstacles 4 Avoid operating through deep or fast flowing water WARNING The large tires on your RANGER may cause the vehicle to float in deep or fast flowing wat
89. ours Calendar Miles Km Steering Front suspension Rear suspension Tires Brake fluid level Pre Ride Make adjustments as needed Brake pedal travel See Pre Ride Checklist on page 36 Brake system Wheels fasteners Frame fasteners Engine oil level E Intake Screens Daily Inspect clean often as needed E Engine intake pre filter Daily Inspect clean often Coolant z Daily Check level daily change coolant every 2 years gt Power steering unit if equipped Daily Inspect daily clean often Headlamp tail lamp Daily Verify proper operation A Brake pad wear 10 H Monthly 100 160 Inspect periodically Battery 25H Monthly 200 320 Check terminals clean test E Air filter 25H Monthly 200 320 Inspect replace as needed gt Front gearcase oil 25H 1M Perform a break in oil level check gt Transmission oil 25H 1M Perform a break in oil level check gt Engine oil change break in 25 H 500 800 Perform a break in oil change gt General lubrication 50 H 3M 500 800 Lubricate all fittings pivots cables etc Shift Linkage 50 H 6M 500 800 Inspect lubricate adjust D Steering 50H 6M 500 800 Lubricate gt Front Suspension 50 H 6M 500 800 Lubricate gt Rear Suspension 50 H 6M 500 800 Lubricate gt Perform these procedures more often for vehicles subjected to severe use E Emission Related Service D Have an authorized POLARIS dealer perform these services 60 Periodic Maintenanc
90. p Consider practicing the operation and use of your winch before you actually need to use it in the field AWARNING Improper winch use can result in SEVERE INJURY or DEATH Always follow all winch instructions and warnings in this manual Each winching situation is unique 52 Take your time to think through the winching you are about to do Proceed slowly and deliberately Never hurry or rush during winching Always pay attention to your surroundings You may need to change your winching strategy if it is not working Always remember that your winch is very powerful There are simply some situations that you and your winch will not be able to deal with Do not be afraid to ask others to help when this happens Always inspect the vehicle winch winch cable and winch controls for any signs of dam age or parts in need of repair or replacement before each use Pay particular attention to the first 3 feet 1 meter of winch cable if the winch is being used or has been used for lifting an accessory plow assembly Promptly replace any worn or damaged cable Never operate a winch or a vehicle in need of repair Or service A ds Always apply your vehicle s park brake and or park QS mechanism to hold the vehicle in place during Hook Strap A you winching Use wheel chocks if needed un Ca WINCH GUIDE Winch Operation 4 Always use the hook strap when handling the hook WARNING Never put your fingers into the
91. rage Washing the Vehicle Keeping your POLARIS vehicle clean will not only improve its appearance but it can also extend the life of various components NOTICE High water pressure may damage components POLARIS recommends washing the vehicle by hand or with a garden hose using mild soap NOTICE Certain products including insect repellents and chemicals will damage plastic 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 Avoid the use of harsh cleaners which can scratch the finish Do not use a power washer to clean the vehicle Do not use medium to heavy duty compounds on the finish Always use clean cloths and pads for cleaning and polishing Old or reused cloths and pads may contain dirt particles that will scratch the finish Grease all zerk fittings immediately after washing Allow the engine to run for a while to evaporate any water that may have entered the engine or exhaust system If a high pressure water system is used for cleaning not recommended exercise extreme caution The water may damage components and could remove paint and labels Avoid directing the water stream at
92. reases the operator s risk of losing control Always operate at a speed that s appropriate for the terrain the visibility and operating conditions your skills and experience and your passengers skills and experience Operating on Pavement This vehicle s tires are designed for off road use only not for use on pavement Operating this vehicle on paved surfaces including sidewalks paths parking lots and driveways may adversely affect the handling of the vehicle and may increase the risk of loss of control and accident or rollover Avoid operating the vehicle on pavement If it s unavoidable travel slowly travel short distances and avoid sudden turns or stops 18 SAFETY Operator Safety Operating on Public Roads Operating this vehicle on public streets roads or highways could result in a collision with another vehicle Never operate this vehicle on any public street road or highway including dirt and gravel roads unless designated for off highway use In some areas it s unlawful to operate this vehicle on public streets roads and highways Turning Improperly Turning improperly could cause loss of traction loss of control accident or rollover Always follow proper procedures for turning as described in this owner s manual Never turn abruptly or at sharp angles Never turn at high speeds Practice turning at slow speeds before attempting to turn at faster speeds Operating in Unfamiliar Terrain Failure to use extra caution
93. rformance and are not adjustable pn m HEU The emissions label is located on the main frame under a m the driver s seat and storage compartment r M Electromagnetic Interference This spark ignition system complies with Canadian ICES 002 This vehicle complies with the EMC requirements of European directives 97 24 EC and 2004 108 EC Non ionizing Radiation This vehicle emits some electromagnetic energy People with active or non active implantable medical devices such as heart monitoring or controlling devices should review the limitations of their device and the applicable electromagnetic standards and directives that apply to this vehicle 58 MAINTENANCE Periodic Maintenance Chart Careful periodic maintenance will help keep your vehicle in the safest most reliable condi tion Inspection adjustment and lubrication of important components are explained in the periodic maintenance chart Inspect clean lubricate adjust and replace parts as necessary When inspection reveals the need for replacement parts use genuine POLARIS parts available from your POLARIS dealer Record maintenance and service in the Maintenance Log beginning on page 104 Tip Service and adjustments are important for proper vehicle operation If you re not familiar with safe service and adjustment procedures have a qualified dealer perform these operations Vehicles subjected to heavy or severe use patterns must be inspected and serviced
94. rol With non Polaris approved accessories they may seriously affect stability ALWAYS Wear your seat belt Vehicle rollover can cause severe injury or death Secure cab nets or doors and keep hands and feet inside vehicle at all times Wear a helmet eye protection gloves long sleeve shirt long pants and over the ankle boots Reduce speed and use extra caution when carrying passengers Avoid sharp turns or turns while applying heavy throttle Operate slowly in reverse avoid sharp turns or sudden braking Make sure passengers read and understand all safety labels ALL RIDERS MUST WEAR AN APPROVED HELMET AND PROTECTIVE GEAR ALL RIDERS MUST WEAR SEAT BELTS NEVER USE ON PUBLIC ROADS NEVER USE WITH DRUGS OR ALCOHOL READ OWNER S MANUAL FOLLOW ALL INSTRUCTIONS AND WARNINGS For your nearest Polaris dealer call 1 800 POLARIS or visit www polaris com Polaris Sales Inc PELARIS 2100 Hwy 55 Medina MN 55340 Phone 1 888 704 5290 Part No 9924548 Rev 01 Printed in USA
95. roper break in period Careful treatment of a new engine will result in more efficient perfor mance and longer life for the engine Perform the following procedures carefully NOTICE Excessive heat build up during the first three hours of operation will damage close fitted engine parts Do not operate at full throttle or high speeds for extended periods during the first three hours of use Engine and Drivetrain Break in 1 Fill the fuel tank with clean fresh fuel Review the fuel warnings on page 18 2 Check the oil level Add the recommended oil as needed to maintain the oil level in the normal safe operating range 3 Drive slowly at first Select an open area that allows room to familiarize yourself with vehicle operation and handling 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 36 6 During the break in period change both the oil and the filter at 25 hours 7 Check fluid levels of transmission and all gearcases after the first 25 hours of operation and every 100 hours thereafter 8 Pull only light loads PVT Break in Clutches Belt A proper break in of the clutches and drive belt will ensure a longer life and better perfor mance Break in the clutches and belt by operating at slower speeds during the break in period as recommended Pull only light loads Avoid aggressive acceler
96. rstand the Owner s Manual and all warning and instruction labels before operating the vehicle All operators should review the safety DVD provided with this vehicle and take a ROHVA training course www rohva org Using Alcohol or Drugs Operating the vehicle after consuming alcohol or drugs could adversely affect operator judgment reaction time balance and perception 2 Never drink alcohol or use drugs or medications before or while as operating this vehicle Seat Belts Riding in this vehicle without wearing the seat belt increases the risk of serious injury in the event of rollover loss of control other accident or sudden stop Seat belts may reduce the severity of injury in these circumstances All riders must wear seat belts at all times Protective Apparel Riding in this vehicle without wearing an approved helmet and protective eyewear increases the risk of a serious injuries in the event of an accident Operator and all passengers must always wear an approved helmet that fits properly and eye protection goggles or face shield 16 SAFETY Operator Safety Cab Nets Riding in this vehicle without using the cab nets or doors if equipped increases the risk of serious injury or death in the event of an accident or rollover Always use the cab nets or doors while riding in this vehicle Always keep hands and feet inside the vehicle at all times Failure to Inspect Before Operating Failure to inspect and verify
97. rve coolant levels and maintain as recommended by adding coolant to the overflow bottle Adding or Changing Coolant To ensure that the coolant maintains its ability to protect the engine we recommend that the system be completely drained every two years and a fresh mixture of antifreeze and water added POLARIS recommends the use of POLARIS Antifreeze 60 40 premix or a 50 50 mixture of high quality aluminum compatible anti freeze coolant and distilled water POLARIS Antifreeze is already premixed and ready to use Do not dilute with water See page 94 for the part numbers of POLARIS products Always follow the manufacturer s mixing recommendations for the freeze protection required in your area Any time the cooling system has been drained for maintenance or repair replace the coolant If the recovery bottle has run dry the level in the radiator should be inspected Add coolant as needed Radiator and Cooling Fan Always check and clean the screen and radiator fins at the intervals outlined in the Periodic Maintenance Chart beginning on page 59 Do not obstruct or deflect air flow through the radiator by installing unauthorized accessories in front of the radiator or behind the cooling fan Interference with the radiator air flow can lead to overheating and consequent engine damage NOTICE Washing the vehicle with a high pressure hose could damage the radiator fins and impair the radiator s effectiveness Using a high pressure system is no
98. se discomfort or injury to a passenger Vehicle handling may change with a passenger and or cargo on board Allow more time and distance for braking 10 Always follow all operating guidelines as outlined on safety labels and in this manual Driving Over Obstacles Follow these precautions when operating over obstacles 1 2 Always check for obstacles before operating in a new area Look ahead and learn to read the terrain Be constantly alert for hazards such as logs rocks and low hanging branches Travel slowly and use extra caution when operating on unfamiliar terrain Not all obsta cles are immediately visible Avoid operating over large obstacles such as large rocks and fallen trees If unavoidable use extreme caution and operate slowly Always have all passengers dismount and move away from the vehicle before operating over an obstacle that could cause a rollover 39 OPERATION Driving on Slippery Surfaces AWARNING Skidding or sliding can cause loss of control or rollover if tires regain traction unexpectedly When operating on slippery surfaces such as ice or loose gravel reduce speed and use extra caution to reduce the chance of skidding or sliding out of control Do not operate on excessively slippery surfaces Whenever riding on slippery surfaces such as wet trails or loose gravel or during freezing weather follow these precautions 1 Do not oper
99. smission in PARK Measure the distance from the floor to the center of the headlight and make a mark on the wall at the same height Apply the brakes Start the engine Turn on the headlights Observe the headlight aim The most intense part of the headlight beam should be aimed 8 20 cm below the mark placed on the wall Include the weight of a rider on the seat while performing this step If a headlight needs adjustment locate the adjustment screw on the side of the headlight Loosen the screw Adjust the headlight then tighten the screw Repeat steps 5 7 until the lamp is properly adjusted MAINTENANCE Fuses If the engine stops or will not start or if you experience other electrical failures a fuse may need replacement Locate and correct any short circuits that may have caused the blown fuse then replace the fuse Raise the passenger seat to access the fuses Spare fuses are provided in the fuse box The power steering fuse if equipped is located on the power steering wiring harness near the fuse box If you suspect that a fuse or relay may not be working properly please see your POLARIS dealer Fuse Feature Supported 10A Brake Lights 10A Fuel Pump 10A Drive System 20A Accessories 12V Power Receptacle 20A Engine Control Module 20A Lights 30A Power Steering if equipped EPS EFI FAN FUEL PUMP RELAY RELAY RELAY RELAY OPT LIGHTS DRIVE
100. sociation ROHVA training course at www rohva org This vehicle is an ADULT VEHICLE ONLY You MUST be at least age 16 and have a valid driver s license to operate this vehicle No person under the age of 12 may ride as a passenger in this vehicle All riders must be able to sit with backs against the seat both feet flat on the floor and both hands on the steering wheel if driving or on a passenger hand hold Never permit a guest to operate this vehicle unless the guest has read this manual and all product labels Always use the cab nets or doors while riding in this vehicle Always keep hands feet and all other body parts inside the vehicle at all times Always wear a helmet eye protection gloves long sleeve shirt long pants and over the ankle boots Never use this vehicle with drugs or alcohol as these conditions impair judgment and reduce operator reaction time INTRODUCTION The RANGER is an off road vehicle Familiarize yourself with all laws and regulations con cerning the operation of this vehicle in your area The following signal words and symbols appear throughout this manual and on your vehicle Your safety is involved when these words and symbols are used Become familiar with their meanings before reading the manual A The safety alert symbol indicates a potential personal injury hazard DANGER A DANGER indicates a hazardous situation that if not avoided will result in death or serious injury
101. st 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 4 To release the seat belt press the square red button in the buckle s center Seat Belt Inspection Inspect all seat belts for proper operation before each use of the vehicle 1 Push the latch plate into the buckle until it clicks The latch plate must slide smoothly into the buckle A click indicates that it s securely latched 2 Push the red release latch in the middle of the buckle to make sure it releases freely 3 Pulleach seat belt completely out and inspect the full length for any damage including cuts wear fraying or stiffness If any damage is found or if the seat belt does not oper ate properly have the seat belt system checked and or replaced by an authorized POLARIS dealer 4 To clean dirt or debris from the seat belts sponge the straps with mild soap and water Do not use bleach dye or household detergents 29 FEATURES AND CONTROLS Instrument Cluster High water pressure may damage components Wash the vehicle by hand or with a garden hose using mild soap Do not use alcohol to clean the instrument cluster Do not allow insect sprays to contact the lens Speedometer The speedometer displays vehicle speed in either miles per hour MPH or kilometers per hour km h See page 32 Center Indicator Lamps Speedometer Indicator Rider In
102. sts that you use your original selling dealer however you may use any POLARIS Servicing Dealer to perform warranty service In the country where your product was purchased Warranty or Service Bulletin repairs must be done by an authorized POLARIS dealer If you move or are traveling within the country where your product was purchased Warranty and Service Bulletin repairs may be requested from any authorized POLARIS dealer that sells the same line as your product Outside the country where your product was purchased If you are traveling temporarily outside the country where your product was purchased you should take your product to an authorized POLARIS dealer You must show the dealer photo identification from the country of the selling dealer s authorized location as proof of residence Upon residence verification the servicing dealer will be authorized to perform the warranty repair If you move If you move to another country be sure to contact POLARIS Customer Assistance and the customs department of the destination country before you move Product importation rules vary considerably from country to country You may be required to present documentation of your move to POLARIS in order to continue your warranty coverage You may also be required to obtain documentation from POLARIS in order to register your product in your new country You should warranty register your product at a local POLARIS dealer in your new country immediately a
103. sult in vehicle damage loss of control and severe injury or death Position the vehicle on a level surface Block the wheels to prevent vehicle movement Place the transmission in neutral Lift the cargo box 3 Remove the clutch cover screws using an 8mm socket with ratcheting wrench and extension 4 Pull the bottom of the cover outward and over the suspension to remove it gr Step 4 5 Make sure the cover gasket does fall out of the groove when removing the cover 6 Squeeze the belt together so that it submarines further into the driven clutch creating slack in the belt between the clutches 7 Remove the belt by using the slack to pull part of the belt off the driven clutch 71 MAINTENANCE POLARIS Variable Transmission PVT System Belt Replacement Debris Removal 8 Rotate the driven clutch by hand until the belt is completely off 10 11 12 Tip 13 14 15 72 Slide the front of the belt out from between the drive clutch and inner clutch cover to completely remove it Remove all debris wrapped in and around the PVT system Remove all debris from the entire clutch air duct passage Check for signs of damage to seals on the trans mission and engine See your dealer promptly for service if any seals appear to be damaged Belt slip is responsible for creating excessive heat that destroys belts wears clutch components and causes outer
104. t high speeds or while the rear wheels are spinning Slow the vehicle to nearly stopped before ati 4 engaging the differential Locking the differential in slippery or low traction conditions helps improve traction Move the rocker switch to the center position 2WD to lock the differential and operate in rear wheel drive Press the bottom of the switch to unlock the differ ential and allow the rear drive wheels to operate 4 independently This mode of operation is well suited to turf driving or whenever aggressive trac tion is not required 49 WINCH GUIDE These safety warnings and instructions apply if your vehicle came equipped with a winch or if you choose to add an accessory winch to your vehicle AWARNING Improper winch use can result in SEVERE INJURY or DEATH Always follow all winch instructions and warnings in this manual Your winch may have a cable made of either wire rope or specially designed synthetic rope The term winch cable will be used for either unless noted otherwise Winch Safety Precautions WP wN Pe 10 11 12 50 Read all sections of this manual Never use alcohol or drugs before or while operating the winch Never allow children under 16 years of age to operate the winch Always wear eye protection and heavy gloves when operating the winch Always keep body hair clothing and jewelry clear of the winch cable fairlead
105. t recommended 68 MAINTENANCE Cooling System Overflow Bottle Coolant Level Always check and change the coolant at the intervals outlined in the Periodic Maintenance Chart beginning on page 59 Maintain the coolant level between the minimum and maximum marks on the bottle when the fluid is cool 1 Position the vehicle on a level surface Place the transmission in PARK Remove the hood See page 26 Maximum Level Cold M 4 View the coolant level in the overflow bottle Minimum Level 5 Ifthe coolant level is below the safe operating range use a funnel to add coolant through the filler opening Reinstall the cap Tip If coolant must be added often or if the overflow bottle runs completely dry there may be a leak in the sys tem Have the cooling system inspected by your POLARIS dealer Radiator Cap Radiator Coolant Level 1 Remove the hood See page 26 CAUTION Escaping steam can cause burns Never remove the pressure cap while the engine is warm or hot Always allow the engine to cool before removing the pressure cap 2 Slowly remove the radiator cap 3 View the coolant level through the opening 4 Usea funnel and slowly add coolant as needed Tip This procedure is required only if the cooling system has been drained for maintenance and or repair But if the overflow bottle has run dry the level in the radiator should also be inspected 5 Reinstall the pressure cap Use of
106. t the real process Take the vehicle to your dealer for service as soon as possible Vehicle Immersion NOTICE If your vehicle becomes immersed major engine damage can result if the machine is not thoroughly inspected Take the vehicle to your dealer before starting the engine If it s impossible to take your RANGER to a dealer before starting it follow the steps outlined below 1 TD O9 A PWD Move the vehicle to dry land or at the very least to water below the floorboard Dry any water present in the air box Filter replacement is required if water is present Dry any water present in the intake manifold Remove the spark plugs Turn the engine over several times using the electric start Dry the spark plugs and reinstall or replace with new plugs Attempt to start the engine If necessary repeat the drying procedure Take the vehicle to your dealer for service as soon as possible whether you succeed in starting it or not If water has been ingested into the PVT follow the PVT Drying procedure 73 MAINTENANCE Filter Systems Air Filter Always change the air filter at the intervals outlined in the Periodic Maintenance Chart beginning on 5 Latches page 59 Service the air filter more frequently if the vehicle is operated in wet conditions or at high throttle for extended periods l Liftthe cargo box to access the air box 2 Release the five 5 air box i Tem cover latches and lower the bot Left
107. tch Always replace damaged parts before using the winch 5 Never remove the hook strap from the hook 6 Release the winch clutch and pull out the winch cable 7 Pulling out as much cable as possible maximizes the winch s pulling capacity Always be sure that at least five 5 full turns of winch cable are wrapped around the winch drum at all times The friction provided by this wrapped cable allows the drum to pull on the winch cable and move the load YES NO 53 WINCH GUIDE Winch Operation 8 10 11 12 13 54 Read and adhere to the following information for winch damping to ensure safe winch use A In order to absorb energy that could be released by a winch cable failure always place a damper on the winch cable A damper can be a heavy jacket tarp or other soft dense object A damper can absorb much of the energy released if a winch cable breaks when winching Even a tree limb can help as a damper if no other items are available to you B Lay the damper on top of the mid point of the winch cable length that is spooled out C Onalong pull it may be necessary to stop winching so that the damper can be repositioned to the new mid point of the winch cable Always release the tension on the winch cable before repositioning the damper D Avoid being directly in line with the winch cable whenever possible Also never permit others to stand near or in line with the winch cable during winch operation Never
108. the spark plugs Torque to specification See page 67 4 Turn the engine over several times Oil will be forced in and around the piston rings and ring lands coating the cylinder with a protective film of fresh oil 5 Apply dielectric grease to the inside of each spark plug cap and reinstall the caps onto the plugs 6 If POLARIS fuel system additive is not used fuel tank fuel lines and injectors should be completely drained of gasoline Storage Area Covers Be sure the storage area is well ventilated Cover the vehicle with a genuine POLARIS cover Do not use plastic or coated materials They do not allow enough ventilation to pre vent condensation and may promote corrosion and oxidation 88 MAINTENANCE Removal from Storage Charge the battery if necessary Install it in the vehicle Make sure the spark plug is tight Fill the fuel tank with fuel Check all the points listed in the Daily Pre Ride Inspection section on page 36 Tightness of the bolts nuts and other fasteners should be checked by an authorized POLARIS dealer Tee qo rt 5 Lubricate at the intervals outlined in the Periodic Maintenance Chart beginning on page 59 Transporting the RANGER Follow these procedures when transporting the vehicle 1 Place the transmission in PARK 2 Stop the engine 3 Secure the fuel cap hood and cargo box Ensure that the seats are attached correctly and are not loose WARNING Cargo and other loose vehicle parts may fl
109. the vehicle on a level surface 63 MAINTENANCE Engine Oil Oil and Filter Change 3 Place the transmission in PARK 4 Stand clear and pull up on the cargo box release lever Lift the front of the cargo box 5 Locate the crankcase drain plug access hole in the skid plate 6 Clean the area around the crankcase drain plug CAUTION Hot oil can cause burns to skin Do not allow hot oil to contact skin 7 10 11 12 13 14 15 16 17 18 19 20 21 64 Place a drain pan under the engine crankcase and remove the drain plug Allow the oil to drain com pletely Using an oil filter wrench turn the filter counter clockwise to remove it Using a clean dry cloth clean the filter sealing surface on the crankcase 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 fil ter gasket contacts the sealing surface then turn an additional 1 2 turn Reinstall the drain plug Torque the drain plug to 12 ft Ibs 16 Nm Remove the oil fill cap and add 2 5 quarts 2 4 1 of recommended oil Reinstall the fill cap Start the engine and check for leaks Stop the engine and wait 15 seconds before removing the dipstick Remove the dipstick Wipe it dry with a clean cloth Reinstall the dipstick completely Remove the dipstick and check the oil level E Oil
110. tifreeze 60 40 Premix gal 3 8 Grease Specialized Lubricants 2871312 Grease Gun Kit All Season Grease 2871322 All Season Grease 3 0z 89 ml cartridge 2871423 All Season Grease 14 0z 414 ml cartridge 2876160 ATV Angle Drive Fluid qt 95 I 2872276 ATV Angle Drive Fluid 2 5 gal 9 5 I 2871460 Premium Starter Grease 2871515 U Joint Grease 3 0z 89 ml cartridge 2871551 U Joint Grease 14 0z 414 ml cartridge 2871329 Dielectric Grease Nyogel Additives Miscellaneous 2871326 Carbon Clean 2870652 Fuel Stabilizer 2872189 DOT 4 Brake Fluid 2871956 Loctite 565 Thread Sealant 2859044 POLARIS Battery Tender Charger 94 TROUBLESHOOTING Drive Belt Wear Burn Possible Cause Solution Driving onto a pickup or tall trailer in high range Use low range during loading Starting out going up a steep incline Use low range See warnings on page 41 Driving at low RPM or ground speed 3 7 MPH Drive at a higher speed or use low range more frequently Insufficient warm up at low ambient temperatures Warm the engine at least 5 minutes With the transmission in neutral advance the throttle to about 1 8 throttle in short bursts 5 to 7 times The belt will become more flexible and prevent belt burning Slow easy clutch engagement Use the throttle quickly and effectively Towing pushing at low RPM low ground speed Use low range only Utility use plowing Use low range on
111. tio High Front 4 03 1 Rear 12 05 1 Transmission Gear Ratio Low Front 8 56 1 Rear 25 59 1 Transmission Gear Ratio Reverse Front 7 67 1 Rear 22 92 1 Front Drive Ratio 3 818 1 Tire Size Front 26x9 12 Tire Size Rear 26x 11 12 Tire Pressure Front 14 psi 96 kPa Tire Pressure Rear 16 psi 110 kPa Brakes Front Rear Foot Activated 4 wheel hydraulic disc Hood Headlight 2 single beam 50W quartz halogen Taillights 10 L E D 28W Brake Light 10 L E D 3 1W Clutching See your POLARIS dealer for clutching specifications 93 POLARIS PRODUCTS Part Number Description Engine Lubricant 2870791 Fogging Oil 12 0z 355 ml Aerosol 2876244 PS 4 Full Synthetic 5W 50 4 Cycle Oil qt 95 I 2876245 PS 4 Full Synthetic 5W 50 4 Cycle Oil gal 3 8 1 2878920 PS 4 Extreme Duty Synthetic 10W 50 4 Cycle Oil qt 95 I 2878919 PS 4 Extreme Duty Synthetic 10W 50 4 Cycle Oil gal 3 8 I Gearcase Transmission Lubricants 2878068 AGL Full Synthetic Gearcase Lubricant amp Transmission Fluid qt 95 I 2878069 AGL Full Synthetic Gearcase Lubricant amp Transmission Fluid gal 3 8 1 2877922 Demand Drive Fluid qt 95 I 2877923 Demand Drive Fluid gal 3 8 I 2870465 Pump for Gallon 3 8 I Jug Coolant 2871534 Polaris Antifreeze 60 40 Premix qt 95 1 2871323 Polaris An
112. tive spark plugs Inspect clean and or replace spark plugs Worn or defective spark plug wires See your dealer Incorrect spark plug gap or heat range Set gap to specs or replace plugs Loose ignition connections Check all connections and tighten Water present in fuel Replace with new fuel Low battery voltage Recharge battery to 12 8 VDC Incorrect fuel Replace with recommended fuel Clogged air filter Inspect and clean or replace Clogged intake screen Inspect and clean with soapy water or replace Throttle release switch malfunction See your dealer Other mechanical failure See your dealer Engine Stops or Loses Power Possible Cause Solution Out of fuel Refuel Water is present in fuel Replace with new fuel Fouled or defective spark plugs Inspect clean and or replace spark plug Worn or defective spark plug wires See your dealer Incorrect spark plug gap or heat range Set gap to specs or replace plug Loose ignition connections Check all connections and tighten Low battery voltage Recharge the battery to 12 8 VDC Incorrect fuel Replace with fresh recommended fuel Clogged air filter Inspect and clean or replace Clogged intake screen Inspect and clean with soapy water or replace Throttle release switch malfunction See your dealer Other mechanical failure See your dealer Overheated engine Clean radiator screen and core clean engine exterior see your dealer WARRANTY LIMIT
113. tructions for minor mainte nance but information about major repairs is outlined in the POLARIS Service Manual and should be performed only by a Factory Certified Master Service Dealer MSD Technician Your POLARIS dealer knows your vehicle best and is interested in your total satisfaction Be sure to return to your dealership for all of your service needs during and after the warranty period POLARIS POLARISG RANGER RANGER XP and RANGER CREW are registered trademarks of POLARIS Industries Inc Copyright 2013 POLARIS Sales Inc All information contained within this publication is based on the latest product information at the time of publication Due to constant improvements in the design and quality of production components some minor discrepancies may result between the actual vehicle and the information presented in this publication Depictions and or procedures in this publication are intended for reference use only No liability can be accepted for omissions or inaccuracies Any reprinting or reuse of the depictions and or procedures contained within whether whole or in part is expressly prohibited The original instructions for this vehicle are in English Other languages are provided as translations of the original instructions Printed in U S A 2014 RANGER XP 900 RANGER CREW 900 Owner s Manual P N 9924548 2 TABLE OF CONTENTS Introduction ssasecesithernkeR ERTIERRSC e ES REFERRI ETERRERE 4 Safely coi renoi
114. uncertainty Variations in the machine such as wear of components Variation of machine operators such as experience or physique Ability of the worker to reproduce typical work during measurements Environmental factors such as ambient noise or temperature SAFETY Safe Riding Gear The driver and all passengers must wear helmet eye protection gloves long sleeve shirt long pants over the ankle boots and seat belt at all times Protective gear reduces the chance of injury Helmet Wearing a helmet can prevent a severe head injury Whenever riding this POLARIS vehicle always wear a helmet that meets or exceeds established safety standards Approved helmets in the USA and Canada bear a U S Department of Transportation DOT label Approved helmets in Europe Asia and Oceania bear the ECE 22 05 label The ECE mark consists of a circle surrounding the letter E followed by the distinguishing number of the country which has granted approval The approval number and serial number will also be displayed 051039 on the label 0006 31 SAFETY Safe Riding Gear Eye Protection Do not depend on eyeglasses or sunglasses for eye protection Whenever riding this POLARIS vehicle always wear shatterproof goggles or use a shatterproof helmet face shield POLARIS recommends wearing approved Personal Protective Equipment PPE bearing markings such as VESC 8 V 8 Z87 1 or CE Make sure protective eye wear is kept clean Glov
115. vehicle Coat the terminals with dielectric grease or petroleum jelly Connect and tighten the red cable first Connect and tighten the black cable last Install the hold down strap 9 tB Reinstall the storage bin and seat 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 85 POLARIS recommends maintaining battery charge by using a POLARIS Battery Tender charger or by charging about once a month to make up for normal self discharge Battery Tender can be left connected during the storage period and will automatically charge the bat tery if the voltage drops below a pre determined point See page 94 for the part numbers of POLARIS products 84 MAINTENANCE Battery Battery Charging The following battery charging instructions apply only to the installation of a sealed battery Read all instructions before proceeding with the installation of this battery The sealed battery is already filled with electrolyte and has been sealed and fully charged at the factory Never pry the sealing strip off or add any other fluid to this battery The single most important thing about maintaining a sealed battery is to keep it fully charged Since the battery is sealed and the s
116. warning indicator information 24 FEATURES AND CONTROLS Seat and Storage Compartments The electrical compartment is located under the center rear most seat Never use this area for storage Storage compartments are located under all other seats Remove the storage bin under the right rear most passenger seat to access the battery CREW models are equipped with a storage console and cup holders located between the front seats Lift the console lid to access the storage compartment Pull the rear edge of a seat upward to release the latch pins from the grommets Roll the seat forward to access the under seat area To completely remove a seat roll the seat forward and lift the seat tabs from the seat base mounts Always make sure all seats are properly installed and securely latched before operating Push down firmly on the rear of each seat until the latch pins are fully seated into the grommets Rear Most Under Seat Area e 6 Storage ompartment lt Under Seat o o o o o o o Electrical Fuse Compartment Battery Not For Storage Under Storage Bin Storage Compartment With Cup Holders CREW 25 FEATURES AND CONTROLS Fuel Cap The fuel tank filler cap is located on the left side of the vehicle near the driver s seat Use only unleaded gasoline with a minimum pump octane number of 87 R M 2 octane Unleaded fuel blends with up to 10 ethanol can be used NOTICE Never use fuel blends with more t
117. well ventilated area Sit in the driver s seat and fasten the seat belt Secure the cab nets or doors Place the transmission in PARK Apply the brakes Do not press the throttle pedal while starting the engine Ur odes UA pA Es Turn the ignition key past the ON RUN position to START Engage the starter for a max imum of five seconds Release the key when the engine starts D If the engine does not start within five seconds release the ignition switch and wait five seconds Repeat steps 5 and 6 until the engine starts 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 WARNING A rolling vehicle can cause serious injury Always place the transmission in PARK when stopping the engine Braking 1 Release the throttle pedal completely Tip When the throttle pedal is released completely and the engine speed drops near an idle the vehi cle has no engine braking 2 Press on the brake pedal evenly and firmly Tip If the throttle pedal and brake pedal are applied simultaneously engine power may be limited 3 Practice starting and stopping using the brakes until you re familiar with the controls 37 OPERATION Driving Procedure CHONDA RWN Wear a helmet eye protection gloves long sleeve shirt long pants and over the ankle boots Perform the pre ride inspection See page 36 Sit in the driver s seat and fasten
118. when driving Headlight and taillight lenses become dirty during normal operation Clean lights frequently and replace burned out lamps promptly Do not operate this vehicle at night or in low light conditions until the headlight is replaced Always make sure lights are adjusted properly for best visibility When servicing a halogen lamp don t touch the lamp with bare fingers Oil from your skin leaves a residue causing a hot spot that will shorten the life of the lamp Headlight Lamp Replacement Access a headlamp wiring harness through the front wheel well CAUTION Hot components can cause burns to skin Allow lamps to cool before servicing 1 Unplug the headlamp from the wiring harness Be sure to pull on the connector not on the wir ing Connector 2 Turn the lamp counter clockwise to remove it 3 Install the new lamp Tip Make sure the tab on the lamp locates properly in the housing 4 Reinstall the harness assembly into the headlight assembly 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 Depress the brake pedal The brake light should come on after about 10 mm 0 4 in of pedal travel 81 MAINTENANCE Lights Headlight Beam Adjustment 82 V 8 20 cm Place the vehicle on a level surface with the headlight approximately 25 ft 7 6 m from a wall Place the tran
119. when operating on unfamiliar terrain could result in an accident or rollover Unfamiliar terrain may contain hidden rocks bumps or holes that could cause loss of control or rollover Travel slowly and use extra caution when operating on unfamiliar terrain Always be alert to changing terrain conditions Jumps and Stunts Attempting wheelies jumps and other stunts increases the risk of an accident or rollover Never attempt wheelies jumps or other stunts Avoid exhibition driving Improper Hill Climbing Climbing hills improperly can cause loss of control or vehicle rollover Always follow proper procedures for climbing hills as described in this owner s manual See page 41 Descending Hills Improperly Improperly descending a hill could cause loss of control or rollover Always follow proper procedures for traveling down hills as described in this owner s manual See page 41 Stalling While Climbing a Hill Stalling or rolling backwards while climbing a hill could cause a rollover Always maintain a steady speed when climbing a hill If all forward speed is lost Apply the brakes Place the transmission in reverse and slowly allow the vehicle to roll straight downhill while applying light brake pressure to control speed If you begin rolling downhill Never apply engine power Apply the brakes gradually until the vehicle is fully stopped Place the transmission in reverse and slowly allow the vehicle to roll straight down
120. y off while transporting this vehicle Secure or remove all cargo and inspect the unit for loose parts prior to transport 4 Always tie the frame of the RANGER to the transporting unit securely with suitable straps or rope Do not attach tie straps to the front A arm bolt pockets 5 Remove the key to prevent loss during transporting 89 SPECIFICATIONS Maximum Weight Capacity RANGER XP 900 1500 Ibs 681 kg including operator passenger cargo accessories 1100 Ibs 499 kg Models sold in California Dry Weight 1360 Ibs 617 kg Test GVW Rollover Protection System ROPS 3000 Ibs 1361 kg per OSHA 29 CFR 1928 53 Fuel Capacity 10 gal 37 8 1 Engine Oil Capacity 2 5 qts 3 4 I Coolant Capacity 5 qts 4 751 Towing Capacity 2000 Ibs 907 kg Hitch Tongue Capacity 150 Ibs 68 kg Max Cargo Box Load 1000 Ibs 454 kg 600 Ibs 272 kg Models sold in California Overall Length 116 in 295 cm Overall Width box 60 in 152 4 cm Overall Width tires 58 in 147 3 cm Overall Height 76 in 193 cm Wheelbase 81 in 205 7 cm Cargo Box Dimensions Inside 36 5 x 54 x 11 5 in 93 x 137 x 29 cm Ground Clearance 12 in 30 5 cm Min Turning Radius 161 in 409 cm Engine 4 Stroke DOHC Twin Cylinder Displacement 875 cc Bore x Stroke 93mm x 64 4mm Alternator Output 575 W 3000

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