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Polaris 500 4X4 User's Manual

1. P LARIS The Way Out 2006 RANGER 500 4X4 RANGER 500 2X4 RANGER TM 2X4 for Maintenance and Safety Read this manual carefully It contains important safety information is is an adult vehicle only Operation is prohibited for those under 16 years of age AWARNING Improper vehicle use can result in SEVERE INJURY or DEATH NEVER Operate on public roads A collision can occur with another vehicle e Carry more than two passengers or passengers under age five e Use ALCOHOL or DRUGS before or while operating this vehicle e Operate at speeds too fast for your skills or the conditions Operate this vehicle on HILLS steeper than 15 degrees 15 To prevent flipover in hilly terrain use throttle and brakes gradually ALWAYS e Avoid paved surfaces which may adversely affect handling and control e Use proper RIDING TECHNIQUES to avoid vehicle overturns on hills and rough terrain and in turns e Wear eye protection REVERSE operation can be dangerous even at low speeds Steering becomes difficult To prevent flipover avoid sharp turns The park brake will supply increased braking but should be used as a parking brake only READ OWNER S MANUAL FOLLOW ALL INSTRUCTIONS AND WARNINGS THIS GENERAL PURPOSE OFF ROAD UTILITY VEHICLE DOES NOT MEET FEDERAL MOTOR VEHICLE SAFETY STANDARDS FOR ON ROAD VEHICLES e For your nearest Polaris dealer PELARIS The
2. 50 Driving Downhill 40 Driving in Reverse 43 Driving On Slippery Surfaces 38 Driving Over Obstacles 42 Driving Procedures 37 Driving Safely 37 48 122 Driving Through Water 41 Driving Uphill 39 Dumping the Cargo 46 E Electromagnetic Interference 52 Emission Control Systems 51 52 Engaging Front Gearcase 50 Engine Idle RPM Adjustment 81 Engine Oll ees 60 67 Equipment Modifications 10 Exhaust Emission Control System 51 F Filter Systems TM 80 Filter Systems 2x4 4X4 78 79 Front Gearcase 4X4 70 Fuel Cap c nei rer ea 26 Fuel 79 Fuel Gauge 5 26 Fuel Safety 22 G Gear 1 29 Gearcase Specification Chart 68 Gearcases 68 71 H Hauling 45 47 Headlight Beam Adjustment 93 Ignition Switch 30 Indicator Lamp Replacement 94 Indicator Lights 26 L Light Switch 30 uber Rs 92 94 Lubrication Recommendations 58 59 M Main Gearcase 69 Maintenance 53 100 Maintenance Log 120 121 N Noise Emission Control System 52 Oil and Filter Change 2x4 4X4 62 63 Oil and Filter Cha
3. You are responsible for presenting your LSI engine to a dealer authorized by POLARIS as soon as a problem exists The warranty repairs should be completed in a reasonable amount of time not to exceed 30 days If you have any questions regarding your warranty rights and responsibilities you should contact the Polaris Warranty Department at 1 763 417 8650 Limited Warranty California Only POLARIS warrants to the owner of 2005 and later LSI engines that the LSI engine 1 has been designed built and equipped at the time of manufacture so as to conform with the applicable regulations of the California Air Resources Board and 2 is free from defects in materials and workmanship which may cause it to fail to conform with those regulations as applicable according to the terms and conditions stated below 114 WARRANTY California Emission Control Warranty Statement Warranty Period This warranty period begins on the date which the LSI engine is delivered to the origi nal retail purchaser and ends two years after that date During this two year period POLARIS warrants to the original retail purchaser and each subsequent purchaser that the LSI engine is free from defect in material and workmanship that can cause the failure of a warranted emission related part What is Covered Under This Warranty Repair and or replacement of any warranted emission related part will be performed at no charge provided the work is performed at an authorize
4. IMPROPER TIRE PRESSURE OR OVERLOADING can cause loss of control resulting in SEVERE INJURY OR DEATH TIRE PRESSURE PSI FRONT _ REAR MAXIMUM WEIGHT CAPACITY Gross Vehicle Weight INCLUDING MACHINE DRIVER AND CARGO IS LBS Reduce speed and allow greater distance for braking when carrying cargo Overloading or carrying tall off center or unsecured loads will increase your risk of losing control Loads should be centered and carried as low as possible in box For stability on rough or hilly terrain reduce speed and cargo Be careful if load extends over the side of the box Read Owner s Manual for more detailed loading information Location 3 Safety Decals and Locations SAFETY A WARNING A G9 g Remove flammable containers from box before refueling A WARNING Passengers can be thrown off This can cause serious injury or death Never carry passengers in cargo box WARNING Maximum Box Load is Ibs Location 4 inside front of box Fuel Passenger Warning Decal Text Remove flammable containers from box before refueling Passengers can be thrown off This can cause serious injury or death Never carry passengers in cargo box Maximum 2X4 TM Box Load 750 165 340 kg Maximum 4X4 Box Load 1000 16 454 kg 19 SAFETY Safety Decals and Locations MANUFACTURED BY POLARIS IND INC DATE THIS
5. Never start or operate this vehicle if it has a sticking or improperly operating throttle pedal Immediately contact your dealer for service if throttle problems arise Always check the pedal for free movement and return before starting the engine and occasionally during operation Throttle Freeplay If the throttle pedal 1 has excessive play due to cable stretch or misadjustment it will cause a delay in throttle response especially at low engine speed The throttle may also not open fully If the throttle pedal has no freeplay the throttle may be hard to control and the idle speed may be erratic Check the throttle pedal freeplay at the intervals outlined in the Periodic Maintenance Chart beginning on page 53 Adjust the freeplay if necessary 84 MAINTENANCE AND LUBRICATION Throttle System Throttle Freeplay Inspection 1 Apply the parking brake 2 and shift the transmission to neutral 2 Start the engine and warm it up thoroughly 3 Measure the distance the throttle pedal moves before the engine begins to pick up speed Freeplay should be 1 16 to 1 8 inches Throttle Freeplay Adjustment 1 Slide the boots 1 off the inline cable adjuster sleeve 2 Loosen the adjuster locknut 3 2 Turn the adjuster until 1 16 to 1 8 inch freeplay is achieved NOTE While adjusting flip the throttle lever back and forth 3 Tighten the locknut and slide the boots over the cable adjuster until they touch at the midp
6. including safe operating procedures The RANGER is an off road vehicle Familiarize yourself with all laws and regulations concerning the operation of this vehicle in your area We strongly advise you to strictly follow the recommended maintenance program outlined in your owner s manual This preventive maintenance program is designed to ensure that all critical components on your vehicle are thoroughly inspected at specific intervals SAFETY Operator Safety The following signal words and symbols appear throughout this manual and on your RANGER Your safety is involved when these words and symbols are used Become familiar with their meanings before reading the manual A A The safety alert symbol on your vehicle or in this manual alerts you to the potential for personal injury WARNING The safety alert warning indicates a potential hazard that may result in serious injury or death CAUTION The safety alert caution indicates a potential hazard that may result in minor personal injury or damage to the vehicle CAUTION A caution indicates a situation that may result in damage to the vehicle NOTE A note will alert you to important information or instructions SAFETY Operator Safety 4 WARNING Serious injury or death can result if you do not follow these instructions and procedures which are outlined in further detail within your owner s manual Read this manual and all labels carefully Follow the o
7. lubrication cables etc i 50H Inspect lubricate adjust 1M Shift Linkage 25H Carburetor float 50H Drain bowl periodically and bowl prior to storage Throttle Cable 50H Inspect adjust lubricate ETC Switch replace if necessary 50H Inspect adjust lubricate replace if necessary 7 d E i Choke cable S Carburetor air Inspect ducts for proper intake ducts sealing air leaks flange Inspect adjust replace as needed Cooling system if applicable Engine oil change 100 H Oil filter change 100 H Inspect coolant strength seasonally pressure test system yearly Perform a break in oil change at 25 hours one month Replace with oil change Oil tank vent hose 100 H 12M Inspect routing condition p Perform these procedures more often for vehicles subjected to severe use E Emission Related Service m Have an authorized Polaris dealer perform these services ELA ELM NIA ES ELA ww 56 MAINTENANCE AND LUBRICATION Periodic Maintenance Chart Maintenance Interval whichever comes first Calendar Miles Km Fuel system 100 H 12M Check for leaks at tank cap lines fuel valve filter pump carburetor replace lines every two years H Fuel filter 100 H ee ae Replace yearly Radiator 100 H 12M Inspect clean external if applicable surfaces Cooling hoses 100 H 12M Inspect for leaks if applicable Exhaust muffler 100 H 12M Inspect pipe H Spark plug 100 H Inspect replace as n
8. riding conditions and an average vehicle speed of approximately 10 miles per hour Vehicles subjected to severe use must be inspected and serviced more frequently Severe Use Definition Frequent immersion in mud water or sand Racing or race style high RPM use Prolonged low speed heavy load operation Extended idle Short trip cold weather operation Pay special attention to the oil level A rise in oil level during cold weather can indicate contaminants collecting in the oil sump or crankcase Change oil immediately if the oil level begins to rise Monitor the oil level and if it continues to rise discontinue use and determine the cause or see your dealer 53 MAINTENANCE AND LUBRICATION Periodic Maintenance Chart Maintenance Chart Key p gt Perform these procedures more frequently for vehicles subjected to severe use E Emission related service Failure to conduct this maintenance will not void the emissions warranty but may affect emissions m Have an authorized Polaris dealer perform these services 4 WARNING Improperly performing the procedures marked with a m could result in component failure and lead to serious injury or death Have an authorized Polaris dealer perform these services 54 MAINTENANCE AND LUBRICATION Periodic Maintenance Chart Perform all services at whichever maintenance interval is reached first Maintenance Interval whichever comes first Calendar Miles Km Pre Ride O M
9. 86 Main Gearcase Oil Premium AGL Syn Maintain as recommended on page 69 Transmission thetic Gearcase Lube Front Gearcase Oil Premium Demand Maintain as recommended on page 70 Drive Hub Fluid Rear Gearcase Oil Premium ATV Angle Maintain as recommended on page 71 Drive Fluid 1 Prop Shaft U joints Locate fittings and grease Front Prop Shaft Yoke eGrease Locate fittings and grease 4X4 3 pumps maximum Ball Joint gt xGrease Locate fitting back side of struts grease with grease gun 2 Swing Arm Grease Locate fittings on swing arm and Bushings grease with grease gun 58 MAINTENANCE AND LUBRICATION Lubrication Recommendations TM TM 4X4 59 MAINTENANCE AND LUBRICATION Engine Oil Always check and change the engine oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 53 Always change the oil filter whenever changing oil Premium 4 Synthetic Oil Polaris Premium 4 All Season Synthetic engine oil has been specially formulated for use in Polaris 4 cycle engines It s a fully synthetic high performance multi viscosity oil designed to provide the ultimate in lubrication performance and protection See page 101 for the part numbers of Polaris products Premium 4 possesses unsurpassed film strength over the widest possible temperature range It resists viscosity and frictional breakdown in ambient temperatures from 40 F to 120 F Its exceptional frictiona
10. SYSTEMS Crankcase Emission Control System This engine is equipped with a closed crankcase system Blow by gases are forced back to the combustion chamber by the intake system All exhaust gases exit through the exhaust system Exhaust Emission Control System The emissions from the exhaust of this vehicle are controlled by engine design including factory set fuel delivery and ignition The engine and related components must be maintained at Polaris specifications to achieve optimal performance Engine idle speed is the only adjustment Polaris recommends that the operator perform Any other adjustments should be performed by an authorized Polaris dealer The RANGER TM emissions label 1 is located on the front of the engine Remove the service panel 2 to view the label The label on the RANGER 2X4 and 4X4 3 is located on the recoil cover Remove the seat and look through the gap in the aluminum exhaust shield to view the label NOTE The installation of devices that effectively increase exhaust emissions beyond their legal limits will void all manufacturer warranties and may violate laws governing the registration and operation of this vehicle 51 EMISSION CONTROL SYSTEMS Noise Emission Control System Do not modify the engine intake or exhaust components as doing so may affect compliance with U S A EPA noise control requirements 40 CFR 205 and local noise level requirements Op
11. apply the parking brake after stopping the engine 1 Stop the vehicle on a level surface 2 When the engine has stopped apply the parking brake 3 Remove the ignition switch key to prevent unauthorized use 4 WARNING Gasoline is extremely flammable and can be explosive under certain conditions When parking inside a garage or other structure be sure that the structure is well ventilated and that the vehicle is not close to any source of flame or sparks including any appliance with pilot lights 48 OPERATION Differential Operation Modes The rear axle is equipped with a lockable differential On AWD models engaging AWD locks the front differential and the rear differential CAUTION Damage to the differential can occur if it is engaged while the vehicle is traveling at high speeds or while the rear wheels are spinning Slow the vehicle to nearly stopped before engaging the differential AWD 4X4 When in AWD the rear wheels rotate at the same speed The front wheels also rotate at the same speed See page 50 for AWD operating instructions 2WD Rear Differential Locked When the rear differential is locked both rear wheels rotate at the same speed It s beneficial to lock the differential in low traction situations To lock the differential on the TM push the lock lever up To lock the differential on the 2X4 and 4X4 move the AWD Differential Switch to the center ZWD position OFF Differential Unloc
12. arrows on the tire point toward forward rotation Attach the wheel nuts and washers and finger tighten Carefully lower the vehicle to the ground Torque the wheel nuts according to the specifications on page 90 91 MAINTENANCE AND LUBRICATION Lights When servicing a halogen lamp don t touch the lamp with bare fingers Oil from your skin leaves a residue causing a hot spot that will shorten the life of the lamp 4 WARNING Poor lighting while driving can result in severe injury or death Headlight and taillight lenses become dirty during normal operation Wash the headlights frequently to maintain lighting quality Hot components can cause serious burns to skin Do not service the headlamps until they ve cooled sufficiently dioe Mg Lamp Replacement Open the hood s Unplug the headlamp from the wiring harness 1 Be sure to pull on the connector not on the wiring 3 Turn the lamp counterclockwise to remove it 4 Install the new lamp NOTE Make sure the tab on the lamp locates properly in the housing 5 Reinstall the harness assembly into the headlight assembly 92 MAINTENANCE AND LUBRICATION Lights Beam Adjustment Place the vehicle on a level surface with the headlight approximately 25 ft 7 6 m from a wall 2 Measure the distance from the floor to the center of the headlight and make a mark on the wall at the same height 3 Start the engine and switch on the headlight 4 Obse
13. authorized Polaris dealer 5 Lubricate at the intervals outlined in the Periodic Maintenance Chart beginning on page 53 Bw m 4 WARNING Engine exhaust contains poisonous carbon monoxide and can cause loss of consciousness or death Never run an engine in an enclosed area 97 MAINTENANCE AND LUBRICATION Battery Keep the battery terminals and connections free of corrosion If cleaning is necessary remove the corrosion with a stiff wire brush Wash with a solution of one tablespoon baking soda and one cup water Rinse well with tap water and dry off with clean shop towels Coat the terminals with dielectric grease or petroleum jelly Be careful not to allow cleaning solution or tap water into the battery 4 WARNING Battery electrolyte is poisonous It contains sulfuric acid Serious burns can result from contact with skin eyes or clothing Antidote External Flush with water Internal Drink large quantities of water or milk Follow with milk of magnesia beaten egg or vegetable oil Call physician immediately Eyes Flush with water for 15 minutes and get prompt medical attention Batteries produce explosive gases Keep sparks flame cigarettes etc away Ventilate when charging or using in an enclosed space Always shield eyes when working near batteries KEEP OUT OF REACH OF CHILDREN 98 MAINTENANCE AND LUBRICATION Battery Replenishing Battery Fluid Conventional Battery A poorly maintained batter
14. be advised of the appropriate dealer where the warranty repair is to be performed 118 WARRANTY U S A EPA Emissions Limited Warranty This All Terrain Vehicle ATV or Off Road Utility Vehicle ORUV emissions limited warranty is in addition to the Polaris standard limited warranty for this vehicle Polaris warrants that this vehicle is 1 designed built and equipped to conform at the time of initial sale with the requirements of 40 CFR 1051 and 2 free from defects in materials and workmanship that may keep it from meeting these requirements The emissions warranty period for this vehicle begins on the date the vehicle is delivered to the original retail purchaser and ends 30 months 2 5 years after that date or after 5000 km 3100 miles whichever comes first This emission related warranty covers components whose failure would increase an en gine s emissions including electronic controls fuel injection exhaust gas recirculation aftertreatment or any other system utilized in this vehicle to control emissions Replac ing or repairing other components not covered by this emissions warranty or the standard warranty is the responsibility of the owner including the parts labor and other costs associated with recommended maintenance The exclusive remedy for breach of this limited warranty shall be at the exclusive option of Polaris repair or replacement of any defective materials components or products THE REMEDIES SET
15. forcefully for a few seconds and check for fluid leakage around the fittings 4 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 86 MAINTENANCE AND LUBRICATION Brakes Brake Inspection 1 2 3 4 Check the brake system for fluid leaks Check the brake pedal for excessive travel or a spongy feel Check the friction pads for wear damage and looseness Inspect the brake disc spline and pad wear surface for excessive wear Change pads when worn to 3 64 1 em Parking Brake Inspection 1 2 Parking Brake Adjustment 1 2 3 Slowly push the parking brake down with your foot After 8 to 12 clicks of lever travel check the vehicle for movement The vehicle should not roll while parked If the vehicle moves adjustment is necessary Position the vehicle on a level surface Place the transmission in neutral Loosen or tighten the nuts on each end of the parking brake cable as needed 87 MAINTENANCE AND LUBRICATION Steering Wheel Inspection Check the steering wheel for specified freeplay and smooth operation at the intervals outlined in
16. necessary Inspect lubricate if necessary Ensure free operation nspect condition and pressure nspect ensure fastener tightness nspect ensure tightness Ensure proper levels Ensure proper level Inspect for leaks Ensure proper operation Ensure operation Air filter pre filter Inspect clean Air box sediment tube Drain deposits whenever visible Headlamp Check operation apply Polaris dielec tric grease when lamp is replaced Brake light tail lamp Check operation apply Polaris dielec 93 tric grease when lamp is replaced 33 OPERATION Starting the Engine 4 amp WARNING Starting a Cold Engine 1 2 3 NOTE Do not use the choke before 4 NOTE Do not press the throttle pedal while 34 Engine exhaust contains poisonous carbon monoxide and can cause loss of consciousness resulting in severe injury or death Never run an engine in an enclosed area CAUTION Operating the vehicle immediately after starting could cause engine damage Allow the engine to warm up for several minutes before operating the vehicle Place the transmission in neutral Lock the parking brake Sit in the driver s seat and fasten the seat belt attempting to start the TM model If the engine does not start on the first attempt without choking proceed to step 4 Pull the choke knob 1 all the way out 2 starting the engine CAUTION Do not operate the starter continuously for more than five seconds or the starter
17. oil 65 MAINTENANCE AND LUBRICATION Engine Oil Oil and Filter Change TM 1 Position the vehicle on a level surface 2 Run the engine two to three minutes until warm then stop the engine 3 Clean the area around the drain plug 6 at the bottom of the engine The plug is accessible through the access hole in the bottom of the skid plate 4 CAUTION Hot oil can cause serious burns Do not allow hot oil to come into contact with skin 4 Place drain pan beneath the engine and remove the drain plug Allow the oil to drain completely 5 Replace the sealing washer on the drain plug NOTE The sealing surfaces on the drain plug and crankcase should be clean and free of burrs nicks or scratches 6 Reinstall the drain plug and torque to 14 ft Ibs 19 Nm 66 MAINTENANCE AND LUBRICATION Engine Oil Oil and Filter Change TM 7 Place shop towels beneath the oil filter 1 Using an oil filter wrench 2 turn the filter counterclockwise to remove 8 Usinga clean dry cloth clean the filter sealing surface on the crankcase 9 Check to make sure the o ring 3 is in good condition Lubricate the o ring on the new filter with a film of engine oil 10 Install the new filter and turn by hand until the filter gasket contacts the sealing surface then turn an additional 3 4 turn NOTE The sealing surfaces on the drain plug and crankcase should be clean and free of burrs nicks or scratches 11 Add 1 64 quar
18. s securely latched 2 Push the red button in the middle of the buckle to make sure it releases freely 3 Check the belt webbing for wear cuts or damage If any irregularities are found have the seat belt system checked and or replaced by an authorized Polaris dealer The RANGER seat belt is adjustable and should be adjusted for both the operator and passenger before driving Although having the belt at 30 is typical for many people it will not accommodate all body 1 sizes and shapes Make sure the seat belt is adjusted to the lowest possible lap position before riding 1 To adjust loosen the bolts 1 2 Reposition both the buckle and retractor Tighten the bolts NOTE The center belt does not self adjust Before riding pull on the strap to secure the belt on the lap of the center passenger 4 WARNING Failure to follow the age recommendations for this vehicle could result in serious injury or death No one under the age of 16 may operate this vehicle No one under the age of 5 may ride as a passenger in this vehicle 89 MAINTENANCE AND LUBRICATION Tires 4 amp WARNING Operating your vehicle with worn tires will increase the possibility of skidding loss of control and an accident which could result in serious injury or death Always replace tires when the tread depth measures 1 8 3 cm or less Improper tire inflation or the use of non standard size or type of tires may adversely affect vehicle handli
19. the vehicle to your dealer for service as soon as possible whether you succeed in starting it or not NOTE f water has been ingested into the PVT follow the procedure on page 76 for drying 77 MAINTENANCE AND LUBRICATION Filter Systems 2X4 4X4 Air Filter Always change the air filter at the intervals outlined in the Periodic Maintenance Chart beginning on page 53 1 Liftthe cargo box to access the air box 2 Remove the air box cover and inspect the gasket It should adhere tightly to the cover and seal all the way around 3 Remove the air filter 1 4 Do not attempt to clean the main element Install a new air filter NOTE Apply a small amount of general purpose grease to the sealing edges of the filter before installing 5 Inspect the air box for oil or water deposits If present drain them into a suitable container NOTE Service the air filter more frequently if the vehicle is operated in wet conditions or at high throttle openings for extended periods 78 MAINTENANCE AND LUBRICATION Filter Systems 2X4 4X4 Breather Filter and Hoses 1 Liftthe cargo box and locate the air box 2 Follow the right hand breather line 1 out the side of the air box and locate the filter 2 3 Remove and inspect the filter for debris Blow gently through the filter in the direction of the arrow to check for clogging Replace as needed 4 Check hoses for cracks deterioration abrasio
20. tighten the red positive cable 4 Second connect and tighten the black negative cable 5 Verify that cables are properly routed NOTE Wheninstalling a new battery make sure it s fully charged prior to its initial use Using a new battery that has not been fully charged can damage the battery and result in a shorter life It can also hinder vehicle performance Battery Storage When the vehicle is placed in storage for three months or more the battery should be removed stored out of the sun in a cool dry place and tested monthly Before reusing take the battery to your dealer for testing and recharging 100 POLARIS PRODUCTS Part No Description Engine Lubricant 2870791 Fogging Oil 12 oz Aerosol 2871281 Premium 4 Synthetic OW 40 4 Cycle Engine Oil qt 2871844 Premium 4 Synthetic OW 40 4 Cycle Engine Oil gal 2873602 2873603 2871653 2872276 2870465 2671654 2872277 2871322 2871423 2671460 2871515 2871551 2871312 2871329 2872073 2672348 2871323 60 40 Coolant gal 2871534 60 40 Coolant qt 101 SPECIFICATIONS RANGER TM 147 x 106 7 x 25 4 cm Needle st NA NA 8 5 0 NA NA 2 0 102 SPECIFICATIONS RANGER TM Lubrication System Full Pressure Engine Oil 0W 40 Driving System A 4 wheel hydraulic disc NOTE See your Polaris dealer for jetting and clutching specifications 103 SPECIFICATIONS RANGER
21. to obtain documentation from Polaris Industries in order to register your vehicle in your new country How to Get Service If Purchased From A Private Party If you purchase a Polaris product from a private citizen outside of the country in which the vehicle was originally purchased all warranty coverage will be denied Notice If your vehicle is registered outside of the country where it was purchased and you have not followed the procedure set out above your vehicle will no longer be eligible for war ranty or service bulletin coverage of any kind Vehicles registered to Government officials or military personnel on assignment outside of the country where the vehicle was purchased will continue to be covered by the basic warranty For questions call Polaris Customer Assistance United States 1 763 417 8650 Canada 1 204 925 7100 113 WARRANTY California Emission Control Warranty Statement Your Warranty Rights and Obligations The California Air Resources Board and Polaris Industries Inc 2100 Highway 55 Medina Minnesota 55340 herein POLARIS are pleased to explain the emission control system warranty on your 2005 and later Large Spark Ignition Engine herein LSI engine The California Air Resources Board has designated this engine for this vehicle as an LSI engine which produces 25 and greater horsepower and the vehicle has a six 6 or four 4 wheel drive and or a round steering wheel In California this LSI
22. 1 Throttle System 84 85 Tire Tread Depth 90 Ties e Dep MURUS 90 91 ToolKit dee 94 Torque Specifications 90 Towing Capacities 47 Towing Loads 47 Trailer Hitch Bracket 26 Transmission 69 Troubleshooting 108 110 V Vehicle Break In Period 32 Vehicle Identification Numbers 4 Vehicle Immersion TI W Warranty 111 118 Wheel Installation 91 Wheel Removal 91 123
23. 1 is located in front of the right front wheel 1 Position the vehicle on level ground 2 View the coolant level in the overflow bottle 3 Ifthe coolant level is below the safe operating range lift the hood and locate the overflow bottle lid Remove the lid and use a funnel to add coolant through the filler opening Reinstall the cap NOTE f coolant must be added often or if the overflow bottle runs completely dry there may be a leak in the system Have the cooling system inspected by your Polaris dealer 73 MAINTENANCE AND LUBRICATION Cooling System 2X4 4X4 Radiator Coolant Level Always check and change the coolant at the intervals outlined in the Periodic Maintenance Chart beginning on page 53 4 WARNING Escaping steam can cause severe burns Never remove the pressure cap while the engine is warm or hot Always allow the engine to cool before removing the pressure cap 1 Liftthe hood and slowly remove the radiator cap 1 2 View the coolant level through the opening 3 Use a funnel and slowly add coolant as needed NOTE This procedure is required only if the cooling system has been drained for maintenance and or repair But if the overflow bottle has run dry the level in the radiator should also be 1 inspected NOTE Use of a non standard pressure cap will not allow the recovery system to function properly See your dealer for the correct replacement part 74 MA
24. 2x4 147 x 106 7 x 25 4 cm with counter balance 104 SPECIFICATIONS RANGER 2x4 4 wheel hydraulic disc NOTE See your Polaris dealer for jetting and clutching specifications 105 SPECIFICATIONS RANGER 4X4 LxWxH 147 x 106 7 x 25 4 cm with counter balance 106 SPECIFICATIONS RANGER 4X4 4 wheel hydraulic disc NOTE See your Polaris dealer for jetting and clutching specifications 107 TROUBLESHOOTING Contact your Polaris dealer for service if you re unable to identify solutions using the following charts Engine Doesn t Turn Over Possible Cause Solution Tripped circuit breaker Reset the breaker Low battery voltage Recharge battery to 12 5 VDC Loose solenoid connections Check all connections and tighten Engine Turns Over Fails to Start Possible Cause Solution Mechanical failure Engine Pings or Knocks Possible Cause Solution Poor quality or low octane fuel Replace with recommended fuel Incorrect ignition timing See your Polaris dealer Incorrect spark plug gap or heat range Set gap to specs or replace plugs 108 TROUBLESHOOTING Engine Backfires Possible Cause Solution Weak spark from spark plugs Inspect clean and or replace spark plugs Incorrect spark plug gap or heat range Set gap to specs or replace plugs Mechanical failure Engine Runs Irregularly Stalls or Misfires Possible Weak Spark Cause Solution Other mechanical failure Possib
25. Be alert to changing terrain Never operate on excessively rough slippery or loose terrain SAFETY Operator Safety Always follow proper procedures for turning as described in this manual Practice turning at slow speeds before attempting to turn at faster speeds Never turn at excessive speeds Always have this vehicle checked by an authorized Polaris dealer if it has been involved in an accident Never operate this vehicle on hills too steep for the vehicle or for your abilities Practice on smaller hills before attempting larger hills Always follow proper procedures for climbing hills as described in this manual Check the terrain carefully before attempting to climb a hill Never climb hills with excessively slippery or loose surfaces Never open the throttle suddenly or 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 Check the terrain care fully before descending a hill Never travel downhill at high speed Avoid going downhill at an angle which would cause the vehicle to lean sharply to one side Travel straight down the hill where pos sible Always check for obstacles before operating in a new area Never attempt to operate over large obstacles such as rocks or fallen trees Always follow the proper procedures outlined in this manual when operating over obstacles Always be careful of skidd
26. FORTH IN THIS LIMITED WARRANTY ARE THE ONLY REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF THIS WARRANTY POLARIS SHALL HAVE NO LIABILITY TO ANY PERSON FOR INCIDENTAL CONSEQUENTIAL OR SPECIAL DAMAGES OF ANY DESCRIPTION WHETHER ARISING OUT OF EXPRESS OR IMPLIED WARRANTY OR ANY OTHER CON TRACT NEGLIGENCE OR OTHER TORT OR OTHERWISE ALL IMPLIED WARRANTIES INCLUDING BUT NOT LIMITED TO ANY IM PLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICU LAR PURPOSE ARE LIMITED IN DURATION TO THE WARRANTY PERIOD DESCRIBED HEREIN POLARIS DISCLAIMS ALL EXPRESS WARRANTIES NOT STATED IN THIS WARRANTY Some states do not allow limitations on how long an implied warranty lasts so the above limitation may not apply if it is inconsistent with the controlling state law This limited warranty excludes failures not caused by a defect in material or workman ship This limited warranty does not cover damage due to accidents abuse or improper handling maintenance or use This limited warranty also does not cover any engine that has been structurally altered or any engine that has been used in racing competition This limited warranty also does not cover physical damage corrosion or defects caused by fire explosions or other similar causes beyond the control of Polaris If you have any questions regarding your warranty rights and responsibilities you should contact the Polaris Warranty Department at 1 763 417 8650 119 MAINTENANCE LOG Periodic Ma
27. HAT CAN HAPPEN Loss of control vehicle overturn HOW TO AVOID THE HAZARD Travel slowly and use extra caution when operating on unfamiliar terrain Always be alert to changing terrain conditions when operating the vehicle You may come upon hidden rocks bumps or holes suddenly without enough time to react 15 SAFETY Operator Safety 4 amp WARNING 16 POTENTIAL HAZARD Failure to follow the minimum age recommendations for this vehicle WHAT CAN HAPPEN Serious injury or death the child or others HOW TO AVOID THE HAZARD Only persons with a valid driver s license should operate a Polaris RANGER Even though a child may be within the age group for which some vehicles are recommended he or she may not have the skills abilities or judgment needed to operate the vehicle safely and may be involved in a serious accident WARNING POTENTIAL HAZARD Operating this vehicle with improper tires or with improper or uneven tire pressure WHAT CAN HAPPEN Loss of control accident and or overturn HOW TO AVOID THE HAZARD Always use the size and type of tires specified in the Owner s Manual for this vehicle See page 103 Always maintain proper tire pressure as described on the decal and in the Owner s Manual See page 103 SAFETY Operator Safety A A WARNING Leaving the keys in the ignition can lead to unauthorized use of the vehicle resulting in serious injury or death Always remove the ignition key when t
28. INTENANCE AND LUBRICATION Spark Plugs CAUTION Using non recommended spark plugs can result in serious engine damage Always use Polaris recommended spark plugs Refer to the specifications section beginning on page 102 Spark Plug Gap Torque Mode Electrode Gap New Plug Torque Used Plug Torque RANGER 025 06 9 11 ft Ibs 9 11 ft Ibs 2X4 4X4 12 15 Nm 12 15 Nm TM 11 8 14 6 Nm 22 5 26 4 Nm Spark plug condition is indicative of engine operation The spark plug firing end condition should be read after the engine is warmed up and the vehicle is driven at higher speeds Immediately check the spark plug for correct color 4 WARNING A hot exhaust system and engine can cause serious burns Wear protective gloves when removing a spark plug for inspection 1 Normal The normal insulator tip is gray tan or light brown There will be few combustion deposits The electrodes are not burned or eroded This indicates the proper type and heat range for the engine and the service NOTE Thetip should not be white A white insulator tip indicates overheating caused by use of an improper spark plug or incorrect carburetion adjustments 2 Wet Fouled The wet fouled insulator tip is black A damp oil film covers the firing end There may be a carbon layer over the entire nose Generally the electrodes are not worn General causes of fouling are excessive oil use of non recommended injection oil improper use of
29. Recommended engine idle RPM for the RANGER 2X4 and 4X4 is 1200 200 Recommended engine idle RPM for the RANGER TM is 1000 100 If the engine idle speed is not satisfactory and all other conditions are favorable the carburetor can be adjusted with the following procedure 1 Engage the parking brake and place the gear shift lever in the neutral position 2 Warm up the engine by running the vehicle approximately five minutes 3 Remove the the seat and locate the idle adjust screw 1 4 Place the transmission in gear with park brake engaged 5 Turn the carburetor idle adjust screw in or out until the desired idle RPM is reached Turn the screw in clockwise to raise RPM Turn the screw out counterclockwise to lower RPM 81 MAINTENANCE AND LUBRICATION Spark Arrestor 4 amp WARNING 82 Failure to heed the following warnings while servicing the spark arrestor could result in serious injury or death Do not perform service on the spark arrestor while the system is hot Exhaust system temperatures can reach 1000 Allow components to cool sufficiently before proceeding Remove any combustible materials from the area Wear eye protection and gloves Do not stand behind or in front of the vehicle while purging Never run the engine in an enclosed area Exhaust contains poisonous carbon monoxide gas that can cause loss of consciousness or death in a very short time Never go under the vehicle whil
30. VEHICLE IS A GENERAL PURPOSE OFF ROAD UTILITY VEHICLE AND IS NOT INTENDED FOR USE ON PUBLIC ROADS CE V HICULE USAGE GENERAL VEHICULE UTILIT AIRE POUR SERVICE HORS ROUTE QUI NEST PAS DES TINE A ETRE UTILISE SUR LES CHEMINS PUBLICS 7078472 Location 5 under hood ATTENTION Operation of this vehicle without the Specific carburetor jetting and adjust filter element will severely damage ments are required depending on the engine temperature and altitude See your Clean air filter often more frequent Owner s Manual cleaning required in dusty conditions Factory setting Operation of this vehicle without en 40 to 80 F at 0 3000 feet gine breather filter s can cause en o o z gine damage Consult owner s Reece Peel SOT meters manual for details 7079902 Location 6 4 CAUTION To avoid transmission damage shift only when vehicle is stationary and at idle 7172674 Location 7 20 SAFETY Safety Decals and Locations Discretionary Warning Decal 4 WARNING Improper vehicle use can result in SEVERE INJURY or DEATH Location 8 Improper vehicle use can result in SEVERE INJURY or DEATH NEVER e Operate on public roads A collision can occur with another vehicle Carry more than two passengers or passengers under age five Use ALCOHOL or DRUGS before or while operating this vehicle Operate at speeds too fast for your skills or the c
31. Way Out as or visit www polarisindustries com Polaris Sales Inc 2100 Hwy 55 Medina MN 55340 Phone 763 417 8650 Fax 763 542 0599 Part No 9920210 Rev 01 Printed in USA AWARNING The engine exhaust from this product contains chemicals known to cause cancer birth defects or other reproductive harm WELCOME Thank you for purchasing a Polaris vehicle and welcome to our world wide family of Polaris owners We proudly produce an exciting line of utility and recreational products Snowmobiles All terrain vehicles ATVs RANGER utility vehicles Victory motorcycles We believe Polaris sets a standard of excellence for all utility and recreational vehicles manufactured in the world today Many years of experience have gone into the engineering design and development of your Polaris vehicle making it the finest machine we ve ever produced For safe and enjoyable operation of your vehicle be sure to follow the instructions and recommendations in this owner s manual Your manual contains instructions for minor maintenance but information about major repairs is outlined in the Polaris Service Manual and should be performed only by a Factory Certified Master Service Dealer MSD Technician Your Polaris dealer knows your vehicle best and is interested in your total satisfaction Be sure to return to your dealership for all of your service needs during and after the warranty period We
32. acement of any defective materials or components or products THE REMEDIES SET FORTH IN THIS WARRANTY ARE THE ONLY REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF THIS WARRANTY POLARIS SHALL HAVE NO LIABILITY TO ANY PERSON FOR INCIDENTAL CONSEQUENTIAL OR SPECIAL DAMAGES OF ANY DE SCRIPTION WHETHER ARISING OUT OF EXPRESS OR IMPLIED WARRANTY OR ANY OTHER CONTRACT NEGLIGENCE OR OTHER TORT OR OTHER WISE Some states do not permit the exclusion or limitation of incidental or consequen tial damages or implied warranties so the above limitations or exclusions may not apply to you if inconsistent with controlling state law 111 WARRANTY LIMITATIONS OF WARRANTIES AND REMEDIES ALL IMPLIED WARRANTIES INCLUDING BUT NOT LIMITED TO THE IM PLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICU LAR PURPOSE ARE LIMITED IN DURATION TO THE ABOVE SIX MONTH WARRANTY PERIOD POLARIS FURTHER DISCLAIMS ALL EXPRESS WAR RANTIES NOT STATED IN THIS WARRANTY Some states do not allow limitations on how long an implied warranty lasts so the above limitation may not apply to you if inconsistent with controlling state law HOW TO OBTAIN WARRANTY SERVICE If your vehicle requires warranty service you must take it to a Polaris Servicing Dealer When requesting warranty service you must present your copy of the Warranty Registra tion form to the dealer THE COST OF TRANSPORTATION TO AND FROM THE DEALER IS YOUR RESPONSIBILITY Polaris suggests that you
33. ake adjustments as need Fars near Ded e mene 7 peer mer mene e meme weesmemes meme menemmes meme gt Enaine offevel mene 7 Air filter pre filter Daily Inspect clean often replace as needed Air box sediment Daily Drain deposits when visible tube Coolant Daily Check level daily change if applicable coolant every 2 years Headlamp tail Daily Check operation apply lamp dielectric grease if replacing Air filter Weekly Inspect replace as needed main element Recoil housing Weekly Drain water as needed check often if operating in wet conditions H Brake pad wear Monthly MZ Inspect periodically Front gearcase oil 25 H Monthly Inspect level change yearly if equipped Rear gearcase oil 25H Monthly Inspect level change yearly if equipped gt Transmission n Monty inspectievel change year p Perform these procedures more often for vehicles subjected to severe use Emission Related Service m Have an authorized Polaris dealer perform these services 55 MAINTENANCE AND LUBRICATION Periodic Maintenance Chart Maintenance Interval whichever comes first Calendar Miles Km Engine breather Monthly Inspect replace if necessary filter if equipped Perform a break in oil change at one month Engine oil change in oi break in General Lubricate all fittings pivots
34. also take great pride in our complete line of apparel parts and accessories available through our online store at www purepolaris com Have your accessories and clothing delivered right to your door POLARIS The Way Out Copyright 2005 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 Printed in U S A 2006 RANGER 2X4 4X4 TM Owner s Manual P N 9920210 2 TABLE OF CONTENTS VEHICLE IDENTIFICATION NUMBERS 4 SAFETY sew dieu Rae tux az Dabo ecd et e 5 FEATURES AND CONTROLS 23 OPERABNON aotem osea ahead Grates 32 EMISSION CONTROL SYSTEMS 51 MAINTENANCE AND LUBRICATION 53 POLARIS PRODUCTS 101 SPECIFICATIONS 102 TROUBLESHOOTING 108 WARRANTY cs idet dea RO e x 111 MAINTENANCE LOG 120 INDE acu ok Ri ob e HAE 122 VEHICLE IDENTIFICATION NUMBERS Reco
35. ange at one month Throttle Cable 50H Inspect adjust lubricate ETC Switch replace if necessary Choke cable 50H Inspect adjust lubricate replace if necessary Carburetor air 50H 6M Inspect ducts for proper intake ducts sealing air leaks flange Engine oil change 100 H Perform a break in oil change at 25 hours one month Oil filter change 100 H NEUEN Replace with oil change Oil tank vent hose 100 H Inspect routing condition Fuel system 100 H 12M Check for leaks at tank cap lines fuel valve filter pump carburetor replace lines every two years H Fuel filter 100 H EET Replace yearly H Spark plug 100 H pr Inspect replace as needed 117 WARRANTY California Emission Control Warranty Statement Repair and Replacement of Emission Related Parts It is recommended that only LSI engine replacement parts which have been authorized and approved by POLARIS should be used in the performance of any warranty maintenance or repairs of emission related parts These replacement parts will be provided at no charge if the part is still under warranty How to File a Warranty Claim Where to Get Warranty Service All repairs qualifying under this Limited Warranty must be performed by a dealer who sold you the LSI engine or a dealer authorized by POLARIS In the event that any emission related part is found to be defective during the warranty period you must notify the Polaris Warranty Department at 1 763 417 8650 and you will
36. ceived the customer copy please contact your dealer immediately NO WARRANTY COVERAGE WILL BE ALLOWED UNLESS YOUR VEHICLE IS REGISTERED WITH POLARIS Initial dealer preparation and set up of your vehicle is very important in ensuring trouble free operation Purchasing a machine in the crate or without proper dealer set up will void your warranty coverage WARRANTY COVERAGE AND EXCLUSIONS LIMITATIONS OF WARRANTIES AND REMEDIES The Polaris limited warranty excludes any failures that are not caused by a defect in ma terial or workmanship This warranty does not cover accidental damage normal wear and tear abuse or improper handling This warranty also does not cover any vehicle that has been altered structurally neglected improperly maintained used for racing or used for purposes other than for which it was manufactured or for any damages which occur during trailer transit or as a result of unauthorized service or the use of unauthorized parts In addition this warranty does not cover physical damage to paint or finish stress cracks tearing or puncturing of upholstery material corrosion or defects in parts com ponents or the vehicle caused by fire explosions or any other cause beyond Polaris con trol This warranty does not cover the use of unauthorized lubricants chemicals or fuels that are not compatible with the vehicle The exclusive remedy for breach of this warranty shall be at Polaris exclusive option repair or repl
37. d dealer There will also be no charge for any diagnostic labor performed at an authorized dealer which leads to the determination that a warranted emission related part is defective Any warranted part which is not scheduled for replacement as required maintenance or which is scheduled only for regular inspection to the effect of repair or replace as necessary shall be warranted for the warranty period Any warranted part which is scheduled for replacement as required maintenance shall be warranted for the period of time up to the first scheduled replacement of that part This warranty shall apply only towards the repair replacement and or adjustment of the component parts listed below Emission Related Parts Covered Under This Warranty 1 Fuel Metering System i Carburetor and internal parts and or pressure regulator or fuel injection system 1 Air fuel ratio feedback and control system if applicable iii Cold start enrichment system if applicable iv Regulator assy gaseous fuel if applicable 2 Air Induction System i Intake manifold if applicable ii Air filter 3 Ignition System i Spark plugs ii Magneto or electronic ignition system iii Spark advance retard system if applicable 4 Exhaust manifold if applicable 5 Miscellaneous Items Used in Above Systems i Electronic controls if applicable ii Hoses belts connectors and assemblies iii Filter lock assy gaseous fuel if applicable If an au
38. e No person under the age of five years may ride in the RANGER To wear the seat belt properly follow this procedure 1 Place the belt across your lap as low on your hips as possible taking care that the belt is not twisted 2 Push the latch plate into the buckle until it clicks 3 Release the strap it will self tighten NOTE The center belt must be tightened manually by pulling on the strap To unfasten press the square red button in the buckle s center 27 FEATURES AND CONTROLS Console Cup Holder Indicator Lights Shift Lever Light Switch AWD Differential Switch if equipped Hour Meter Glove Box with Lid 12V Accessory Plug Storage Tray Choke Knob Ignition Switch Differential Lock Lever if equipped Storage Box ONU ROO SND erem WN 28 FEATURES AND CONTROLS Gear Selector 1 RANGER 2X4 4X4 H High Gear L Low Gear N Neutral R Reverse RANGER TM H High Gear N Neutral nb R Reverse R NOTE Low is the primary driving range tor the RANGER 2X4 and 4X4 High is intended for use on hard packed surfaces with light loads To change gears stop the vehicle and with the engine idling move the lever to the desired gear Do not attempt to shift gears with engine speed above idle or while the vehicle is moving x x D Z rr z Always place the transmission in gear with the parking brake locked whenever the
39. e it s inclined MAINTENANCE AND LUBRICATION Spark Arrestor Use the following procedure to periodically purge accumulated carbon from the exhaust pipe 1 Remove the arrestor clean out plugs 1 located on the bottom of the muffler Place the transmission in neutral and start the engine Purge accumulated carbon from the system by momentarily revving the engine several times If carbon is expelled cover or plug the exhaust outlet 2 and rap on the pipe around the clean out plugs while revving the engine several more times If particles are still suspected to be in the muffler elevate the rear of the vehicle one foot higher than the front Set the parking brake and block the wheels Make sure the vehicle is in neutral and repeat steps 2 and 4 If particles are still suspected to be in the muffler drive the vehicle onto the incline so the front of the vehicle is one foot higher than the rear Set the parking brake and block the wheels Make sure the vehicle is in neutral and repeat steps 3 and 4 until no more particles are expelled when the engine is revved Stop the engine and allow the arrestor to cool Reinstall the arrestor plugs and remove the outlet cover or plug 83 MAINTENANCE AND LUBRICATION Throttle System 4 amp WARNING Failure to check or maintain proper operation of the throttle system can result in an accident and lead to serious injury or death if the throttle pedal sticks during operation
40. e the fill plug and check the oil level 3 Add the recommended hub fluid as needed 4 Reinstall the fill plug Torque to specification See page 68 Oil Change 1 Support the vehicle securely with a jackstand 2 Remove the front tire on the driver s side 3 Remove the fill plug 4 Remove the gearcase drain plug 2 located on the bottom right hand side and drain the oil into a drain pan Discard used oil properly 5 Clean and reinstall the drain plug Torque to specification See page 68 6 Add 5 oz 150 ml of the recommended hub fluid Refer to the Gearcase Specifications Chart on page 68 7 Reinstall the fill plug Torque to specification See page 68 8 Check for leaks 70 MAINTENANCE AND LUBRICATION Gearcases Rear Gearcase Always check and change the rear gearcase oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 53 Maintain the oil level even with the bottom thread of the fill plug hole We recommend the use of Polaris ATV Angle Drive Fluid See page 101 for the part numbers of Polaris products The rear gearcase fill plug 1 is on the driver s side of the rear gearcase Oil Check 1 Position the vehicle on a level surface 2 Remove the fill plug and check the oil level 3 Add the recommended fluid as needed 4 Reinstall the fill plug Torque to specification See page 68 Oil Change 1 Remove the fill plug 2 Remove the drain plug 2 from t
41. educe your alertness and slow your reaction time In most states and provinces it s prohibited by law to drive while intoxicated or under the influence of drugs 13 SAFETY Operator Safety 4 amp WARNING 14 POTENTIAL HAZARD Operating this vehicle at excessive speeds WHAT CAN HAPPEN Loss of control accident HOW TO AVOID THE HAZARD Always travel at a speed proper for the terrain visibility and operating conditions and your experience WARNING POTENTIAL HAZARD Attempting jumps and other stunts WHAT CAN HAPPEN Loss of control accident and or vehicle overturn HOW TO AVOID THE HAZARD Never attempt jumps and other stunts Avoid exhibition driving WARNING POTENTIAL HAZARD Operating on frozen bodies of water WHAT CAN HAPPEN Severe injury or death can result if the vehicle and or the operator fall through the ice HOW TO AVOID THE HAZARD Never operate the RANGER on a frozen body of water SAFETY Operator Safety 4 WARNING POTENTIAL HAZARD Failure to inspect the vehicle before operating Failure to properly maintain the vehicle WHAT CAN HAPPEN Accident equipment damage HOW TO AVOID THE HAZARD Always inspect your RANGER before each use to make sure it s in safe operating condition Always follow the inspection and maintenance procedures and schedules described in the Owner s Manual 4 WARNING POTENTIAL HAZARD Failure to use extra caution when operating this vehicle on unfamiliar terrain W
42. eeded Wiring 100 H 12M Inspect for wear routing security apply dielectric grease to connectors subjected to water mud etc 12M Inspect clean replace worn parts 2M a Inspect replace as needed Change every two years bearings Adjust as needed Inspect periodically adjust Toe adjustment when parts are replaced Auxiliary brake if Inspect daily adjust as needed Adjust as needed p Perform these procedures more often for vehicles subjected to severe use E Emission Related Service m Have an authorized Polaris dealer perform these services equipped Headlight aim 1 Clutches drive and driven Ll HN Ri E 57 MAINTENANCE AND LUBRICATION Lubrication Recommendations Check and lubricate all components at the intervals outlined in the Periodic Maintenance Chart beginning on page 53 Items not listed in the chart should be lubricated at the General Lubrication interval Lubrication Chart Key p gt More often under severe use such as wet or dusty conditions Polaris Premium all Season Grease or grease conforming to NLGI No 2 such as Conoco Superlube M or Mobilegrease Special e Use Polaris Premium U Joint Lube every 500 miles before long periods of storage or after pressure washing or submerging im Engine Oil Polaris Premium 4 Add to proper level on dipstick Synthetic OW40 Brake Fluid DOT 3or DOT 4 Maintain level between fill lines See page
43. engine must be designed built and equipped to meet the state s stringent anti smog stan dards Polaris must warrant the emission control system on your LSI engine for the peri od of time described below provided there has been no abuse neglect or improper maintenance of your LSI engine Your emission control system includes parts such as the carburetor and the ignition sys tem Also included may be hoses connectors and other emission related assemblies Where a warrantable condition exists POLARIS will repair your LSI engine at no cost to you including diagnosis parts and labor Manufacturer s Warranty Coverage The 2005 and later LSI engines are warranted for two 2 years If any emission related part on your LSI engine is defective the part will be repaired or replaced by POLARIS Owner s Warranty Responsibilities As the LSI engine owner you are responsible for the performance of the required maintenance listed in your Owner s Safety and Maintenance Manual herein Own er s Manual POLARIS recommends that you retain all receipts covering mainten ance on your LSI engine but POLARIS cannot deny warranty solely for the lack of receipts or for your failure to ensure the performance of all scheduled maintenance Asthe LSI engine owner you should however be aware that POLARIS may deny you warranty coverage if your LSI engine or a part has failed due to abuse neglect improper maintenance or unapproved modifications
44. eration on Public Lands in the U S A Your Polaris vehicle has a spark arrestor that was tested and qualified to be in accordance with the USDA Forest Service Standard 5100 1C Federal law requires that this spark arrestor be installed and functional when the vehicle is operated on public lands Operation of off road vehicles on public lands in the U S A is regulated by 43 CFR 8343 Violations are subject to monetary penalties Federal regulations can be viewed online at Ww gpoaccess gov ecfr Electromagnetic Interference This spark ignition system complies with Canadian ICES 002 This vehicle complies with European directives 97 24 EC and 89 336 EEC 52 MAINTENANCE AND LUBRICATION Periodic Maintenance Chart Careful periodic maintenance will help keep your vehicle in the safest most reliable condition Inspection adjustment and lubrication of important components are explained in the periodic maintenance chart Inspect clean lubricate adjust and replace parts as necessary When inspection reveals the need for replacement parts use genuine Polaris parts available from your Polaris dealer Record maintenance and service in the Maintenance Log beginning on page 120 NOTE Service and adjustments are important for proper vehicle operation If you re not familiar with safe service and adjustment procedures have a qualified dealer perform these operations Maintenance intervals in the following chart are based upon average
45. ever descend a hill at high speed Excessive speed may result in loss of vehicle control and lead to serious injury or death Always operate slowly when traveling downhill Avoid descending a hill at an angle which would cause the vehicle to lean sharply to one side Travel straight downhill when possible OPERATION Driving Safely Driving Through Water 4 WARNING The large tires on your RANGER may cause the vehicle to float in deep or fast flowing water which could result in loss of control and lead to serious injury or death Never cross deep or fast flowing water with your RANGER Your Polaris RANGER can operate through water up to a maximum recommended depth equal to the floorboards 1 Follow these procedures when operating through water 1 Always determine water depths and current before entering 2 Choosea crossing where both banks have gradual inclines 3 Proceed slowly avoiding rocks and obstacles 4 After leaving water always dry the brakes by applying light pressure to the lever repeatedly until braking action is normal NOTE After running your vehicle in water it s critical that you perform the services outlined in the Periodic Maintenance Chart beginning on page 53 Give special attention to engine transmission oil front and rear gearcases and all grease ittings CAUTION Immersion can result in major damage if the vehicle isn t serviced correctly and promptly After immersion always ta
46. feet on the floor 4 Proceed at a steady rate of speed and throttle opening 4 WARNING Climbing hills improperly can cause loss of control or vehicle overturn Always check the terrain carefully before climbing a hill Braking and handling are greatly affected when operating in hilly terrain Improper procedure could cause loss of control or overturn and result in serious injury or death Avoid climbing steep hills 15 maximum Use extreme caution when operating on hills and follow proper operating procedures outlined in the owner s manual Never climb hills with excessively slippery or loose surfaces Never open the throttle suddenly Never go over the crest of a hill at high speed An obstacle a sharp drop or another vehicle or person could be on the other side of the hill 39 OPERATION Driving Safely Sidehilling 4 WARNING Crossing hillsides or turning on hills can result in loss of control or vehicle overturn resulting in severe injury or death Avoid crossing the side of a hill when possible When unavoidable exercise extreme caution Avoid operating on steep hills 15 maximum Driving Downhill Whenever descending a hill follow these precautions 1 Proceed directly downhill 2 Slow down 3 Apply the brakes slightly to aid in slowing 4 WARNING 40 Traveling downhill improperly could cause loss of control or vehicle overturn Always check the terrain carefully before descending a hill N
47. ff season storage the following steps should be taken to preserve its condition 1 Perform all necessary repairs and thoroughly clean the vehicle 2 Remove the spark plug and pour approximately one ounce of Premium 4 oil into the cylinder Operate the starter for a few seconds and reinstall the spark plug 3 Remove the battery Store it in a cool dry place out of the sun 4 Lubricate suspension pivot points lower steering post and rear axle fittings 5 Drain the engine side cover 4X4 6 Block the vehicle so all tires are suspended off the ground 7 Spray oil on all unpainted metal surfaces to prevent rusting Avoid getting oil on rubber parts or in the brakes 8 Lubricate all cables 9 Tiea plastic bag over the exhaust pipe and air cleaner inlet to prevent moisture or small animals from entering 10 Cover the vehicle with a canvas cover Do not use plastic or coated materials since they do not allow ventilation for the vehicle 96 MAINTENANCE AND LUBRICATION Removal from Storage 1 Check the battery electrolyte level and charge the battery if necessary Install it in the vehicle Make sure the battery vent hose is routed properly and that it s not pinched or restricted in any way 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 33 NOTE Tightness of the bolts nuts and other fasteners should be checked by an
48. for AWD operating instructions See page 49 for differential operating instructions Differential Lock Lever 4 TM To lock the differential on the TM push the lock lever up See page 49 for differential operating instructions 30 FEATURES AND CONTROLS Brake Pedal 1 Depress the brake pedal to slow or stop the vehicle Throttle Pedal 2 Push the pedal down to increase engine speed Spring pressure returns the pedal to the rest position when released Always check that the throttle pedal 1 returns normally before starting the engine Make sure there s 3 adequate throttle pedal freeplay 2 See page 85 for throttle pedal adjustment procedures Parking Brake Lever 3 Engage the parking brake when parking the vehicle to help prevent the vehicle from rolling To apply the parking brake push down on the pedal with your foot Parking Brake Release 4 To release the parking brake pull the release handle Spring pressure helps return the lever to the released position Make sure the parking brake lever is functioning properly before each operation 31 OPERATION Vehicle Break In Period The break in period for your new Polaris RANGER is the first twenty hours of operation or the time it takes to use the first two tanks full of gasoline No single action on your part is as important as a proper break in period Careful treatment of a new engine will result in more efficient performance and longer life for t
49. gine and inspect for leaks Re check the oil level on the dipstick and add oil as necessary to bring the level to the upper mark on the dipstick Dispose of used filter and oil properly 63 MAINTENANCE AND LUBRICATION Engine Oil Oil Pump Priming 2x4 4X4 This priming procedure must be performed whenever the oil hose connection between the oil tank and pump inlet has been disconnected 1 Clamp or pinch off the vent line 1 approximately 2 from the oil tank 2 between the end of the oil tank vent fitting and the vent line s pressure relief slit 3 2 Run the engine for 15 20 seconds 3 Remove the vent line clamp The oil pump will now be properly primed and ready for operation 64 MAINTENANCE AND LUBRICATION Engine Oil Oil Check TM 1 2 3 NOTE Arising oil level between checks Position the vehicle on a level surface Start the engine and let it idle for 20 30 seconds Stop the engine and remove the seat as described on page 27 Remove the service panel 1 by pulling upward Remove the dipstick 2 and wipe it dry with a clean cloth Replace the dipstick and seat it completely Remove the dipstick and check to see that the oil level is between the FULL 3 and ADD 4 marks Add oil through the oil filler hole 5 as needed Do not overfill in cool weather driving can indicate moisture collecting in the oil reservoir If the oil level is over the full mark change the
50. handling and control of the vehicle and may cause the vehicle to go out of control Avoid operating the vehicle on pavement If you must operate on a paved surface travel slowly and do not make sudden turns or stops WARNING POTENTIAL HAZARD Operating this vehicle without proper instruction WHAT CAN HAPPEN Loss of control accident HOW TO AVOID THE HAZARD The risk of an accident is greatly increased if the operator does not know how to operate the vehicle properly in different situations and on different types of terrain All operators must read and understand the Owner s Manual and all warning and instruction labels before operating the vehicle SAFETY Operator Safety 4 WARNING POTENTIAL HAZARD Operating this vehicle on public streets roads or highways WHAT CAN HAPPEN Collision with another vehicle HOW TO AVOID THE HAZARD Never operate this vehicle on any public street road or highway including dirt or gravel In many states it s illegal to operate vehicles of this type on public streets roads and highways 4 WARNING POTENTIAL HAZARD Operating this vehicle after consuming alcohol or drugs WHAT CAN HAPPEN Could seriously affect your judgment Could cause you to react more slowly Could affect your balance and perception Could result in an accident HOW TO AVOID THE HAZARD Driving a RANGER requires your full attention DO NOT drink alcohol or use drugs or medications before or while driving They will r
51. he bottom of the gearcase and drain the oil into a drain pan Discard used oil properly 3 Clean and reinstall the drain plug Torque to specification See page 68 4 Add the recommended fluid Refer to the Gearcase Specifications Chart on page 68 5 Reinstall the fill plug Torque to specification See page 68 6 Check for leaks 71 MAINTENANCE AND LUBRICATION Cooling System 2X4 4X4 Operation The engine coolant level is controlled or maintained by the recovery system The recovery system components are the overflow bottle radiator filler neck radiator pressure cap and connecting hose As coolant operating temperature increases the expanding heated excess coolant is forced out of the radiator past the pressure cap and into the overflow bottle As engine coolant temperature decreases the contracting cooled coolant is drawn back up from the tank past the pressure cap and into the radiator NOTE Some coolant level drop on new vehicles is normal as the System is purging itself of trapped air Observe coolant levels and maintain as recommended by adding coolant to the overflow bottle Adding or Changing Coolant To ensure that the coolant maintains its ability to protect the engine we recommend that the system be completely drained every two years and a fresh mixture of antifreeze and water added Polaris recommends the use of Polaris Premium 60 40 anti freeze coolant or a 50 50 mix
52. he engine Perform the following procedures carefully 32 CAUTION Excessive heat build up during the first three hours of operation will damage close fitted engine parts Do not operate at full throttle or high speeds for extended periods during the first three hours of use Use of any oils other than those recommended by Polaris may cause serious engine damage We recommend the use of Polaris Premium 4 Synthetic Oil for your 4 cycle engine Fill the fuel tank with gasoline Heed the gasoline warnings on page 22 Check the oil level on the dipstick See page 61 Add Polaris Premium 4 Synthetic Oil if necessary to maintain the oil level in the normal safe operating range Drive slowly at first Select an open area that allows room to familiarize yourself with vehicle operation and handling Vary throttle positions Do not operate at sustained idle Perform regular checks on fluid levels controls and areas outlined on the daily pre ride inspection checklist See page 33 Pull only light loads During the break in period change both the oil and the filter at 25 hours OPERATION Pre Ride Inspection WARNING If a proper inspection is not done before each use severe injury or death could result Always inspect the vehicle before each use to ensure it s in proper operating condition Pre Ride Checklist Brake system lever travel Brake fluid Ensure proper operation Ensure proper level Inspect lubricate if
53. he vehicle is not in use WARNING After any overturn or accident have a qualified service dealer inspect the entire vehicle for possible damage including but not limited to brakes throttle and steering systems CAUTION Always keep combustible materials away from the exhaust system Exposure to the hot components could result in a fire 17 SAFETY Safety Decals and Locations Warning decals have been placed on the RANGER for your protection Read and follow the instructions of the decals on the RANGER carefully If any of the decals depicted in this manual differ from the decals on your RANGER always read and follow the instructions of the decals on the RANGER If any decal becomes illegible or comes off contact your Polaris dealer to purchase a replacement Replacement safety decals are provided by Polaris at no charge The part number is printed on the decal 18 4 WARNING VEHICLE ROLLOVER could cause severe injury or death The cab frame is not designed or intended to provide rollover protection ALWAYS WEAR YOUR SEAT BELT for maximum protection 7172676 Location 1 A WARNING Moving parts hazard under belt clutch guard prevent serious injury do not operate vehicle with guard removed Do not modify engine or clutch Doing so can cause part failure possible imbalance and excessive engine RPM which can result in serious injury or death NO STEP ns Location 2 WARNING
54. ing 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 Wet brakes may have reduced stopping ability Test your brakes after leaving water If necessary apply them lightly several times to let friction dry out the pads Always be sure there are no obstacles or people behind your vehicle when operating in reverse When it s safe to proceed in reverse move slowly Avoid turning at sharp angles in reverse Always use the proper size and type of tires specified in this manual Always maintain proper tire pressure as specified on page 103 SAFETY Operator Safety Never modify this vehicle through improper installation or use of accessories Never exceed the stated load capacity for this vehicle Cargo should be properly distributed and securely attached Reduce speed and follow the instructions in this manual for hauling cargo or pulling a trailer Allow a greater distance for braking Always wear the seat belts when operating this vehicle Seat belts reduce the severity of injury in case of a sudden stop or collision Always keep arms and legs inside the cab frame while the vehicle is in motion Always apply the parking brake before getting out of the vehicle See page 31 Always activate the foot pedal brake before releasing the park brake Alwa
55. intenance Record Use the following chart to record periodic maintenance DATE MILES KM TECHNICIAN SERVICE PERFORMED COMMENTS 120 MAINTENANCE LOG DATE MILES KM TECHNICIAN SERVICE PERFORMED COMMENTS 121 INDEX A Age Restrictions 5 Air Filter 2x4 4 4 78 Air Filter TM 80 All Wheel Drive AWD 49 50 Auxiliary Outlet 26 AWD Switch 4X4 30 B Battery Li zi esc bss 98 100 Battery Fluid 99 Battery Installation 100 Battery Removal 99 Battery Storage 100 Brake 86 Brake Inspection 87 Brake Lights 93 Brake Pedal 31 Brakes 0 0 00 00 000 86 87 Braking seed tattered des 36 Breather Filter and Hoses 79 C Carburetor Adjustment 81 Cleaning Your RANGER 95 Component Locations 23 25 C ns0le Ier De ves 28 Coolant e vo ree ever OE 72 Coolant 1 73 Cooling System 2x4 4X4 72 74 Cooling System Operation 72 Crankcase Emission Control System 51 Cylinder Head Torque 88 D Decals and Locations 18 21 Differential Operation Modes 49 Differential Lock Operation 49 Differential Lock Switch 4X4 30 Disengaging AWD
56. ion the vehicle on a level surface 2 Remove the fill plug 1 which is located on the rear of the vehicle 3 Check the oil level and add as needed 4 Reinstall the fill plug Torque to specification See page 68 Oil Change The drain plug 2 is located on the bottom of the transmission Access the drain plug through the drain hole in the skid plate 1 Remove the fill plug 2 Remove the drain plug and drain the oil into a drain pan Dispose of used oil properly 3 Wipe the magnetic end of the drain plug clean to remove accumulated metallic filings 2 4 After the oil has drained completely install a new sealing washer and reinstall the drain plug Torque to specification See page 68 NOTE Refer to the Gearcase Specifications Chart on page 68 5 Add the recommended oil as needed Do not overfill 6 Reinstall the fill plug Torque to specification 7 Check for leaks 69 MAINTENANCE AND LUBRICATION Gearcases Front Gearcase 4X4 Always check and change the front gearcase oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 53 Maintain the oil level even with the bottom thread of the fill plug hole We recommend the use of Polaris Premium Demand Drive Hub Fluid See page 101 for the part numbers of Polaris products The front gearcase fill plug 1 is located on the right side of the front gearcase Oil Check 1 Position the vehicle on a level surface 2 Remov
57. ith this vehicle To avoid injury and property damage always heed the warnings and towing capacities outlined on page 47 Auxiliary Outlet 1 The 12 volt receptacle has spade connections on the back that may be used to power an auxiliary light or other optional accessories or lights The connections are behind the console under the hood Fuel Cap Fuel Gauge 2 The fuel tank filler cap is located on the right hand side of the vehicle near the passenger seat It has a built in fuel gauge that indicates the amount of fuel remaining in the tank When the indicator needle nears the E empty mark refuel at the earliest opportunity When refueling always use either leaded or unleaded gasoline with a minimum pump octane number of 87 R M 2 octane 26 FEATURES AND CONTROLS Seat Removal Pull up on the front of the seat and slide it toward the front of the vehicle Install the seat by sliding the tabs into the rear of the seat base Push down firmly on the front of the seat until the pins are fully seated into the grommets Seat Belts The RANGER is equipped with lap style seat belts for the operator and passenger 4 WARNING Falling from a moving vehicle could result in serious injury or death Always fasten your seat belt securely before operating or riding in the RANGER Passengers under five years of age require special restraints which are not available with this vehicl
58. ke the vehicle to your dealer service Do not start the engine If it s impossible to bring the vehicle to your dealer before starting the engine perform the service outlined on page 77 and take the vehicle to your dealer at the first opportunity 41 OPERATION Driving Safely Driving Over Obstacles SM wrk ee Be alert Look ahead and learn to read the terrain you re traveling on Watch for hazards such as logs rocks and low hanging branches 4 amp WARNING Severe injury or death can result if your vehicle suddenly comes in contact with a hidden obstacle Not all obstacles are immediately visible Reduce speed and travel with caution in unfamiliar terrain 42 OPERATION Driving Safely Driving in Reverse Follow these guidelines when operating in reverse 1 Back slowly 2 Apply the brakes lightly for stopping 3 Avoid turning at sharp angles 4 Always avoid backing downhill 5 Never open the throttle suddenly while backing 6 Always inspect left and right fields of vision before backing 4 WARNING Failure to use caution when operating in reverse can result in serious injury or death Before shifting into reverse always check for obstacles or people behind the vehicle and follow the reverse operation procedures outlined in this manual Always back slowly 43 OPERATION Driving Safely Parking on an Incline Avoid parking on an incline if possible If it s u
59. ked When the rear differential is unlocked the rear wheels can rotate at different speeds Unlock the differential to make maneuvering easier and minimize damage to turf To unlock the differential on the TM push the lock lever down To unlock the differential on the 2X4 and 4X4 move the AWD Differential Switch to the lowest OFF position 49 OPERATION All Wheel Drive AWD When in AWD the front gearcase will automatically engage anytime the rear wheels lose traction When the rear wheels regain traction the front gearcase will automatically disengage There is no limit to the length of time the vehicle may remain in AWD Engaging Front Gearcase The AWD switch may be turned on or off while the vehicle is moving Initially the vehicle s electronic system will not enable the AWD until the engine RPM is below 3100 Once enabled the AWD remains enabled until the AWD switch is turned off If the switch is turned off while the front gearcase is moving it will not disengage until the rear wheels regain traction See page 49 for AWD switch operation Engage the AWD before getting into conditions where front wheel drive may be needed If the rear wheels are spinning release the throttle before switching to AWD CAUTION Switching to AWD while the rear wheels are spinning may cause severe drive shaft and gearcase damage Always switch to AWD while the rear wheels have traction or are at rest 50 EMISSION CONTROL
60. kit with your vehicle at all times A screwdriver An open end wrench 8 10 mm An open end wrench 12 14 mm A tire pressure gauge A spark plug wrench and handle A spanner wrench for shock adjustment NOTE Additional tools will be necessary to perform routine 94 maintenance MAINTENANCE AND LUBRICATION Cleaning Your RANGER Keeping your vehicle clean will not only improve its appearance but it can also extend the life of various components With a few precautions your vehicle can be cleaned much like an automobile The best and safest way to clean your vehicle is with a garden hose and a pail of mild soap and water Use a professional type washing mitten cleaning the upper body first and the lower parts last Rinse with water frequently and dry with a chamois to prevent water spots NOTE f warning labels are damaged contact your Polaris dealer for free replacement If a high pressure type car wash system is used extreme care must be taken to avoid water damage to the wheel bearings transmission seals body panels brakes headlights and warning labels Many expensive repair bills can result from using high pressure detergent systems NOTE Ifa high pressure car wash is used grease all zerk fittings immediately after washing Also run the vehicle to evaporate any water that may have entered the engine or exhaust system 95 MAINTENANCE AND LUBRICATION Storage If your vehicle is to be placed in extended or o
61. l properties result in more efficient operation more power output and lower fuel consumption Although Polaris Premium 4 is the only oil recommended for use in this engine use of any API certified SH oil is allowable as long as it s 0W 40 Oil may need to be changed more frequently if Polaris Premium 4 is not used Follow the manufacturer s recommendations for ambient temperature operation CAUTION Mixing brands or using a non recommended oil may cause serious engine damage We recommend the use of Polaris Premium 4 All Season synthetic oil or API certified SH oil OW 40 Never substitute or mix oil brands Use only OW 40 4 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 60 1 2 3 MAINTENANCE AND LUBRICATION Engine Oil Always check and change the oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 53 We recommend the use of Polaris Premium 4 All Season Synthetic engine oil Oil Check 2x4 4X4 The oil tank is located under the seat Position the vehicle on a level surface Start the engine and let it idle for 20 30 seconds Stop the engine and remove the seat see page 27 Remove the dipstick 1 and wipe it dry with a clean cloth Reinstall the dipstick and scre
62. le Lean Fuel Mixture Cause Solution Possible Rich Fuel Mixture Cause Solution 109 TROUBLESHOOTING Engine Stops or Loses Power Possible Cause Solution Kinked or plugged fuel vent line Water present in fuel Overuse of choke Fouled or defective spark plugs Worn or defective spark plug wires Incorrect spark plug gap or heat range Loose ignition connections Low battery voltage Clogged air filter Other mechanical failure Overheated engine Clean radiator screen and core if equipped Clean engine exterior See your Polaris dealer 110 WARRANTY LIMITED WARRANTY Polaris Sales Inc 2100 Highway 55 Medina MN 55340 gives a SIX MONTH LIM ITED WARRANTY on all components of the Polaris RANGER against defects in mate rial or workmanship This warranty covers the parts and labor charges for repair or replacement of defective parts which are covered by this warranty This warranty begins on the date of purchase This warranty is transferrable to another consumer during the warranty period through a Polaris dealer REGISTRATION At the time of sale the Warranty Registration Form must be completed by your dealer and submitted to Polaris within ten days Upon receipt of this registration Polaris will record the registration for warranty No verification of registration will be sent to the purchaser as the copy of the Warranty Registration Form will be the warranty entitle ment If you have not signed the original registration and re
63. line powered engine exhaust fumes are poisonous and can cause loss of consciousness and death in a short time FEATURES AND CONTROLS Some Polaris vehicles are equipped with special features such as the cab frame Not all models come with all features Refer to the specifications section beginning on page 102 Component Locations or trot POLams RAAZ Cab Frame if equipped Hip Bar Console Steering Wheel Seat Cargo Box Seat Belts Fuel Tank Cap Fuel Gauge Battery cJ ON PR Nr 23 FEATURES AND CONTROLS Component Locations 10 Headlights 11 Radiator if equipped 12 Front Bumper Brush Guard 13 Hood Hold Down Strap 24 FEATURES AND CONTROLS Component Locations 14 Taillights 15 Tailgate 16 Tailgate Latch Release 17 Muffler Spark Arrester 18 CV Boot Rear Caliper 19 Air Box 20 Receiver Hitch 25 FEATURES AND CONTROLS Indicator Lights The indicator lights on the console display 1 High Gear 2 Low Gear if equipped 3 Neutral Gear 4 Reverse Gear 5 High Temperature 6 Brakes Trailer Hitch Bracket 3 This vehicle is equipped with a receiver hitch bracket for a trailer hitch Trailer towing equipment is not supplied w
64. lug Stopping the Engine 1 Release the throttle pedal completely and brake to a complete stop 2 Put the gear shift lever into neutral 3 Apply the parking brake 4 WARNING A rolling vehicle can cause property damage and serious injury Always apply the parking brake after stopping the engine 35 OPERATION Braking 1 Release the throttle pedal completely 2 Press on the brake pedal evenly and firmly NOTE Practice starting and stopping using the brakes until you re familiar with the controls NOTE When the throttle pedal is released completely and the engine speed drops near an idle the vehicle has no engine braking 4 WARNING Failure to allow for increased braking distance when hauling cargo or towing a trailer may result in accident and injury Always slow down and allow additional braking distance when towing or hauling cargo 36 OPERATION Driving Safely Driving Procedures REN A Pw Sit in the driver s seat and fasten the seat belt After starting the engine and allowing it to warm up shift the transmission into gear Check your surroundings and determine your path of travel Release the parking brake Keeping both hands on the steering wheel slowly depress the throttle with your right foot and begin driving Vehicle speed is controlled by the amount of throttle opening and Polaris Variable Transmission PVT shifting is automatic Drive slowly Practice maneuvering and u
65. n or leaks Replace as needed 5 Reinstall the filter with the arrow pointing toward the engine and secure the clamps CAUTION Operation of the vehicle without a breather filter can cause engine damage Always reinstall the breather filter after removing it for service Fuel Filter Your Polaris vehicle is equipped with an in line fuel filter Have your dealer replace it after every 100 hours of operation Do not attempt to clean the fuel filter 79 MAINTENANCE AND LUBRICATION Filter Systems TM Air Filter Always check and change the air filter at the intervals outlined in the Periodic Maintenance Chart beginning on page 53 1 Remove the seat to access the air cleaner 2 Remove the breather hose 1 from the cylinder 3 Remove the wing nut 2 and remove the air cleaner cover 3 4 Remove the primary filter 4 and the secondary filter 5 NOTE Do not attempt to clean the primary filter Install new 5 Wash the secondary foam filter with hot soapy water Rinse and dry thoroughly 6 Inspect the filter for tears or damage Replace with a new filter if needed 7 Apply foam filter oil or clean engine oil and squeeze the filter until excess oil is removed 8 Reassemble all components 80 MAINTENANCE AND LUBRICATION Carburetor Engine Idle RPM Adjustment The idle speed adjustment should be performed as outlined in the Periodic Maintenance Chart or whenever the idle speed is changed
66. navoidable follow these precautions 1 Place the transmission in gear 2 Setthe parking brake 3 Block the rear wheels on the downhill side 4 WARNING A rolling vehicle can cause property damage and serious injury Always apply the parking brake after stopping the engine Always block the downhill side of the wheels if leaving the vehicle on a hill or park the vehicle in a sidehill position instead Operating the vehicle while the parking brake is engaged could cause loss of control and result in serious injury or death Always disengage the parking brake before operating the vehicle 44 OPERATION Hauling Cargo 4 amp WARNING Hauling cargo improperly can alter vehicle handling and may cause loss of control or brake instability which can result in serious injury or death Always follow these precautions when hauling cargo Always load the cargo box with the load as far forward as possible Always operate the vehicle with extreme care when hauling or towing loads Slow down and arive in the lowest gear available The RANGER has been designed to carry or tow specific capacities Always read and understand the load distribution warnings listed on the warning labels Never exceed the following capacities Maximum Capacities Cargo Box Level Ground RANGER 4X4 1500 Ibs 681 kg 1000 Ibs 454 kg RANGER 2X4 1250 Ibs 567 kg 750 Ibs 340 kg RANGER 1250 Ibs 567 kg 750 Ibs 340 kg 4 WARNING Drivi
67. ng which could result in vehicle damage or personal injury Always maintain proper tire pressure When replacing tires always use original equipment size and type Tire Tread Depth Always replace tires when tread depth is worn to 1 8 3 cm or less 1 8 3 cm Axle and Wheel Nut Torque Specifications Inspect the following items occasionally for tightness and if they ve been loosened for maintenance service Location Specification Front Wheel Nuts 35 ft Ibs 47 Nm Rear Wheel Nuts 35 ft Ibs 47 Nm Front Spindle Nut 70 ft Ibs 95 Nm Center and Rear Hub 110 ft Ibs 150 Nm Retaining Nuts 90 MAINTENANCE AND LUBRICATION Tires amp WARNING Improperly installed wheels can adversely affect tire wear and vehicle handling which can result in serious injury or death Always ensure that all nuts are torqued to specification Do not service axle nuts that have a cotter pin installed See your Polaris dealer Wheel Removal 1 2 3 4 Stop the engine place the transmission in gear and lock the parking brake Loosen the wheel nuts slightly Elevate the side of the vehicle by placing a suitable stand under the frame Remove the wheel nuts and washers Remove the wheel Wheel Installation 1 3 4 With the transmission in gear and the parking brake locked place the wheel in the correct position on the wheel hub Be sure the valve stem is toward the outside and rotation
68. ng 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 SLST 45 OPERATION Hauling Cargo Dumping the Cargo Box 4 WARNING 6 7 8 Operating the vehicle while the cargo box is raised could result in severe injury The box could close unexpectedly and cause injury to the driver or passenger The rear tires will also catch the rear of a raised box damaging the vehicle and creating hazardous driving conditions Never operate this vehicle with the cargo box in the raised position Select a level site to dump the cargo box Do not attempt to dump or unload the vehicle while parked on an incline Set the parking brake Dismount the vehicle Ensure that the cargo is positioned evenly or toward the front of the cargo box Release the tailgate by pulling up on the tailgate latch Stand clear and pull up on the cargo box release lever 1 Lift the front of the cargo box to dump the cargo Lower the cargo box and push down securely to latch 4 WARNING 46 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 fr
69. nge TM 66 67 Oil Check 2x4 4X4 61 Oil Check TM 65 Oil Pump Priming 2x4 4X4 64 Operator Safety 5 17 Parking Brake Adjustment 87 Parking Brake Inspection 87 Parking Brake Lever 31 Parking Brake Release 31 Parking on an Incline 44 Parking the RANGER 48 Periodic Maintenance Chart 53 57 Polaris Products 101 Pre Ride Inspection 33 Premium 4 Synthetic Oil 60 PVT Drying 76 PVTSyste m 4 e eR es 76 R Radiator and Cooling Fan 73 Radiator Coolant Level 74 Rear Gearcase 71 Rear Spring Adjustment 88 Removal from Storage 97 S Safety ivoire bep ess 5 22 Seat Belts 27 89 Seat Removal 27 Sidehiling 40 S Spark 82 83 Spark Plugs 75 Specifications 102 107 Starting a Cold Engine 34 Starting a Warm Engine 35 Starting the Engine 34 35 Steering Wheel Inspection 88 Stopping the Engine 35 Storage soya ee i nem ede me 96 Suspension Adjustment 2X4 4X4 88 SWITCHES ius e EEr E edes 30 T Throttle Cable Adjustment TM 85 Throttle Freeplay 84 Throttle Pedal 3
70. ngested into the PVT system Use the following instructions to dry it out before operating 1 76 Shift the transmission into neutral and apply full throttle for no longer than 10 seconds and repeat as necessary This will expel the moisture and air dry the belt and clutches Allow the engine RPM to settle to idle speed then shift the transmission to the lowest available range Test for belt slippage If the belt slips repeat the process Take the vehicle to your dealer for service as soon as possible MAINTENANCE AND LUBRICATION Vehicle Immersion CAUTION If your vehicle becomes immersed major engine damage can result if the vehicle is not thoroughly inspected Take the vehicle to your dealer before starting the engine If it s impossible to take your RANGER to a dealer before starting it follow the steps outlined below 1 Move the vehicle to dry land or at the very least to a water level below the floor 2 Disconnect the fuel pump wires 3 Remove the spark plug 4 Placea clean container under the engine and loosen the carburetor drain screw 1 two turns ce i RANGER 2X4 4X4 RANGER TM xd Turn the engine over several times with electric start Inspect the drained fuel for water or sediment Dry the spark plug and reinstall or install a new plug Tighten the carburetor drain screw Reconnect the fuel pump wires Attempt to start the engine If necessary repeat the drying procedure 10 Take
71. ntial safety hazard and increase the risk of bodily injury The warranty on your Polaris RANGER is terminated if any equipment has been added to the vehicle or if any modifications have been made to the vehicle that increase its speed or power NOTE The addition of certain accessories including but not limited to mowers blades tires sprayers or large racks may change the handling characteristics of the vehicle Use only Polaris approved accessories and familiarize yourself with their function and effect on the vehicle 10 SAFETY Operator Safety 4 amp WARNING POTENTIAL HAZARD Stalling rolling backwards while climbing a hill WHAT CAN HAPPEN Vehicle overturn HOW TO AVOID THE HAZARD Maintain a steady speed when climbing a hill If you lose all forward speed Apply the brakes Lock the parking brake after fully stopped If you begin rolling backwards Never apply engine power Apply the brake gradually When fully stopped lock parking brake In the event of an accident have a qualified service dealer check the complete vehicle for possible damage including but not limited to brakes throttle and steering 11 SAFETY Operator Safety 4 amp WARNING 12 POTENTIAL HAZARD Operating this vehicle on paved surfaces WHAT CAN HAPPEN Loss of control HOW TO AVOID THE HAZARD This vehicle s tires are designed for off road use only not for use on pavement Paved surfaces may seriously affect
72. nty or service bulletin coverage if you have any questions This policy does not apply to vehicles registered to government officials or military per sonnel on assignment outside the country of the selling dealer s authorized location This policy does not apply to Safety Recalls How to Get Service In the Country where your vehicle was purchased Warranty or Service Bulletin repairs must be done by an authorized Polaris dealer If you move or are traveling within the country where your vehicle was purchased Warranty or Service Bulletin repairs may be requested from any authorized Polaris dealer who sells the same line as your vehicle Outside the Country where your vehicle was purchased If you are traveling temporarily outside the country where your vehicle was purchased you should take your vehicle to an authorized Polaris dealer You must show the dealer photo identification from the country of the selling dealer s authorized location as proof of residence Upon residence verification the servicing dealer will be authorized to per form the warranty repair If You Move If you move to another country be sure to contact Polaris Customer Assistance and the customs department of the destination country before you move Vehicles importation rules vary considerably from country to country You may be required to present docu mentation of your move to Polaris Industries in order to continue your warranty cover age You may also be required
73. o the tank threads Continue to rotate the fitting until the nipple of the fitting aligns with the mark 4 on the tank NOTE Do not over tighten Maximum torque for the screen fitting is 25 ft Ibs 34 Nm 62 MAINTENANCE AND LUBRICATION Engine Oil Cil and Filter Change 2x4 4X4 8 9 10 11 12 13 Reattach the oil line Place shop towels beneath the oil filter 5 Using an oil filter wrench turn the filter counterclockwise to remove Using a clean dry cloth clean the filter sealing surface on the crankcase Lubricate the gasket on the new filter with a film of new engine oil Check to make sure the gasket is in good condition Also make sure the gasket from the old filter is not still on the engine Install the new filter and turn by hand until the filter gasket contacts the sealing surface then turn and additional 1 2 turn Approximately one cup of engine oil will remain in the crankcase To drain remove the drain plug on the lower right side of the crankcase NOTE The sealing surfaces on the drain plug and crankcase should 14 15 16 17 18 19 be clean and free of burrs nicks or scratches Reinstall the drain plug and torque to 14 ft Ibs 19 Nm Remove the dipstick and fill the tank with two quarts 1 9 I of Polaris Premium 4 Synthetic Oil Place the gear selector in neutral and set the parking brake Prime the oil pump using the procedure on page 64 Then stop the en
74. oint of adjuster 1 2 3 Throttle Cable Adjustment TM If the proper freeplay cannot be obtained with the throttle block adjuster adjust the cable at the carburetor using the following procedure 1 Remove the seat and loosen the clamp screw 1 and the throttle cable adjustment screw 2 2 Adjust the cable as needed 3 Tighten both screws and reinstall the seat 4 Check for proper throttle operation and correct freeplay in all steering wheel positions 85 MAINTENANCE AND LUBRICATION Brakes The front and rear brakes are hydraulic disc type brakes Press down on the brake pedal to engage the brakes See page 31 Brake Fluid Routine inspections are recommended to keep the brake system in good operating condition Inspect the level of the brake fluid before each operation Change the brake fluid at the intervals outlined in the Periodic Maintenance Chart beginning on page 53 The brake fluid should also be changed if it becomes contaminated if the fluid level is below the minimum or if the type and brand of the fluid in the reservoir are unknown 1 Position the vehicle on a level surface 2 View the brake fluid level at the reservoir 1 under the hood Maintain the fluid level between the upper MAX and lower MIN marks on the reservoir 3 Ifthe fluid level is lower than the lower level line add brake fluid to the upper MAX line 4 Apply the brake
75. onditions Operate this vehicle on HILLS steeper than 15 degrees To prevent flipover on hilly terrain use throttle and brakes gradually ALWAYS Avoid paved surfaces which may adversely affect handling and control Use proper RIDING TECHNIQUES to avoid vehicle overturns on hills and rough terrain and in turns e Wear eye protection REVERSE operation can be dangerous even at low speeds Steering becomes difficult To prevent flipover avoid sharp turns The park emergency brake lever will supply increased braking but should be used as an emergency or parking brake only READ OWNER S MANUAL FOLLOW ALL INSTRUCTIONS AND WARNINGS IF OWNER S MANUAL IS MISSING CONTACT A POLARIS DEALER FOR A REPLACEMENT THIS GENERAL PURPOSE OFF ROAD UTILITY VEHICLE DOES NOT MEET FEDERAL MOTOR VEHICLE SAFETY STANDARDS FOR ON ROAD VEHICLES 21 SAFETY Fuel Safety 4 amp WARNING 22 Gasoline is highly flammable and is explosive under certain _ conditions Always exercise extreme caution whenever handling gasoline Always stop the engine when refueling Always refuel outdoors or in a well ventilated area Do not smoke or allow open flames or sparks in or near the refueling area or where gasoline is stored Do not over fill the tank Do not fill the tank neck If gasoline spills on your skin or clothing immediately wash it off with soap and water and change clothing Never start the engine or let it run in an enclosed area Gaso
76. ont of the box OPERATION Hauling Cargo Towing Loads 4 WARNING Towing improperly can alter vehicle handling and may cause loss of control or brake instability which can result in serious injury or death Always follow these precautions when towing Never load more than 150 Ibs 68 1 kg tongue weight on the towing bracket Do not operate the vehicle faster than 10 mph 16 km h when towing Towing a trailer increases braking distance Do not tow more than the recommended weight for the vehicle See the towing capacity chart below and the specifications charts beginning on page 102 Attach a trailer to the trailer hitch bracket only Do not attach a trailer to any other location or you may lose control of the vehicle Never tow a trailer on a grade steeper than 15 Maximum Towing Capacities Level Ground Total Towed Total Towed Total Hitch Maximum Load Weight Load Weight Vertical Towing level ground 15 grade Weight Speed RANGER 1000 Ibs 600 Ibs 100 Ibs 10 mph TM 454 kg 272 kg 45 4 kg 16 kph RANGER 1000 Ibs 600 Ibs 100 Ibs 10 mph 2X4 454 kg 272 kg 45 4 kg 16 kph RANGER 1500 Ibs 850 Ibs 150 Ibs 10 mph 4X4 681 kg 386 kg 68 1 kg 16 kph Belt Life To extend belt life use the lowest gear possible when hauling or towing heavy cargo 47 OPERATION Driving Safely Parking the RANGER 4 WARNING A rolling vehicle can cause property damage and serious injury Always
77. perating pro cedures described Never allow anyone without a valid driver s license to operate this vehicle Minimum age recommendation for passengers is five years old Pas sengers under five years of age require special restraints which are not available with this vehicle Driver and passenger should wear their seat belts at all times Never permit a guest to operate this vehicle unless the guest has read this manual and all product labels To reduce tipover risk be especially careful when encountering ob stacles and slopes and when braking on hills or during turns This vehicle is for off road use only Never operate on public roads Always avoid paved surfaces Helmets are recommended whenever driving this vehicle in an aggressive manner Eye protection is recommended at all times Never consume alcohol or drugs before or while operating this ve hicle Never operate at excessive speeds Always travel at a speed proper for the terrain visibility and operating conditions and your experi ence Never attempt wheelies jumps or other stunts Always inspect your vehicle each time you use it to make sure it s in safe operating condition Always follow the inspection and mainte nance procedures and schedules described in this manual Always keep both hands on the steering wheel and both feet on the floorboards of the vehicle during operation Always travel slowly and use extra caution when operating on unfa miliar terrain
78. rd your vehicle s identification numbers and key number in the spaces provided Remove the spare key and store it in a safe place Your key can be duplicated only by mating a Polaris key blank with one of your existing keys so if both keys are lost the ignition switch must be replaced Vehicle Model Number behind left front wheel Frame VIN 1 under hood Engine Serial Number 2 right front side of engine crankcase Key Number 3 SAFETY Operator Safety 4 amp WARNING Failure to follow the warnings contained in this manual can result in severe injury or death A Polaris RANGER is not a toy and can be hazardous to operate This vehicle handles differently than other vehicles such as motorcycles and cars A collision or rollover can occur quickly even during routine maneuvers like turning or driving on hills or over obstacles if you fail to take proper precautions Read and understand your owner s manual and all warnings before operating the vehicle Age Restrictions This vehicle is an ADULT VEHICLE ONLY Operation is prohibited for anyone under 16 years of age No person under the age of 5 may ride as a passenger in this vehicle Know Your Vehicle As the operator of the vehicle you are responsible for your personal safety the safety of others and the protection of our environment Read and understand your owner s manual which includes valuable information about all aspects of your vehicle
79. rve the headlight aim 2 The most intense part of the headlight beam should be aimed 8 20 3 cm below the mark placed on the wall in step 2 NOTE Include the weight of a rider on the seat while performing this step 5 Adjust the beam to the desired position by turning the adjustment screw 1 Brake Lights When the brake pedal is depressed the console brake light comes on Check the brake light before each ride 1 Turn the ignition switch to the ON position 2 Depress the brake pedal The brake light should come on after about 10mm 0 4 in of pedal travel If the light doesn t come on check the bulb 93 MAINTENANCE AND LUBRICATION Lights Indicator Lamp Replacement 1 2 7 8 Lift the hood Reach in behind the console panel and lift the release 1 to unplug the light from the harness Using a flathead screwdriver press on the tab 2 on the top of the light to remove the indicator light assembly from the console panel Using a screwdriver turn the light that needs to be replaced 1 4 turn counterclockwise Grip the light with a needle nose plier and remove the light from the assembly Install the new light and use a small flat head screwdriver to seat it into place 1 4 turn clockwise Snap the assembly back into the console panel and reconnect the harness Close the hood Tool Kit To help you perform routine maintenance a tool kit is provided with your vehicle Keep the tool
80. sing the throttle and brakes on level surfaces NOTE Low is the primary gear for operating the RANGER 4X4 High gear is intended for use on hard packed surfaces with light loads 37 OPERATION Driving Safely Driving On Slippery Surfaces When driving on slippery surfaces such as wet trails loose gravel or ice be alert for the possibility of skidding and sliding Under these conditions follow these precautions 1 2 3 38 Slow down when entering slippery areas Maintain a high level of alertness reading the trail and avoiding quick sharp turns which can cause skids Correct a skid by turning the steering wheel in the direction of the skid Drive with AWD engaged if equipped to assist in controlling the vehicle CAUTION Severe damage to the drive train may occur if the AWD is engaged while the wheels are spinning Always allow the wheels to stop spinning before engaging AWD WARNING Failure to exercise care when operating on slippery surfaces can result in loss of tire traction and cause loss of control accident and serious injury or death Never apply the brakes during a skid Do not operate on excessively slippery surfaces Always reduce speed and use additional caution when operating on slippery surfaces OPERATION Driving Safely Driving Uphill Whenever traveling uphill follow these precautions 1 Always travel straight uphill 2 Avoid steep hills 15 maximum 3 Keep both
81. the Periodic Maintenance Chart beginning on page 53 1 Position the vehicle on level ground 2 Lightly turn the steering wheel left and right 3 There should be 0 8 1 0 in 20 25 mm of free play 4 If there is excessive freeplay or strange noises or the steering feels rough or catchy have the steering system inspected by an authorized Polaris dealer Cylinder Head Cylinder Base Fastener Torque Have your dealer check the RANGER cylinder head and cylinder base fasteners for proper torque at the first service or after 25 hours Rear Spring Adjustment The rear shock absorber springs are adjusted by rotating the adjustment cam 1 either clockwise or counterclockwise to increase or decrease spring tension Suspension Adjustment 2x4 4X4 The rear suspension of the RANGER 2X4 and 4X4 may be adjusted to provide a stiffer suspension if necessary The shocks are mounted to the inside mounting holes A at the factory but they may be relocated to the outside mounting holes B 1 Remove the shock mounting bolts 2 Reposition the shocks to the outside mounting holes 3 Reinstall the shock mounting bolts Torque to 30 ft Ibs 40 Nm 88 MAINTENANCE AND LUBRICATION Seat Belts Inspect all three seat belts for proper operation before each use of the vehicle 1 Push the latch plate into the buckle until it clicks The latch plate must slide smoothly into the buckle A click indicates that it
82. the choke or incorrect carburetion adjustments Spark Plug Removal and Replacement 1 Remove the seat to access the engine compartment 2 Remove the spark plug cap Using the spark plug wrench provided in the tool kit remove the plug by rotating it counterclockwise 3 Reverse the procedure for spark plug installation Torque to specification 75 MAINTENANCE AND LUBRICATION Polaris Variable Transmission PVT System WARNING Failure to comply with the instructions in this warning can result in severe injury or death Do not modify any component of the PVT system Doing so may reduce its strength so that a failure may occur at a high speed The PVT system has been precision balanced Any modification will cause the system to be out of balance creating vibration and additional loads on components The PVT system rotates at high speeds creating large amounts of force on clutch components Extensive engineering and testing has been conducted to ensure the safety of this product However as the owner you have the following responsibilities to make sure this system remains safe Always follow all recommended maintenance procedures See your dealer as outlined in the owner s manual This PVT system is intended for use on Polaris products only Do not install it in any other product Always make sure the PVT housing is securely in place during operation PVT Drying There may be some instances when water is accidently i
83. thorized dealer determines that other LSI engine components have been damaged due to the failure of a warranted emission related part during the warranty period POLARIS will repair and or replace the necessary components 115 WARRANTY California Emission Control Warranty Statement What is Not Covered Under This Warranty This warranty does not cover any emission related part which malfunctions fails or is damaged due to alterations and or modifications such as changing adding or removing parts When the LSI engine is being serviced under warranty POLARIS and any of its authorized dealers shall not be liable for any loss of use of the LSI engine for any damage to goods or loss of time or inconvenience This limited warranty also does not apply to any emission related part which malfunctions fails or is damaged due to failure to follow the maintenance and operating instructions specified in the 2005 and later Owner s Manual including a Improper or inadequate maintenance of any warranted emission related part b Improper installation adjustment or repair of the LSI engine or any warranted emission related part unless performed by an authorized dealer c Failure to use recommended fuel as specified in the 2005 and later Owner s Manual d Repairs and diagnosis performed outside of an authorized dealer e Use of parts which are not authorized by POLARIS Maintenance Schedule The LSI engine owner is responsible for ha
84. ts 1550 ml of the recommended oil 12 Start the engine and allow it to run for two to three minutes 13 Place the gear selector in neutral and set the parking brake 14 Stop the engine and check the oil level on the dipstick Add oil to the FULL mark if necessary 15 Dispose of used filter and oil properly 67 MAINTENANCE AND LUBRICATION Gearcases Gearcase Specification Chart Gearcase Lubricant Capacity Fill Plug Drain Plug Torque Torque Main Gearcase Premium AGL 15 2 oz Transmission Synthetic Gearcase 450 ml 4X4 Lube Main Gearcase Premium AGL 18 2 oz 14 ft Ibs 14 ft Ibs Transmission Synthetic Gearcase 540 ml 19 4 Nm 19 4 Nm 2X4 TM Lube Front Gearcase Premium Demand 5 oz 8 10 ft Ibs 11 ft Ibs 4X4 Drive Hub Fluid 150 ml 11 13 6 Nm 15 Nm Rear Gearcase Premium ATV Angle 18 oz 40 50 ft Ibs 30 45 in Ibs 2X4 4X4 Drive Fluid 532 ml 54 68 Nm 3 5 Nm Rear Gearcase Premium ATV Angle 10 oz 14 ft Ibs 14 ft Ibs TM Drive Fluid 300 ml 19 4 Nm 19 4 Nm 68 MAINTENANCE AND LUBRICATION Gearcases Transmission Main Gearcase Always check and change the transmission oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 53 Maintain the oil level even with the bottom of the fill plug hole We recommend the use of Premium AGL Synthetic Gearcase Lubricant See page 101 for the part numbers of Polaris products Oil Check 1 Posit
85. ture of high quality aluminum compatible anti freeze coolant and distilled water Polaris Premium 60 40 is already premixed and ready to use Do not dilute with water See page 101 for the part numbers of Polaris products NOTE Always follow the manufacturer s mixing recommendations for the freeze protection required in your area Any time the cooling system has been drained for maintenance or repair replace the coolant If the recovery bottle has run dry the level in the radiator should be inspected Add coolant as needed 72 MAINTENANCE AND LUBRICATION Cooling System 2X4 4X4 Radiator and Cooling Fan Always check and clean the screen and radiator fins at the intervals outlined in the Periodic Maintenance Chart beginning on page 53 Do not obstruct or deflect air flow through the radiator by installing unauthorized accessories in front of the radiator or behind the cooling fan Interference with the radiator air flow can lead to overheating and consequent engine damage CAUTION Washing the vehicle with a high pressure hose could damage the radiator fins and impair the radiator s effectiveness Exercise caution if a high pressure system is used for washing the vehicle Coolant Level Always check and change the coolant at the intervals outlined in the Periodic Maintenance Chart beginning on page 53 Maintain the coolant level between the minimum and maximum marks on the bottle when the fluid is cool The overflow bottle
86. use your original selling dealer however you may use any Polaris Servicing Dealer to perform warranty service Please work with your dealer to resolve any warranty issues Should your dealer require any additional assistance they will contact the appropriate person at Polaris This warranty gives you specific legal rights and you may also have other rights which vary from state to state If any of the above terms are void because of state or federal law all other warranty terms will remain in effect Lubricants 1 Mixing oil brands or using non recommended oil may cause engine damage We recommend the use of Polaris engine oil 2 Damage resulting from the use of non recommended lubricants may not be covered by warranty SPARK ARRESTOR Polaris warrants that the spark arrestor in this vehicle will meet the efficiency requirements of 43 CFR 8340 1 c for at least 1000 hours when subjected to normal use and when mainte nance and installation are in accordance with Polaris recommendations 112 WARRANTY Exported Vehicles EXCEPT WHERE SPECIFICALLY REQUIRED BY LAW THERE IS NO WARRANTY OR SERVICE BULLETIN COVERAGE ON THIS VEHICLE IF IT IS SOLD OUTSIDE THE COUNTRY OF THE SELLING DEALER S AUTHORIZED LOCATION This policy does not apply to vehicles that have received authorization for export from Polaris Industries Dealers may not give authorization for export You should consult an authorized dealer to determine this vehicle s warra
87. vehicle is left unattended Maintaining shift linkage adjustment is important to assure proper transmission function See your dealer if you experience any shifting problems CAUTION Do not attempt to shift the transmission while the vehicle is moving or damage to the transmission could result Always shift when the vehicle is stationary and the engine is at idle Always place the transmission in gear with the parking brake applied and turn the vehicle off whenever the vehicle is left unattended 29 FEATURES AND CONTROLS Ignition Switch 1 The ignition switch is a three position key operated switch The key can be removed from the switch when it is in the OFF position The engine is off Electrical circuits are off except Acc 12V ON Electrical circuits are on Electrical equipment can be used EM Turn the key to the START position to engage the electric starter The key returns to the ON position when released 4 WARNING Leaving the keys in the ignition can lead to unauthorized use of the vehicle resulting in serious injury or death Always remove the ignition key when the vehicle is not in use Light Switch 2 The ignition switch key must be in the ON position to operate the headlights The switch has three positions A High Beam B Low Beam C Off AWD Differential Lock Switch 3 2X4 4X4 The AWD Differential Switch has three positions D AWD 4X4 only 2WD Differential Lock F Off See page 50
88. ving all scheduled inspection and maintenance services performed at the intervals specified in the 2005 and later Owner s Manual and to retain records of these services as having been performed These records should be transferred to each subsequent owner of the LSI engine POLARIS cannot deny a claim solely because there are no records of scheduled maintenance however a warranty claim may be denied if the failure to perform the scheduled maintenance and inspection resulted in the failure of a warranted emission related part As a minimum the LSI engine owner is responsible for the scheduled inspection and maintenance described below which are based on the procedures described in the Owner s Manual NOTE p Perform these procedures more often for vehicles subjected to severe use E Emission Control System Service California m Have an authorized Polaris dealer perform these services 116 WARRANTY California Emission Control Warranty Statement Maintenance Schedule Maintenance Interval whichever comes first Calendar Miles Km Engine oil level Pre Ride Make adjustments as need ed See Pre Ride Checklist on page 33 4 Air filter pre filter gt liters i Inspect clean often Air box sediment Daily Drain deposits when visible tube Air filter Weekly Inspect replace as needed main element Engine breather 25H Monthly Inspect replace if necessary filter if equipped Engine oil change 25H 1M Perform a break in oil break in ch
89. w it in completely NOTE The dipstick must be screwed in completely to keep the angle and depth of the stick consistent t ADD8 oz FULL AM 2 6 Remove the dipstick and check to see that the oil level is between the full and add marks 2 Add oil if necessary Do not overfill NOTE A rising oil level between checks in cool weather driving can indicate moisture collecting in the oil reservoir If the oil level is above the full mark change the oil 61 MAINTENANCE AND LUBRICATION Engine Oil Oil and Filter Change 2x4 4X4 4 CAUTION Hot oil can cause serious burns Do not allow hot oil to come into contact with skin 1 Run the engine two to three minutes until warm Stop the engine 2 Clean the area around the drain plug 1 at the bottom of the oil tank 3 Place a drain pan beneath the oil tank and remove the drain plug Allow the oil to drain completely 4 Install a new sealing washer 2 on the oil drain plug NOTE The sealing surfaces on the drain plug and oil tank should be clean and free of burrs nicks or scratches 5 Reinstall the drain plug and torque to 14 ft Ibs 19 Nm 6 Disconnect the lower oil delivery hose and remove the screen fitting 3 from the oil tank Clean the fitting NOTE The fitting threads must be sealed with LOCTITE PST 505 or PTFE seal tape 7 Reinstall the screen fitting and rotate the fitting clockwise a minimum of 2 1 2 turns int
90. will overheat and the battery power will drop temporarily Wait at least five seconds between each operation of the starter to allow it to cool and to allow battery power recovery Do not turn the ignition switch key to the START position while the engine is running Damage to the starter can result Turn the ignition key to START 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 After the engine starts push the choke knob in half way 3 Vary the engine RPM slightly with the throttle to aid in warm up until the engine idles smoothly Push the choke completely in 4 OPERATION Starting the Engine Starting a Warm Engine Warm engines do not normally require the use of the choke Overuse of the choke can cause the spark plug to become wet fouled 1 Place the transmission in neutral and move the vehicle to a level surface Lock the parking brake Sit in the driver s seat and fasten the seat belt Turn the ignition key to START If the engine has cooled and does not readily start intermittent use of the choke knob pulled half way out may be necessary If the engine is over choked when warm depress the throttle lever fully while cranking to aid in starting 7 Release the throttle lever immediately after the engine starts a NOTE Ifthe engine does not start and all conditions are favorable change the spark p
91. y will deteriorate rapidly Check the battery fluid level often The fluid level should be kept between the upper and lower level marks 1 To refill use only distilled water Tap water contains minerals that are harmful to a battery 4 WARNING Improperly connecting or disconnecting battery cables can result in an explosion and cause serious injury or death When removing the battery always disconnect the negative black cable first When reinstalling the battery always connect the negative black cable last Battery Removal 1 Open the hood 2 Remove the battery vent tube from the battery 3 Disconnect the black negative battery cable first 4 Disconnect the red positive battery cable next 5 Lift the battery out of the vehicle being careful not to tip it sideways and spill any electrolyte 4 CAUTION If electrolyte spills immediately wash it off with a solution of one tablespoon baking soda and one cup water to prevent damage to the vehicle 99 MAINTENANCE AND LUBRICATION Battery Battery Installation 1 Setthe battery in its holder 2 Install the battery vent tube It must be free from obstructions and securely installed If not battery gases could accumulate and cause an explosion The tube should be routed away from the frame and body to prevent corrosion Avoid skin contact with electrolyte as severe burns could result 3 First connect and
92. ys turn off the engine before refueling Make sure the refueling area is well ventilated and free of any source of flame or sparks Gasoline is extremely flammable See page 22 for refueling instruc tions Always remove the ignition key when the vehicle is not in use to prevent unauthorized use or accidental starting FOR MORE INFORMATION ABOUT SAFETY call Polaris at 1 800 342 3764 SAFETY Operator Safety 4 amp WARNING Make sure your RANGER is in excellent operating condition at all times We strongly recommend that the operator check all safety components before each ride Polaris RANGERs are designed to provide safe operation when used as directed Failure of critical machine components may result from operation with any modifications especially those that increase speed or power The RANGER may become aerodynamically unstable at speeds higher than those for which it is designed Loss of control may occur at higher speeds Modifications may also create a safety hazard and lead to bodily injury Do not make any modifications to your RANGER Equipment Modifications We are concerned for the safety of our customers and for the general public Therefore we strongly recommend that consumers do not install on a Polaris RANGER any equipment that may increase the speed or power of the vehicle or make any other modifications to the vehicle for these purposes Any modifications to the original equipment of the vehicle create a substa

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