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Polaris 4X4 700 EFI Offroad Vehicle User Manual

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Contents

1. Accessory Storage Outlet Compartment Tray Mode with lid Button Auxiliary Outlet The 12 volt accessory plug receptacle has spade connections on the back that may be used to power an auxiliary light or other optional accessories or lights The connections are behind the console under the hood Mode Button The yellow button located directly under the speedometer is used to tog gle through mode options available such as odometer trip meter hour meter tachometer and clock See page 27 for operation of the modes 34 FEATURES AND CONTROLS Gear Selector H High Gear L Low Gear N Neutral R Reverse NOTE Low gear is the primary driving range for the RANGER High gear 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 H L Gear Selector N R NOTE Maintaining shift linkage adjustment is important to assure proper transmission function See your dealer if you experience any shifting problems CAUTION stationary and the engine is at idle 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 35 FEATURES AND CONTROLS Brake Ped
2. 51 Loads Towing 53 Lock Differential 55 Lubricant Part Numbers 112 Lubrication for Storage 105 Lubrication Recommendations 63 64 Front Gearcase 71 69 Main 69 Middle Gearcase 72 Rear Gearcase 73 Transmission 69 M Main Gearcase Lubrication 69 Oil Change 70 Oil 69 Maintenance Log 126 127 Maintenance Periodic 58 62 Middle Gearcase Lubrication 72 Oil 72 Oil 72 Miles to Kilometers Toggle 30 Mode Button 34 Modifications 13 Noise Emission Control System 57 Obstacles 47 27 Oil and Filter Care During Storage 105 Oil Change tah ae oe 67 68 Front Gearcase 71 Main 70 Middle Gearcase 72 Rear Gearcase 74 Transmission 70 130 Oil Check Se Rand Sich noe 66 Front Gearcase 71 Main Gearcase 69 Middle Gearcase 72 Rear Gearcase 73 Transmission 69 Oil
3. 65 68 Operation on Public Lands 57 Operation Cooling System 77 Operation Transmission 80 Operator Safety 8 20 Park Brake Adjustment 88 Inspection 88 36 R leds 36 Parking 49 Parking the Vehicle 54 Periodic Maintenance Chart 58 62 Plug 76 Plug 75 Plug 75 Plug 34 Plugs 76 Plugs 75 76 Polaris Products 112 Polishing the Vehicle 103 Pre Ride Inspection 39 Pressure 5 Programmable Service Interval 29 30 Public Lands 57 PVT 82 PVT 82 PVT 80 PVT 81 R 78 Radiator Coolant Level 79 Rear Gearcase Lubrication 73 Rear Gearcase Oil Change 74 Rear Gearcase Oil Check Checking the Oil Rear 73 Rear Spring Adjustment 89 Rear Suspension Adjustment 89 Receiver Hitch 24 Release Park Brake 36 Removal
4. Item Maintenance Interval Remarks whichever comes first Hours Calendar Miles Km E Fuel system 100 H 12M Check for leaks at tank cap E lines fuel valve filter pump throttle body re Fuel filter 100 H 12M Replace yearly gt Radiator 100 H 12M Inspect clean external in applicable surfaces gt Cooling Hoses 100 H 12M Inspect for leaks gt Engine mounts 100 H 12M Inspect Exhaust muffler 100 H 12M Inspect pipe gt Spark plug 100 H 12M Inspect replace as needed E E Ignition timing 100H 12M Inspect Wiring 100 H 12M Inspect for wear routing security apply dielectric grease to connectors subjected to water mud etc E Clutches drive 100 H 12M Inspect clean replace worn and driven parts E Front wheel 100 H 12M Inspect replace as needed bearings E Brake fluid 200 H 24M Change every two years Spark arrestor 300 H 36M Clean out Idle speed Adjust as needed Toe adjustment Inspect periodically adjust when parts are replaced E Auxiliary brake if Inspect daily adjust as gt equipped needed Headlight aim Adjust as needed Perform these procedures more often for vehicles subjected to severe use E Emission Control System Service 4 Cycle California Have an authorized Polaris dealer perform these services 62 Lubrication Recommendations Check and lubricate all components at the int
5. Drive at a higher speed or use low range more frequently See page 80 Insufficient warm up at low ambient tempera tures Warm the engine at least 5 minutes With the transmission in neutral advance the throttle to about 1 8 throttle in short bursts 5 to 7 times The belt will become more flex ible and prevent belt burning Slow easy clutch engage ment Use the throttle quickly and effectively Towing pushing at low RPM low ground speed Use low range only Utility use plowing Use low range only Stuck in mud or snow Shift the transmission to low range and carefully use fast aggressive throttle application to engage clutch WARNING Excessive throttle may cause loss of control and vehicle overturn Climbing over large objects from a stopped position Shift the transmission to low range and carefully use fast brief aggressive throttle application to engage clutch WARNING Excessive throttle may cause loss of control and vehicle overturn Belt slippage from water or snow ingestion into the PVT system Dry out the PVT See page 82 Inspect clutch seals for damage if repeated leaking occurs Clutch malfunction See your Polaris dealer Poor engine performance Check for fouled plugs or foreign material in gas tank or fuel lines See your dealer Slippage from failure to warm up belt Always warm up the belt by operating below 30 mph for one mile 5 miles or mo
6. Console Storage Box 2 under driver seat lt 2 Battery under hood Cargo Box lean NL Fuel Tank Cap 22 FEATURES AND CONTROLS Component Locations Headlights Radiator if equipped Hood Hold Down Strap Front Bumper Brush Guard 23 FEATURES AND CONTROLS Component Locations Tailgate Latch Release Taillights Taillights Air Box CV Boot Rear Caliper Receiver Hitch Muffler Spark Arrestor Trailer Hitch Bracket This vehicle is equipped with a receiver hitch bracket for a trailer hitch Trailer towing equipment is not supplied with this vehicle To avoid injury and property damage always heed the warnings and towing capacities outlined on pages 50 53 24 FEATURES AND CONTROLS Component Locations Instrument Cluster Your RANGER is equipped with an instrument cluster that senses vehi cle speed from the right front wheel The instrument cluster measures distance in miles as well as time hours of operation and engine RPM Refer to page 34 for the location of the instrument cluster Park Brake Indicator Speedometer Speedometer Needle Rider Information Ba Center NOTE addition to showing vehicle speed the speedometer needle flashes when a low fuel condition exists 25 FEATURES AND CONTROLS Instrument Cluster Rider Information Center The rider information
7. MAINTENANCE Battery Your vehicle may have either a sealed battery which requires little maintenance or a conventional battery A sealed battery can be identi fied by its flat covers on the top of the battery A conventional battery has six filler caps on the top of the battery Conventional Battery Always keep battery terminals and connections free of corrosion If cleaning is necessary remove the corrosion with a stiff wire brush Wash with a solution of one tablespoon baking soda and one cup water Rinse well with tap water and dry off with clean shop towels Coat the terminals with dielectric grease or petroleum jelly Be careful not to allow cleaning solution or tap water into the battery A WARNING Battery electrolyte is poisonous It contains sulfuric acid Serious burns can result from contact with skin eyes or clothing Antidote External Flush with water Internal Drink large quantities of water or milk Follow with milk of magnesia beaten egg or vegetable oil Call physician immediately Eyes Flush with water for 15 minutes and get prompt medical attention Batteries produce explosive gases Keep sparks flame cigarettes etc away Ventilate when charging or using in an enclosed space Always shield eyes when working near batteries KEEP OUT OF REACH OF CHILDREN 96 Battery WARNING Improperly connecting or disconnecting battery cables can result in
8. Pantone 626 CVC RANGER 4X4 700 EFI RANGER 6X6 700 EFI Maintenance and Safety AWARNING Improper vehicle use can result in SEVERE INJURY or DEATH e Operate on public roads 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 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 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 For your nearest Polaris dealer POLARIS 1 5 ie Way or visit www polarisindustries com Polaris Sales Inc 2100 Hwy 55 Medina MN 55340 Phone 763 417 8650 Fax 763 542 0599 Part No 9920636 Rev 01 Printe
9. A WARNING 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 16 SAFETY Operator Safety 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 17 SAFETY Operator Safety 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 A WARNING POTENTIAL HAZARD Failure to use extra caution when operating this vehicle on unfamiliar terrain WHAT CAN HAPPEN Loss of control vehicle overturn HOW TO AVOID THE HAZARD Travel slowly and use extra caut
10. Warning Transmission Modification 81 Washing the Vehicle 102 103 Water Immersion of Vehicle 95 Wear Drive Belt 113 Weight 51 Weight Hitch 53 Wheel Installation 92 Wheel Nut Torque 91 Wheel Removal 92 131
11. 106 Cleaning Air 83 Exhaust System 84 Fuel Filter 83 Spark 84 Clock 28 Component Locations 22 25 Condition Spark Plugs 76 Console lose cise ass etek ale 34 Coolant Level 78 Coolant Level Radiator 79 Coolant Adding or Changing 77 Cooling 78 Cooling System 78 79 Cooling System Operation 77 Corrosion Removal Chrome 104 Cover for 106 Crankcase Emission Control System 57 D Depth Tread 91 Diagnostic Mode 28 30 Diagnostics AWD 29 EFI Blink Codes 32 Gear 29 Differential 55 Differential Lock Switch 37 Disengaging AWD 56 Downloading Blink Codes 31 32 Drive Belt Wear 113 Driving Downhill 45 Driving 48 Driving Sidehill 45 D Driving on Slippery Surfaces 43 Driving Over Obstacles 47 Driving Procedure 42 Driving Safely 42 54 Driving Through Water 46 Driving Uphill 44 Driving After Driving in Water 82 Drying the Transmission 82 Dumping th
12. 58 lt 108 Polaris 112 Troubleshooting 113 Warranty 117 Maintenance Log 126 eee 128 VEHICLE IDENTIFICATION NUMBERS Record your vehicle s identification numbers and key number in the spaces provided Remove the spare key and store it in a safe place An ignition key can be duplicated only by ordering a Polaris key blank using your key number and mating it with one of your existing keys The ignition switch must be replaced if all keys are lost Key Number Engine Serial Number Vehicle Model Number Frame VIN Engine Serial Number Key Number SAFETY Safety Decals and Locations Warning decals have been placed on the vehicle for your protection Read and follow the instructions of the decals on the vehicle carefully If any of the decals depicted in this manual differ from the decals on your vehicle always read and follow the instructions of the decals on the vehicle If any decal becomes illegible or comes off contact your Polaris dealer to purchase a replacement Replacement safety decals are provided by Polaris at no charge The part number is printed on the decal Container Passenger Tire Pressure Warning WARNING Remove flammable material containers from box before fill
13. Battery 97 Removal 33 Removal Wheels 92 Removing the Vehicle from Storage 107 Replacement Headlight Lamp 93 REVETSE 48 Rider Information 26 32 RPM Idle Throttle Body 86 5 Safety Decals 5 7 Safety Symbols 9 Seat Belt Inspection 90 Seat Belts 33 90 Seat 33 Selector 35 Service Interval Indicator 29 30 Service Interval Programming 30 Severe Use Definition 58 Shifting 35 Signal 9 Spark Arrestor Warning 84 Spark Arrestor Cleaning 84 Spark Plug Condition 76 OSs aaa ete eek das 75 Removal 76 Guth ch ed 75 76 Specifications 4 4 108 109 Specifications 6X6 110 111 Specifications Gearcase 68 Speed Idle 86 Speed Towing 53 25 Spring Rear Adjustment 89 Stabilizing the Fuel 105 Starting the Engine 40 Steering Wheel Inspection 89 Stopping the Engine 41 Storage nal sarees 102 106 Storage and Inspection 105
14. Maintenance See pages 99 101 for storage and charging procedures Storage Area Covers Be sure the storage area is well ventilated Cover the vehicle with a gen uine Polaris cover NOTE Do not use plastic or coated materials They do not allow enough ven 106 tilation to prevent condensation and may promote corrosion and oxi dation Removal from Storage 1 3 4 Check the battery electrolyte level and charge the battery if neces sary Install it in the vehicle Make sure the battery vent hose is routed properly and that it s not pinched or restricted in any way 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 39 NOTE Tightness of the bolts nuts and other fasteners should be checked by 5 an authorized Polaris dealer Lubricate at the intervals outlined in the Periodic Maintenance Chart beginning on page 58 A WARNING Engine exhaust contains poisonous carbon monoxide and can cause loss of consciousness or death Never run an engine in an enclosed area Transporting the RANGER Follow these procedures when transporting the vehicle SNe ae Stop the engine Remove the key to prevent loss during transporting Place the transmission in gear Engage the park brake Secure the fuel cap oil cap and seat Always tie the frame of the RANGER to the transporti
15. Maintenance Interval Remarks whichever comes first Hours Calendar Miles Km E Steering Pre Ride eg erat oe need 7 ed See Pre Ride Checklist gt Front suspension Pre Ride 39 gt suspension Pre Ride Tires Pre Ride gt Brake fluid level Pre Ride gt Brake pedal travel Brake system Pre Ride Wheels fasteners Pre Ride Frame fasteners Pre Ride gt Engine level Pre Ride gt Air filter pre filter Daily Inspect clean often replace E as needed gt 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 gt Air filter Weekly Inspect replace as needed E main element gt Brake pad wear 10H Monthly Inspect periodically a Battery 20H Monthly Check terminals clean test gt Front Gearcase 25 Monthly Inspect level change yearly if equipped gt Middle Gearcase 25H Monthly Inspect level change yearly Oil if equipped gt Rear gearcase 25H Monthly Inspect level change yearly if equipped gt Transmission oil 25H Monthly Inspect level change yearly Perform these procedures more often for vehicles subjected to severe use E Emission Control System Service 4 Cycle California Have an authorized Polar
16. REDUCE SPEED AND ALLOW GREATER DISTANCES FOR BRAKING WHEN HAULING CARGO Always load the cargo box with the load as far forward and as low as possible When operating over rough or hilly terrain reduce speed and cargo to maintain stable driving conditions Always operate the vehicle with extreme care when hauling or towing loads Slow down and drive in the lowest gear available SECURE ALL LOADS BEFORE OPERATING Unsecured loads can create unstable operating conditions which could result in loss of control of the vehicle OPERATE ONLY WITH STABLE AND SAFELY ARRANGED LOADS When handling off centered loads that cannot be centered securely fasten the load and operate with extra caution Always attach the tow load to the hitch point designated for your vehicle HEAVY LOADS CAN CAUSE BRAKING AND CONTROL PROBLEMS Use extreme caution when applying brakes with a loaded vehicle Avoid terrain or situations that may require backing downhill USE EXTREME CAUTION when operating with loads that extend over the rack sides Stability and maneuverability may be adversely affected causing the vehicle to overturn DO NOT TRAVEL FASTER THAN THE RECOMMENDED SPEEDS Vehicle should never exceed 10 mph 16 kph while towing a load on a level grass surface Vehicle speed should never exceed 5 mph 8 kph when towing loads in rough terrain while cornering or while ascending or descending a hill 50 Driving Safely Hauling Cargo OPE
17. REPLACEMENT THIS GENERAL PURPOSE OFF ROAD UTILITY VEHICLE DOES NOT MEET FEDERAL MOTOR VEHICLE SAFETY STANDARDS FOR ON ROAD VEHICLES Discretionary Warning SAFETY Operator Safety 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 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 informa tion about all aspects of your vehicle including safe operating proce dures 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
18. Storage and Lubrication 105 Storage 106 Storage Battery dats 99 COVETSS 106 Fluid Levels 105 Oil and 105 Removal From 107 INDEX 5 Suspension Adjustment 89 Switches AWD Switch 37 Differential Lock Switch 37 leito eines 37 ight 97 27 29 Throttle Freeplay Adjustment 86 Throttle Freeplay Inspection 85 Throttle Pedal 36 Throttle System 85 Tire 5 Tire Tread 91 91 92 Torque Axle Nuts 91 Torque Spark Plug 75 Torque Wheel Nut 91 Towing 53 Towing 53 Trailer 24 Transmission Lubrication 69 Oil Change 70 Oil Check 69 Operation 80 ais 252252222200 ead 82 Warming 81 Divine 2 hae ond 82 Transporting the Vehicle 107 Tread Depth 91 Trip Meteri ead 27 Vehicle Identification Numbers 4 Vehicle Immersion 95 Vehicle 107 Warning Symbols 9
19. Transmission fluid e Brake fluid change every two years and any time the fluid looks dark or contaminated e Coolant test strength fill Inspect and Lubricate Inspect all cables and lubricate all areas of the vehicle as recommended in the Periodic Maintenance Chart beginning on page 58 105 MAINTENANCE Cleaning and Storage Storage Tips Fog the Engine 1 Treat the fuel system with Polaris Carbon Clean Follow the instruc tions on the container Start the engine Allow it to idle for several minutes so the Carbon Clean reaches the injectors Stop the engine Remove the spark plugs and add 2 3 tablespoons of Premium 4 Syn thetic 0OW40 engine oil To access the plug holes use a section of clear 1 4 hose and a small plastic squeeze bottle filled with the pre measured amount of oil NOTE Do this carefully If you miss the plug holes oil will drain from the spark 6 plug cavities into the hole at the front of the cylinder head and appear to be an oil leak Reinstall the spark plugs Torque to specification See page 76 Apply dielectric grease to the inside of each spark plug cap and rein stall the caps onto the plugs Turn the engine over several times Oil will be forced in and around the piston rings and ring lands coating the cylinder with a protec tive film of fresh oil If Polaris fuel system additive is not used fuel tank fuel lines and injectors should be completely drained of gasoline Battery
20. WARNING POTENTIAL HAZARD Operating this vehicle without proper instruction WHAT CAN HAPPEN Loss of control accident _ HOW AVOID THE HAZARD The risk of an accident is greatly increased if the operator does not know how to operate the vehicle properly in different situations and on different types of terrain All operators must read and understand the Owner s Manual and all warning and instruction labels before operating the vehicle A WARNING POTENTIAL HAZARD 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 15 SAFETY Operator Safety WARNING POTENTIAL HAZARD Operating this vehicle after consuming alcohol or drugs e 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 reduce 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
21. WARNING VEHICLE ROLLOVER could cause severe injury or death This cab frame is not designed or intended to provide rollover protection ALWAYS WEAR YOUR SEAT BELT for maximum protection SAFETY Safety Decals and Locations Shift Caution CAUTION To avoid transmission damage shift only when vehicle is stationary and at idle Discretionary Warning Shift Caution WARNING Improper vehicle use can result in SEVERE INJURY or DEATH NEVER Operate on public roads A collision can occur with a 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 conditions e Operate this vehicle on HILLS steeper than 15 degrees 15 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 hills and rough terrain and in turns 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
22. 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 2 Open the hood Battery On conventional batteries remove the battery vent tube Disconnect the black nega tive battery cable first Disconnect the red positive battery cable last Lift the battery out of the vehicle Be careful not to tip a conventional battery side ways which could spill elec trolyte 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 97 MAINTENANCE Battery Battery Installation Using a new battery that has not been fully charged can damage the bat tery and result in a shorter life It can also hinder vehicle performance Follow the battery charging instructions on page 100 before installing the battery 1 Ensure that the battery is fully charged 2 Place the battery in the battery holder 3 With conventional batteries install the battery vent tube sealed bat teries do not have a vent tube NOTE The vent tube must be free of obstructions and securely installed Route the tube away from the frame and vehicle body to prevent con tact with electrolyte A WARNING Battery gases
23. center is located in the instrument cluster All seg ments will light up for 2 5 seconds at start up NOTE Ifthe instrument cluster fails to illuminate a battery over voltage may 26 have occurred and the instrument cluster may have shut off to protect the electronic speedometer If this occurs take the vehicle to your Polaris dealer for proper diagnosis Gear Indicator This 3 4 5 6 indicator displays gear shifter position H High Gear L Low Gear N Neutral R Reverse Gear AWD Indicator This 2 indicator illuminates when the AWD switch is in the AWD posi tion Engine Hour Display Indicator Service Interval Diagnostic Mode Indicator Low Battery and Over Voltage This warning usually indicates that the vehicle is operating at an RPM too low to keep the battery charged It may also occur when the engine is at idle and high elec trical load lights cooling fan accessories is applied Drive at a higher RPM or recharge the battery to clear the warning Odometer Tachometer Tripmeter Hour Meter Clock Fuel Gauge The segments of the fuel gauge show the level of fuel in the fuel tank When the last segment clears a low fuel warning is activated All segments will flash FUEL will display in the LCD and the speedometer needle will blink Refuel immediately Check Engine Warning Indicator This indicator serves two pur poses The word HOT displays if the engine overheats It also appears if an EFI
24. could accumulate in an improperly installed vent tube and cause an explosion resulting in serious injury or death Always ensure that the vent tube is free of obstructions and is securely installed as recommended 4 conventional batteries coat the terminals with dielectric grease or petroleum jelly 5 Connect and tighten the red positive cable first 6 Connect and tighten the black negative cable last 7 Verify that cables are properly routed 98 Battery Battery Storage Whenever the vehicle is not used for a period of three months or more remove the battery from the vehicle ensure that it s fully charged and store it out of the sun in a cool dry place Check battery voltage each month during storage and recharge as needed to maintain a full charge See page 100 NOTE Battery charge can be maintained by using a Polaris Battery Tender charger or by charging about once a month to make up for normal self discharge Battery Tender can be left connected during the storage period and will automatically charge the battery if the voltage drops below a pre determined point See page 112 for the part numbers of Polaris products Battery Fluid Conventional Battery A poorly maintained battery will Lower Upper deteriorate rapidly Check the bat Mark Mark tery fluid level often Maintain the fluid level between the upper and lower level marks Add only distilled water Tap water co
25. following pro cedures carefully 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 1 Fill the fuel tank with gasoline Heed the gasoline warnings on page 21 2 Check the oil level See page 66 Add the recommended oil as needed to maintain the oil level in the normal safe operating range 3 Drive slowly at first Select an open area that allows room to famil iarize yourself with vehicle operation and handling 4 Vary throttle positions Do not operate at sustained idle 5 Perform regular checks on fluid levels controls and areas outlined on the daily pre ride inspection checklist See page 39 6 Pull only light loads 7 During the break in period change both the oil and the filter at 25 hours 38 Pre Ride Inspection A 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 Item Remarks Page Brake system pedal travel Ensure proper operation 48 Brake flui
26. front hubs are driving they will not release until the rear wheels regain traction CAUTION Switching to AWD while the rear wheels are spinning may cause severe drive shaft and clutch damage Always switch to AWD while the rear wheels have traction or are at rest AWD Switch Disengaging AWD Under certain conditions it may be possible for the front gearcase to remain locked unnecessarily This condition causes increased steering effort and some vehicle speed restriction If the front gearcase remains locked after following these instructions return the vehicle to your dealer for service 1 Stop the vehicle 2 Operate in reverse for at least 10 feet 3 Stop completely 4 Shift into low gear and drive forward 56 EMISSION CONTROL SYSTEMS Noise Emission Control System Do not modify the engine intake or exhaust components as doing so may affect compliance with U S A EPA noise control requirements 40 CFR 205 and local noise level requirements Operation on Public Lands in the U S A Your Polaris vehicle has a spark arrestor that was tested and qualified to be in accordance with the USDA Forest Service Standard 5100 1C Fed eral law requires that this spark arrestor be installed and functional when the vehicle is operated on public lands Operation of off road vehicles on public lands in the U S A is regulated by 43 CFR 8343 Violations are subject to monetary penalties Federal regulations c
27. may have reduced stop ping ability Test your brakes after leaving water If necessary apply them lightly several times to let friction dry out the pads Always be sure there are no obstacles or people behind your vehicle when operating in reverse When it s safe to proceed in reverse move slowly Avoid turning at sharp angles in reverse Always use the proper size and type of tires specified in this manual Always maintain proper tire pressure as specified on page 5 11 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 fol low 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 engage the park brake before getting out of the vehicle See page 36 Always apply the service brakes before releasing the park brake Always turn off the engine before refueling Make sure the refueling area is well ventilated and free of any source of flame or sparks Gas oline is extremely flammable See page 21 for fuel safety warnings Always remove the ignition key when the vehicle is not i
28. mode 1 2 3 4 2 Turn the key switch off and wait 10 seconds Lock the parking brake Place the transmission in neutral Hold the mode reverse override button and turn the key switch on Release the switch as soon as the display is activated Use the mode button to toggle through the diagnostic screens Clock Screen To reset the clock 1 2 3 28 Enter the diagnostic mode Toggle to the clock screen Press and hold the mode button until the hour display flashes Release the button Press and release the mode button once to advance the setting by one hour Press and hold the mode button to advance the hours quickly When the desired hour is displayed wait approximately four sec onds until the minute display flashes When the display stops flashing the mode has been set Use the same procedure to reset the minutes FEATURES AND CONTROLS Instrument Cluster Rider Information Center Diagnostic Mode Battery Voltage Screen View this screen to check battery voltage level Tachometer Screen View the tachometer to check engine speed AWD Diagnostic Screen The gauge indicates whether or not current is flowing through the AWD coil only on models with switchable AWD This screen is for informa tional purposes only Please see your dealer for all major repairs Gear Circuit Diagnostic Screen This screen displays the resistance value in ohms being read at the gear switch input of the gauge Thi
29. related fault occurs Do not operate the vehicle if this warning appears Serious engine damage could result FEATURES AND CONTROLS Instrument Cluster Rider Information Center Standard Modes Use the yellow mode button located under the speedometer to toggle through the mode options See page 34 Odometer Mode The odometer records the miles traveled by the vehicle Trip Meter Mode The trip meter records the miles traveled by the vehicle on each trip if it s reset before each trip To reset the trip meter select the trip meter mode Press and hold the mode button override button until the total changes to 0 NOTE In the Rider Information Center the trip meter display contains a deci mal point but the odometer displays without a decimal point Hour Meter Mode This mode logs the total hours the engine has been in operation Tachometer Mode The engine RPM is displayed digitally NOTE Small fluctuations in the RPM from day to day may be normal because of changes in humidity temperature and elevation Clock Mode The clock displays time in 12 hour format To reset the clock see page 28 27 FEATURES AND CONTROLS Instrument Cluster Rider Information Center Diagnostic Mode The wrench icon will display when the gauge is in the diagnostic mode To exit the diagnostic mode turn the key switch off and on Any move ment of the tires will also cause the gauge to exit the diagnostic mode To enter the diagnostics
30. repeat the process 10 Take the vehicle to your dealer for service as soon as possible 82 MAINTENANCE Filter Systems Air Filter Always change the air filter at the intervals outlined in the Periodic Maintenance Chart beginning on page 58 1 Lift the cargo box to access the air box 2 Remove the air box cover and inspect the gasket It should adhere tightly to the cover and seal all the way around 3 Remove the air filter 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 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 83 MAINTENANCE Spark Arrestor WARNING 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 F Allow components to cool sufficiently before proceeding Remove any combustible materials from the
31. states do not allow limi tations on how long an implied warranty lasts so the above limitation may not apply to you if inconsistent with controlling state law HOW TO OBTAIN WARRANTY SERVICE If your vehicle requires warranty service you must take it to a Polaris Servicing Dealer When requesting warranty service you must present your copy of the Warranty Registra tion form to the dealer THE COST OF TRANSPORTATION TO AND FROM THE DEALER IS YOUR RESPONSIBILITY Polaris suggests that you use your original selling dealer however you may use any Polaris Servicing Dealer to perform warranty service Please work with your dealer to resolve any warranty issues Should your dealer require any additional assistance they will contact the appropriate person at Polaris This warranty gives you specific legal rights and you may also have other rights which vary from state to state If any of the above terms are void because of state or federal law all other warranty terms will remain in effect Lubricants 1 Mixing oil brands or using non recommended oil may cause engine damage We rec ommend the use of Polaris engine oil 2 Damage resulting from the use of non recommended lubricants may not be covered by warranty SPARK ARRESTOR Polaris warrants that the spark arrestor in this vehicle will meet the efficiency require ments of 43 CFR 8343 1 c for at least 1000 hours when subjected to normal use and when maintenance and installatio
32. the oil into a drain pan Discard used oil properly Clean and reinstall the drain plug Torque to specification Add the recommended fluid Reinstall the fill plug Torque to specification Check for leaks ON OY ae 72 Gearcases Rear Gearcase Always check and change the rear gearcase oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 58 Refer to the Gearcase Specifications Chart on page 68 for recommended lubricants capacities and torque specifications See page 112 for the part numbers of Polaris products The rear gearcase fill plug is on the driver s side of the rear gearcase Oil Check 4X4 below the bottom thread of the fill plug hole Use a light colored non absorbent measuring instrument such as a white cable tie to mea sure the depth 1 Position the vehicle on a level surface 2 Remove the fill plug Check the oil level 3 Add the recommended oil as needed 4 Reinstall the fill plug Torque to specification Oil Check 6X6 The easiest way to check for adequate oil in the 6X6 is to drain and refill the gearcase to capacity see page 68 Perform the oil change as outlined on page 74 73 MAINTENANCE Gearcases Rear Gearcase Oil Change 1 Remove the fill plug 2 Place a drain pan under the drain plug Remove the drain plug 3 Drain the oil Dispose of used oil properly 4
33. the ignition switch and wait five seconds Repeat steps 5 and 6 until the engine starts Vary the engine RPM slightly with the throttle to aid in warm up until the engine idles smoothly CAUTION Operating the vehicle immediately after starting could cause engine damage Allow the engine to warm up for several minutes before operating the vehicle 40 OPERATION Stopping the Engine 1 Release the throttle pedal completely and brake to a complete stop 2 Turn the engine off 3 Engage the park brake WARNING A rolling vehicle can cause property damage and serious injury Always engage the park brake after stopping the engine 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 A WARNING Failure to allow for increased braking distance when hauling cargo or towing a trailer may result in accident and injury Always slow down and allow additional braking distance when towing or hauling cargo 41 Driving Safely Driving Procedure 5 6 Sit in the driver s seat and fasten the seat belt After starting the engine and allowing it to warm up apply the ser vice brakes and s
34. throttle body adjustments Wet Fouled Plug The wet fouled insulator tip is black A damp oil film covers the firing end There may be a carbon layer over the entire nose Generally the electrodes are not worn General causes of fouling are excessive oil use of non recommended injection oil or incorrect throttle body adjust ments 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 specifi cation See page 75 76 MAINTENANCE Cooling System Operation The engine coolant level is controlled or maintained by the recovery system The recovery system components are the overflow bottle radia tor filler neck radiator pressure cap and connecting hose As coolant operating temperature increases the expanding heated excess coolant is forced out of the radiator past the pressure cap and into the overflow bottle As engine coolant temperature decreases the contracting cooled coolant is drawn back up from the tank past the pressure cap and into the radiator NOTE Some coolant level drop on new vehicles is normal as the system is purging itself of trapped air Observe coolant levels and maintain as recommended by adding coolant to the overflow bottle Adding or Changing Coolant To ensure
35. using mild soap Certain products including insect repellents and chemicals will damage plastic surfaces Do not allow these types of products to contact the vehicle The best and safest way to clean your Polaris vehicle is with a garden hose and a pail of mild soap and water 1 Use a professional type washing cloth cleaning the upper body first and the lower parts last 2 Rinse with clean water frequently 3 Dry surfaces with a chamois to prevent water spots Washing Tips Avoid the use of harsh cleaners which can scratch the finish Do not use a power washer to clean the vehicle Do not use medium to heavy duty compounds on the finish e Always use clean cloths and pads for cleaning and polishing Old or reused cloths and pads may contain dirt particles that will scratch the finish 102 MAINTENANCE Cleaning and Storage Washing the Vehicle If a high pressure water system is used for cleaning not recommended exercise extreme caution The water may damage components and could remove paint and decals Avoid directing the water stream at the follow ing items e Wheel bearings e Radiator Transmission seals e Brakes Cab and body panels e Labels and decals e Electrical components and wiring NOTE If warning and safety labels are damaged contact your Polaris dealer for free replacement Grease all zerk fittings immediately after washing Allow the engine to run for a while to eva
36. AGES OF ANY DESCRIPTION WHETHER ARISING OUT OF EXPRESS OR IMPLIED WAR RANTY OR ANY OTHER CONTRACT NEGLIGENCE OR OTHER TORT OR OTHERWISE ALL IMPLIED WARRANTIES INCLUDING BUT NOT LIMITED TO ANY IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PAR TICULAR PURPOSE ARE LIMITED IN DURATION TO THE WARRANTY PERIOD DESCRIBED HEREIN POLARIS DISCLAIMS ALL EXPRESS WARRAN TIES NOT STATED IN THIS WARRANTY Some states do not allow limitations on how long an implied warranty lasts so the above limitation may not apply if it is incon sistent with the controlling state law This limited warranty excludes failures not caused by a 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 120 WARRANTY California Emission Control Warranty Statement The Air Index of this Engine is 3 0 2 4 6 8 10 Most Clean Least Clean Note The lower the Air Index the less pollution T
37. Clean the drain plug Reinstall the drain plug Torque to specifica tion Add the recommended oil Reinstall the fill plug Torque to specification 7 Check for leaks 74 MAINTENANCE Spark Plugs CAUTION Using non recommended spark plugs can result in serious engine damage Always use Polaris recommended spark plugs Refer to the specifications section beginning on page 108 Spark Plug Gap Torque Model Electrode Gap New Plug Torque Used Plug Torque RANGER 035 9 mm 18 ft Ibs 18 ft Ibs 4X4 EFI 24 Nm 24 Nm RANGER 035 9 mm 18 ft Ibs 18 ft Ibs 6X6 EFI 24 Nm 24 Nm Spark plug condition is indicative of engine operation The spark plug firing end condition should be read after the engine is warmed up and the vehicle is driven at higher speeds Immediately check the spark plug for correct color See page 76 A WARNING A hot exhaust system and engine can cause serious burns Wear protective gloves when removing a spark plug for inspection 75 MAINTENANCE Spark Plugs Spark Plug Condition Normal Plug The normal insulator tip is gray tan or light brown There will be few combustion deposits The electrodes are not burned or eroded This indi cates the proper type and heat range for the engine and the service NOTE The tip should not be white A white insulator tip indicates overheating caused by use of an improper spark plug or incorrect
38. 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 obstacles and slopes and when braking on hills or during turns This vehicle is for off road use only Never operate on public roads Always avoid paved surfaces e 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 vehi cle Never operate at excessive speeds Always travel at a speed proper for the terrain visibility and operating conditions and your experi ence Never attempt jumps or other stunts e Always inspect your vehicle each time you use it to make sure it s in safe operating condition Always follow the inspection and mainte nance procedures and schedules described in this manual e Always keep both hands on the steering wheel and both feet on the floorboards of the vehicle during operation e Always travel slowly and use extra caution when operating on unfa miliar terrain Be alert to changing terrain Never operate on excessively rough slippery or loose terrain 10 SAFETY Operator Safety Always follow proper procedures for turning as described in this manual Practice turning at slow speeds before attempting to turn at
39. NG Poor lighting while driving can result in severe injury or death Headlight and taillight lenses become dirty during normal operation Wash the headlights frequently to maintain lighting quality Hot components can cause serious burns to skin Do not service the headlamps until they ve cooled sufficiently Headlight Lamp Replacement 1 Open the hood 2 Unplug the headlamp from the wiring harness Be sure to pull on the connector not on the wiring 3 Turn the lamp counter clockwise 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 Wiring Harness 93 Lights 1 Place the vehicle on a level surface with the headlight approxi mately 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 Apply the brakes Start the engine Turn on the headlights Observe the headlight aim The most intense part of the headlight beam should be aimed 8 20 cm below the mark placed on the wall in step 2 NOTE Include the weight of a rider on the seat while performing this step 5 Ifthe headlight needs adjustment open the hood NOTE The lights are part of the hood assembly 6 Turn the adjustment screw to adjust the beam ae 7 Close th
40. RATION 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 Model Maximum Capacities Level Ground Cargo Box RANGER 4X4 EFI 1500 Ibs 681 kg 1000 Ibs 454 kg RANGER 6X6 EFI 1750 Ibs 794 kg 1250 Ibs 567 kg WARNING Driving with passengers in the cargo box can result in severe injury or death Never allow passengers to ride in the cargo box Passengers must always ride in the cab with seat belts fastened securely 51 OPERATION Driving Safely Dumping the Cargo Box WARNING Operating the vehicle while the cargo box is raised could result in severe injury The box could close unexpectedly and cause injury to the driver or passenger The rear tires will also catch the rear of a raised box damaging the vehicle and creating hazardous driving conditions Never operate this vehicle with the cargo box in the raised position 1 Select a level site to dump the cargo box Do not attempt to dump or unload the vehicle while parked on an incline 2 Engage the park 5 N brake 3 Dismount the vehicle 2 eleas Lever Noa is positioned evenly or toward the front of the cargo box 6 Release the tailgate by pu
41. al Depress the brake pedal to slow or stop the vehicle Apply the brakes while starting the engine Throttle Pedal Push the pedal down to increase engine speed Spring pressure returns the pedal to the rest position when released Always check that the throttle pedal returns normally before starting the engine Make sure there s ade quate throttle pedal freeplay See page 86 for throttle pedal adjustment procedures Park Brake Pedal Engage the park brake when parking the vehicle to help prevent the vehicle from rolling To engage the park brake apply the brakes then push the park brake pedal down firmly and fully with your foot Park Brake Release Always apply the service brakes before releasing the park brake To release the park brake pull the park brake release handle Make sure the park brake pedal is functioning properly before each operation 36 FEATURES AND CONTROLS Switches Ignition Switch A WARNING Leaving the keys in the ignition can lead to unauthorized use of the vehicle resulting in serious injury or death Always remove the ignition key when the vehicle is not in use The ignition switch is a three position AWD Differential key operated switch _ Switch The key can be if equipped removed from the Light Switch switch when it is in f the OFF position Ignition Switch OFF The engine is off Electrical circuits are off except Acc 12V ON Electrical circuits are
42. aler 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 War ranty Department at 1 763 417 8650 and you will be advised of the appropriate dealer where the warranty repair is to be performed 125 MAINTENANCE LOG Use the following chart to record periodic maintenance DATE MILES KM OR HOURS TECHNICIAN SERVICE PERFORMED COMMENTS 126 MAINTENANCE LOG DATE MILES KM OR HOURS TECHNICIAN SERVICE PERFORMED COMMENTS 127 INDEX A Accessory Outlet 34 Adding Coolant 77 Adjustment Headlight Beam 94 Adjustment Park Brake 88 Adjustment Rear Spring 89 Adjustment Rear Suspension 89 Adjustment Throttle Freeplay 86 Age Restrictions Air Filter ese aie 83 Air Filter 83 All Wheel 56 All Wheel Drive Lock Switch 37 Arrestor Spark Warning 84 Auxiliary 34 AWD aha aha 56 AWD Diagnostics 29 AWD Differential Lock Switch 37 Axle Nut Torque 91 B Battery 96 101 Charging 100 101 Flu
43. an be viewed online at www gpoaccess gov ecft Crankcase Emission Control System This engine is equipped with a closed crankcase system Blow by gases are forced back to the combustion chamber by the intake system All exhaust gases exit through the exhaust system Exhaust Emission Control System Exhaust emissions are controlled by engine design An electronic fuel injection EFI system controls fuel delivery The engine and EFI com ponents are set at the factory for optimal performance and are not adjustable The emissions label is located on the engine mount under the seat Electromagnetic Interference This spark ignition system complies with Canadian ICES 002 This vehicle complies with European directives 97 24 EC and 89 336 EEC 57 MAINTENANCE Periodic Maintenance Chart Careful periodic maintenance will help keep your vehicle in the safest most reliable condition Inspection adjustment and lubrication of important components are explained in the periodic maintenance chart Inspect clean lubricate adjust and replace parts as necessary When inspection reveals the need for replacement parts use genuine Polaris parts available from your Polaris dealer Record maintenance and service in the Maintenance Log beginning on page 126 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 operat
44. ange a Front and Rear 35 ft Ibs 47 Nm Nut O Spindle Nut Front 70 ft Ibs 95 Nm Hub Retaining Nuts Center and Rear 110 ft Ibs 150 Nm NOTE Do not lubricate the stud or the lug nut 91 MAINTENANCE Tires A WARNING Improperly installed wheels can adversely affect tire wear and vehicle handling which can result in serious injury or death Always ensure that all nuts are torqued to specification Do not service axle nuts that have a cotter pin installed See your Polaris dealer Wheel Removal 1 Stop the engine Place the transmission in gear Engage the park brake Loosen the wheel nuts slightly 3 Elevate the side of the vehicle by placing a suitable stand under the frame 4 Remove the wheel nuts and washers Remove the wheel Wheel Installation 1 Place the transmis sion in gear 2 Engage the park brake 3 Place the wheel in the correct posi tion on the wheel hub Be sure the valve stem is toward the outside and rotation arrows on the tire point toward for ward rotation 4 Attach the wheel nuts and washers and finger tighten 5 Carefully lower the vehicle to the ground 6 Torque the wheel nuts to specification See page 91 92 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 WARNI
45. ange the coolant at the intervals outlined in the Periodic Maintenance Chart beginning on page 58 Maintain the coolant level between the minimum and maximum marks on the bottle when the fluid is cool The overflow bottle is located in front of the right front wheel 1 Position the vehicle on a level surface 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 Overflow Bottle NOTE If coolant must be added often or if the overflow bottle runs completely dry there may be a leak in the system Have the cooling system inspected by your Polaris dealer 78 Cooling System Radiator Coolant Level Always check and clean the screen and radiator fins at the intervals out lined in the Periodic Maintenance Chart beginning on page 58 Do not obstruct or deflect air flow through the radiator by installing unautho rized accessories in front of the radiator or behind the cooling fan Inter ference with the radiator air flow can lead to overheating and consequentially engine damage A WARNING Escaping steam can cause severe burns Never remove the pressure cap while the engine is warm or hot Always allow the engine to cool before removing the pressure cap 1 Lift the hood 2 Slowly re
46. arburetor and internal parts and or pressure regulator or fuel injection system ii 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 1 Intake manifold if applicable 1 Air filter 3 Ignition System 1 Spark plugs 1 Magneto or electronic ignition system 11 Spark advance retard system if applicable 4 Exhaust manifold if applicable 5 Miscellaneous Items Used in Above Systems 1 Electronic controls if applicable 1 Hoses belts connectors and assemblies iii Filter lock assy gaseous fuel if applicable If an authorized dealer determines that other LSI engine components have been dam aged due to the failure of a warranted emission related part during the warranty period POLARIS will repair and or replace the necessary components 123 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 autho rized 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
47. 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 ina very short time Never go under the vehicle while it s inclined Use the following procedure to periodically purge accumulated carbon from the exhaust pipe 1 Remove the arrestor clean out plugs located on the bottom of the muffler 2 Shift the transmission to neutral Apply the brakes Start the engine 3 Purge accumulated carbon from the system by momentarily rev ving the enging several times Outlet Cl an Out 4 Ifcarbon is expelled cover or Plugs plug the exhaust outlet and rap on the pipe around the clean out plugs while revving the engine several more times 5 Ifparticles are still suspected to be in the muffler elevate the rear of the vehicle one foot higher than the front Engage the park brake Block the wheels Make sure the transmission is in neutral and repeat steps 3 and 4 until no more particles are expelled when the engine is revved 6 Stop the engine Allow the arrestor to cool 7 Reinstall the arrestor plugs and remove the outlet cover or plug 84 MAINTENANCE Throttle System 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
48. 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 e 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 81 MAINTENANCE PVT System PVT Drying There may be some instances when water is accidently ingested into the PVT system Use the following instructions to dry it out before operat ing Loosen the bottom screws that secure the clutch cover Allow the water to drain Tighten the screws Apply the brakes Start the engine Engage the park brake Shift the transmission to neutral ee Nie Apply varying throttle for 10 15 seconds to expel the moisture and air dry the belt and clutches Do not hold the throttle wide open for more than 10 seconds 8 Allow the engine RPM to settle to idle speed Apply the service brakes Release the park brake and shift the transmission to the low est available range 9 Test for belt slippage If the belt slips
49. d Ensure proper level 87 Front suspension Inspect lubricate if necessary 63 Rear suspension Inspect lubricate if necessary 63 Steering Ensure free operation 89 Tires Inspect condition and pressure Wheels fasteners Inspect ensure fastener tightness 91 Frame nuts bolts fasteners Inspect ensure tightness Fuel and oil Ensure proper levels 26 66 Coolant level Ensure proper level 5 Coolant hoses Inspect for leaks Throttle Ensure proper operation 85 Indicator lights switches Ensure operation 37 Air filter pre filter Inspect clean 83 Air box sediment tube Drain deposits whenever visible 83 Headlamp Check operation apply Polaris dielec 93 tric grease when lamp is replaced Brake light tail lamp Check operation apply Polaris dielec 94 tric grease when lamp is replaced 39 Starting the Engine WARNING Engine exhaust contains poisonous carbon monoxide and can cause loss of consciousness resulting in severe injury or death Never run an engine in an enclosed area 1 2 3 4 Sit in the driver s seat and fasten the seat belt Engage the park brake Shift the transmission to neutral Apply the brakes NOTE Do not press the throttle pedal while starting the engine 5 Turn the ignition key past ON RUN position to START Engage the starter for a maximum of five seconds Release the key when the engine starts If the engine does not start within five seconds release
50. d conditions stated below 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 fail ure 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 authorized 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 nec essary shall be warranted for the warranty period Any warranted part which is sched uled 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 122 WARRANTY California Emission Control Warranty Statement Emission Related Parts Covered Under This Warranty 1 Fuel Metering System 1 C
51. d in USA A WARNING Read understand and follow all of the instructions and safety precautions in this manual and on all product labels Failure to follow the safety precautions could result in serious injury or death A WARNING The engine exhaust from this product contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm WELCOME Thank you for purchasing a Polaris vehicle and welcome to our world wide family of Polaris owners We proudly produce an exciting line of utility and recreational products Snowmobiles e All terrain vehicles ATVs e RANGER utility vehicles Victory motorcycles We believe Polaris sets a standard of excellence for all utility and recre ational vehicles manufactured in the world today Many years of experi ence have gone into the engineering design and development of your Polaris vehicle making it the finest machine we ve ever produced For safe and enjoyable operation of your vehicle be sure to follow the instructions and recommendations in this owner s manual Your manual contains instructions for minor maintenance but information about major repairs is outlined in the Polaris Service Manual and should be performed only by a Factory Certified Master Service Dealer MSD Technician Your Polaris dealer knows your vehicle best and is interested in your total satisfaction Be sure to return to your
52. d 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 Fuel Cap Seat Belt The fuel tank filler cap is located on the right hand side of the vehicle near the passenger Gas Cap seat When refueling always use either leaded or unleaded gasoline with a minimum pump octane number of 87 R M 2 octane Do not use E 85 fuel Seat Belts The RANGER is equipped with lap style seat belts for the operator and passenger A 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 vehicle No person under the age of five 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 Make sure 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 4 Torelease the seat belt press the square red button in the buckle s center 33 FEATURES AND CONTROLS Console Instrument AWD Differential Switch Gauge if equipped Holder
53. dealership for all of your ser vice needs during and after the warranty period We also take great pride in our complete line of apparel parts and acces sories available through our online store at www purepolaris com Have your accessories and clothing delivered right to your door POLARIS The Way Out POLARIS POLARIS THE WAY OUT registered trademarks of Polaris Indus tries Inc Copyright 2006 Polaris Sales Inc All information contained within this publication is based on the latest product information at the time of publication Due to constant improvements in the design and quality of production components some minor discrep ancies may result between the actual vehicle and the information presented in this publi cation Depictions and or procedures in this publication are intended for reference use only No liability can be accepted for omissions or inaccuracies Any reprinting or reuse of the depictions and or procedures contained within whether whole or in part is expressly prohibited Printed in U S A 2007 RANGER 4X4 700 EFI RANGER 6X6 700 EFI Owner s Manual P N 9920636 2 TABLE OF CONTENTS Vehicle Identification Numbers 4 22 5 Features and 22 38 Emission Control 57
54. e ORUV emissions limited warranty is in addition to the Polaris standard limited warranty for this vehicle Polaris warrants that this vehicle is 1 designed built and equipped to conform at the time of initial sale with the requirements of 40 CFR 1051 and 2 free from defects in materials and workmanship that may keep it from meeting these requirements The emissions warranty period for this vehicle begins on the date the vehicle is deliv ered to the original retail purchaser and ends 30 months 2 5 years after that date or after 5000 km 3100 miles whichever comes first This emission related warranty covers components whose failure would increase an engine s emissions including electronic controls fuel injection exhaust gas recircula tion aftertreatment or any other system utilized in this vehicle to control emissions Replacing or repairing other components not covered by this emissions warranty or the standard warranty is the responsibility of the owner including the parts labor and other costs associated with recommended maintenance The exclusive remedy for breach of this limited warranty shall be at the exclusive option of Polaris repair or replacement of any defective materials components or prod ucts THE REMEDIES SET FORTH IN THIS LIMITED WARRANTY ARE THE ONLY REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF THIS WAR RANTY POLARIS SHALL HAVE NO LIABILITY TO ANY PERSON FOR INCI DENTAL CONSEQUENTIAL OR SPECIAL DAM
55. e Cargo 52 E EFI Blink Codes 31 32 Electromagnetic Interference 57 Emission Control 57 57 NOESY 57 Emissions Limited Warranty 120 Engine ate pees ek sees 106 Idle 86 65 68 Speed Display 29 40 Stopping 41 Equipment Modifications 13 Exhaust Cleaning 84 Exhaust Emission Control System 57 Exhaust System Warning 84 F Fan 78 Filling the 99 Filter Care During Storage 105 Filter Cleaning 83 Filter Cleaning Fuel 83 Filter 83 Filtet eet eax 83 Filter 83 Fluid Levels During Storage 105 Fluid Battery 99 Fluid Brake 87 Fogging Engine 106 Fouled 76 Freeplay Adjustment Throttle 86 Freeplay Steering Wheel 89 Front Gearcase Lubrication 71 Oil Chan ge A 71 Oil Check 71 33 Fuel 83 Fuel Safety 21 Fuel Stabilizer 105 Fuel Tank Fill
56. e hood Repeat View of driver s headlight with hood lifted steps 4 6 until the beam is properly adjusted Brake Lights When the brake pedal is depressed the console brake light comes on Check the brake light before each ride 1 Turn the ignition switch to the ON position 2 Depress the brake pedal The brake light should come on after about 10 mm 0 4 in of pedal travel If the light doesn t come on check the bulb 94 MAINTENANCE Vehicle Immersion CAUTION If your vehicle becomes immersed major engine damage can result if the machine is not thoroughly inspected Take the vehicle to your dealer before starting the engine If it s impossible to take your RANGER to a dealer before starting it fol low the steps outlined below 1 Move the vehicle to dry land or at the very least to water below the footrests Dry any water present in the air box Filter replacement is required if water is present Thoroughly dry the air pre cleaner located under the hood Remove the spark plugs Turn the engine over several times using the electric start NAAR WH Dry the spark plugs and reinstall or replace with new plugs NOTE Attempt to start the engine If necessary repeat the drying procedure 8 Take the vehicle to your dealer for service as soon as possible whether you succeed in starting it or not NOTE If water has been ingested into the PVT follow the procedure on page 82 for drying 95
57. ectronic Fuel Injection Ignition System ECU Spark Plug Gap 035 in 0 9 mm Front Suspension MacPherson strut w 6 25 in 15 9 cm of travel Center Suspension Independent w 5 25 in 13 3 cm of travel Rear Suspension Swing arm w dual shocks w 6 25 in 15 9 cm of travel 110 Lubrication System SPECIFICATIONS RANGER 6X6 EFI Pressurized Wet Sump Engine Oil 0 40 Driving System PVT Shift Type Single Lever Console H L N R Gear Reduction Low 8 71 1 Gear Reduction Reverse 5 9 1 Gear Reduction High 3 14 1 Drive Ratio Front 3 83 1 Drive Ratio Final 3 70 1 Tire Size Front 25x 10 12 Tire Size Center Rear 25x 11 12 Tire Pressure Front 8 12 psi Tire Pressure Rear 8 12 psi Brakes Front Rear Foot Activated 4 wheel hydraulic disc Brake Park Foot activated mechanical Hood Headlight 2 dual beam 35W quartz halogen Taillights 2 single beam 5W Brake Light 2 single beam 5W Indicator Light 1 0 W NOTE See your Polaris dealer for clutching specifications 111 POLARIS PRODUCTS Part Number Description Engine Lubricant 2870791 Fogging Oil 12 oz Aerosol 2871281 Premium 4 Synthetic OW 40 4 Cycle Engine Oil qt 2871844 Premium 4 Synthetic OW 40 4 En
58. ed parts In addition this warranty does not cover physical damage to paint or finish stress cracks tearing or puncturing of upholstery material corrosion or defects in parts components or the vehicle due to fire explosions or any other cause beyond Polaris control This warranty does not cover the use of unauthorized lubricants chemicals or fuels that are not compatible with the vehicle The exclusive remedy for breach of this warranty shall be at Polaris exclusive option repair or replacement of any defective materials or components or products THE REMEDIES SET FORTH IN THIS WARRANTY ARE THE ONLY REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF THIS WARRANTY POLARIS SHALL HAVE NO LIABILITY TO ANY PERSON FOR INCIDENTAL CONSEQUENTIAL OR SPECIAL DAMAGES OF ANY DESCRIP TION WHETHER ARISING OUT OF EXPRESS OR IMPLIED WARRANTY OR ANY OTHER CONTRACT NEGLIGENCE OR OTHER TORT OR OTHERWISE Some states do not permit the exclusion or limitation of incidental or consequential damages or implied warranties so the above limitations or exclusions may not apply to you if inconsistent with controlling state law 117 WARRANTY LIMITATIONS OF WARRANTIES AND REMEDIES ALL IMPLIED WARRANTIES INCLUDING BUT NOT LIMITED TO THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PAR TICULAR PURPOSE ARE LIMITED IN DURATION TO THE ABOVE SIX MONTH WARRANTY PERIOD POLARIS FURTHER DISCLAIMS ALL EXPRESS WARRANTIES NOT STATED IN THIS WARRANTY Some
59. en the throttle suddenly while backing ON ON Always inspect left and right fields of vision before backing A WARNING Failure to use caution when operating in reverse can result in serious injury or death Before shifting into reverse always check for obstacles or people behind the vehicle and follow the reverse operation procedures outlined in this manual Always back slowly 48 OPERATION Driving Safely Parking on an Incline Avoid parking on an incline if possible If it s unavoidable follow these precautions 1 Place the transmission in gear 2 Engage the park brake 3 Turn the engine off 4 Block the rear wheels on the downhill side WARNING A rolling vehicle can cause property damage and serious injury Always engage the park 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 park brake is engaged could cause loss of control and result in serious injury or death Always disengage the park brake before operating the vehicle 49 Driving Safely Hauling Cargo 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
60. er 33 G Gap Spark Plug 75 Gear Circuit Diagnostics 29 Gear S lectt 35 Gearcase Lubrication 69 Specification Chart 68 Main Lubrication 69 22222222 ho a 68 74 Gears shifting 35 H Hauling Load 50 51 Hauling Cargo 50 51 Headlight Beam Adjustment 94 Headlight Lamp Replacement 93 Hither se Pee ales 24 Hitch 53 Hour 27 Idle Speeds asic 86 Ignition 37 Indicator Service Interval 29 30 Inspection Axle 91 Brakes hee 88 Park Brake 88 PresRidens jot creed santa 39 Seat Belts 90 Steering Wheel 89 Throttle Freeplay 85 Wheel Nuts 91 Installation 98 Installation Wheels 92 Instrument Cluster 25 32 Interference Electromagnetic 57 K Key Maintenance Chart 59 Kilometers to Miles Toggle 30 129 INDEX L Lamp Replacement Headlight 93 Level Coolant 78 79 Light 37 Lights tad 93 94 Lights 94 Load
61. er position to lock the differential and operate in two wheel drive 2WD Press the bottom of the switch to unlock the differential and allow the rear drive wheels to operate indepen dently 1WD This mode of opera tion is well suited to turf driving or whenever aggressive traction is not required 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 55 OPERATION All Wheel Drive AWD The illuminated amber AWD switch indicates that the vehicle is in AWD When the AWD switch is on the front wheels will automatically engage any time the rear wheels lose traction When the rear wheels regain traction the front wheels will automatically disengage There is no limit to the length of time the vehicle may remain in AWD When the RANGER 6X6 AWD switch is in the off position the vehicle is in two wheel drive at all times When the RANGER 4X4 AWD switch is in the off position the differen tial is open and the vehicle is in one wheel drive for operation on turf or when active traction is not needed When the AWD switch is in the cen ter position the differential is locked and the vehicle is in two wheel drive See page 55 The AWD switch may be on or off while the vehicle is moving If the switch is turned off while the
62. ercise 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 A WARNING Traveling downhill improperly could cause loss of control or vehicle overturn Always check the terrain carefully before descending a hill Never descend a hill at high speed Excessive speed may result in loss of vehicle control and lead to serious injury or death Always operate slowly when traveling downhill Avoid descending a hill at an angle which would cause the vehicle to lean sharply to one side Travel straight downhill when possible 45 Driving Safely Driving Through Water A 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 floor boards Follow these procedures when oper ating through water 1 Always determine water depths and current before entering 2 Choose a crossing where both banks eas Floorboard have gradual on aa inclines D 3 Proceed slowly avoiding rocks and obstacles 4 Af
63. ers toggle The display in the tripmeter and odometer can be changed to display either standard or metric units of measurement 1 Enter the diagnostic mode 2 Toggle to the screen that displays either kilometers KM or miles MP 3 Press and hold the mode button until the letters flash then press and release the button once When the display stops flashing the mode has been set 30 FEATURES AND CONTROLS Instrument Cluster Rider Information Center Downloading Codes The EFI diagnostic mode is for informational purposes only Please see your Polaris dealer for all major repairs See page 32 for Blink Codes and Failure Descriptions Use the follow ing procedure to download blink codes failure codes from the EFI module 1 2 3 4 Engage the parking brake Stop the engine Turn the key switch to the ON position Turn the key switch off and on three times in less than five seconds then leave the switch on Any blink code numbers stored in the EFI module will display one at a time on the screen The number 61 and the word END displays after all codes have been transmitted 31 FEATURES AND CONTROLS Instrument Cluster Rider Information Center Downloading Codes Blink Failure Description Code No RPM Signal 21 Loss of Synchronization 45 Barometric Pressure Sensor Circuit Lo
64. ervals outlined in the Peri odic Maintenance Chart beginning on page 58 or more often under severe use such as wet or dusty conditions Items not listed in the chart should be lubricated at the general lubrication interval Item Lube Method Engine Oil Polaris Premium 4 Synthetic Add to proper level on dipstick ow40 See page 66 Brake Fluid DOT 3 or DOT 4 Maintain level between fill lines See page 87 Main Gearcase Oil Premium AGL Synthetic See page 69 Transmission Gearcase Lube Front Gearcase Oil Premium Demand Drive Hub See page 71 Fluid Middle Gearcase Oil Premium ATV Angle Drive page 72 6X6 only Fluid Rear Gearcase Oil Premium ATV Angle Drive page 73 Fluid Prop Shaft U joints Polaris Premium U Joint Lube Locate fittings and grease See page 64 Front Prop Shaft Yoke Polaris Premium U Joint Lube Locate fittings and grease 3 pumps maximum See page 64 Ball Joint Polaris Premium all Season Locate fitting back side of Grease or grease conform struts grease with grease gun ing to NLGI No 2 See page 64 Swing Arm Polaris Premium all Season Locate fittings on swing arm and Bushings Grease or grease conform grease with grease gun See ing to NLGI No 2 page 64 63 MAINTENANCE Lubrication Recommendations 6X6 Prop Shaft U Joints F gt O IG 6X6 Ball Joint Sw
65. 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 trav eling downhill and for braking on hills Check the terrain carefully before descending a hill Never travel downhill at high speed Avoid going downhill at an angle which would cause the vehicle to lean sharply to one side Travel straight down the hill where possible Always check for obstacles before operating in a new area Never attempt to operate over large obstacles such as rocks or fallen trees Always follow the proper procedures outlined in this manual when operating over obstacles Always be careful of skidding or sliding On slippery surfaces such as ice travel slowly and exercise caution to reduce the chance of skid ding or sliding out of control Never operate your vehicle in fast flowing water or in water deeper than that specified in this manual Wet brakes
66. ft Type Single Lever H L N R Gear Reduction Low 8 71 1 Gear Reduction Reverse 5 94 1 Gear Reduction High 3 14 1 Drive Ratio Front 3 83 1 Drive Ratio Final 3 70 1 Tire Size Front 26x 8 12 Tire Size Rear 26x 1 12 Tire Pressure Front 8 12 psi Tire Pressure Rear 8 12 psi Brakes Front Rear Foot Activated 4 wheel hydraulic disc Brake Park Foot activated mechanical Hood Headlight 2 dual beam 35W quartz halogen Taillights 2 single beam 5W Brake Light 2 single beam 5W Indicator Light 1 0 W NOTE See your Polaris dealer for clutching specifications 109 SPECIFICATIONS RANGER 6X6 EFI Gross Vehicle Weight 2900 Ibs 1317 kg Fuel Capacity 9 gal 341 Engine Oil Capacity 2 qts 2 1 1 Coolant Capacity 3 25 qts 3 1 Towing Capacity 1750 165 794 kg Max Cargo Box Load 1250 165 567 kg Overall Length 120 in 304 8 cm Overall Width box 60 in 152 4 cm Overall Width tires 58 in 147 3 cm Overall Height 75 in 190 5 cm Wheelbase 90 in 228 6 cm Cargo Box L x W x H 58 x 48 x 10 in 147 x 122 x 25 4 cm Ground Clearance 7 2 in 18 cm Min Turning Radius 180 in 457 2 cm Engine 4 valve 4 stroke twin cylinder with counter bal ance Displacement 683 cc Bore x Stroke 80 x 68 Alternator Output 500 W 3000 RPM Compression Ratio 9 40 1 Starting System Electric Fuel System El
67. ght Load Weight Vertical Towin Level Ground 15 grade Weight Spee RANGER 1500 lbs 850 lbs 150 165 10 mph 4 4 EFI 681 kg 386 kg 68 1 kg 16 kph RANGER 1750 lbs 1000 Ibs 150 165 10 mph 6X6 EFI 794 kg 454 kg 68 1 kg 16 kph Belt Life To extend belt life use the lowest gear possible when hauling or towing heavy cargo 53 OPERATION Driving Safely Parking the Vehicle WARNING A rolling vehicle can cause property damage and serious injury Always engage the park brake after stopping the engine Stop the vehicle on a level surface Turn the engine off Engage the park brake wees Remove the ignition switch key to prevent unauthorized use 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 54 Differential Lock 4X4 Models Locking the Differential The 4X4 rear axle is equipped with a lockable differential that allows the 4 4 operator to choose between an open differential or a closed differential Locking the differential in slippery or low traction conditions helps improve traction Press the top of the rocker switch to engage All Wheel Drive AWD Move the rocker switch to the cent
68. gine Oil gal Gearcase Transmission Lubricants 2873602 Premium AGL Synthetic Gearcase Lubricant qt 2873603 Premium AGL Synthetic Gearcase Lube gal 2871653 Premium ATV Angle Drive Fluid 8 oz 2872276 Premium ATV Angle Drive Fluid 2 5 gal 2870465 Pump for Gallon Jug 2871654 Premium Demand Drive Hub Fluid 8 oz 2872277 Premium Demand Drive Hub Fluid 2 5 gal Coolant 2871323 60 40 Coolant gal 2871534 60 40 Coolant qt Grease Specialized Lubricants 2871312 Grease Gun Kit Premium All Season 3 oz 2871322 Premium All Season Grease 3 oz cartridge 2871423 Premium All Season Grease 14 oz cartridge 2871460 Starter Drive Grease 2 oz 2871515 Premium U Joint Lube 3 oz 2871551 Premium U Joint Lube 14 oz 2871329 Dielectric Grease Nyogel 2872073 Chain Lube Aerosol 6 25 oz 2872348 Chain Lube Aerosol 16 oz Additives Miscellaneous 2872889 Brake and Clutch Cleaner 2871326 Carbon Clean Plus 12 oz 2870652 Fuel Stabilizer 16 oz 2872189 DOT 4 Brake Fluid 2870990 DOT 3 Brake Fluid 2872893 Engine Degreaser 12 oz 2871956 Loctite 565 Thread Sealant 2871076 Polaris Battery Tender Charger 112 TROUBLESHOOTING Drive Belt Wear Burn Possible Cause Driving onto a pickup or tall trailer in high range Solution Use low range during loading Starting out going up a steep incline Use low range See warnings on page 44 Driving at low RPM or ground speed 3 7 MPH
69. he fill plug Check the oil level 3 Add the recommended oil as needed 4 Reinstall the fill plug Torque to spec ification 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 Drain Plug 4 Place a drain pan under the drain plug on the bottom right hand side 5 Remove the drain plug Drain the oil Discard used oil properly 6 Clean the drain plug Reinstall the drain plug Torque to specifica tion Add the recommended oil 8 Reinstall the fill plug Torque to specification Check for leaks 71 MAINTENANCE Gearcases Middle Gearcase 6X6 Always check and change the middle gearcase oil at the intervals out lined in the Periodic Maintenance Chart beginning on page 58 Maintain the oil level even with the bottom thread of the fill plug hole Refer to the Gearcase Specifications Chart on page 68 for recommended lubricants capacities and torque specifications See page 112 for the part numbers of Polaris products The middle gearcase fill plug is located on the side of the gearcase Oil Check 1 Position the vehicle on a level sur face 2 Remove the fill plug Check the oil level 3 Add the recommended oil as needed 4 Reinstall the fill plug Torque to specification Oil Change 1 Remove the fill plug 2 Remove the drain plug from the Drain Plug bottom of the gearcase Drain
70. hift the transmission into gear Check your surroundings and determine your path of travel Release the park brake Keeping both hands on the steering wheel slowly release the brakes and depress the throttle with your right foot to begin driving Drive slowly Practice maneuvering and using the throttle and brakes on level surfaces NOTE Low gear is the primary range for operating the RANGER High gear is 42 intended for use on hard packed surfaces with light loads 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 con ditions follow these precautions 1 Slow down when entering slippery areas 2 Maintain a high level of alertness reading the trail and avoiding quick sharp turns which can cause skids 3 Correct a skid by turning the steering wheel in the direction of the skid 4 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 o
71. his engine is certified to be emission compliant for 1000 hours of use 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 con trol 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 vehi cle 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 engine must be designed built and equipped to meet the state s stringent anti smog standards Polaris must warrant the emission control system on your LSI engine for the period of time described below provided there has been no abuse neglect or improper mainte nance 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 121 WARRANTY California Emissi
72. ible Rich Fuel Cause Fuel is very high octane Solution Replace with lower octane fuel 115 TROUBLESHOOTING Engine Stops or Loses Power Possible Cause Solution Out of fuel Refuel Kinked or plugged fuel vent line Inspect and replace Water is present in fuel Replace with new fuel Fouled or defective spark plugs Inspect clean and or replace spark plug Worn or defective spark plug wires See your dealer Incorrect spark plug gap or heat range Set gap to specs or replace plug Loose ignition connections Check all connections and tighten Low battery voltage Recharge the battery to 12 8 VDC Incorrect fuel Replace with fresh recommended fuel Clogged air filter Inspect and clean or replace Other mechanical failure See your dealer Overheated engine Clean radiator screen and core clean engine exterior see your dealer 116 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 Polaris also gives a one year limited warranty on the final drive chain for failure due to defects This warranty covers the parts and labor charges for repair or replacement of defective parts which are covered by this warranty This war ranty begins on the date of purchase This warranty is transferab
73. id Replenishment 99 Installation 98 97 99 Beam Adjustment Headlight 94 Before 39 Belt Burning 113 ine 53 Belt 113 Belts 33 90 Blink Codes 31 32 Brake Fluid 87 Brake Inspection 88 Brake Lights 94 Brake 1 36 Brake eee 36 Brake Park Adjustment 88 Brakes et lana een 87 88 Braking 41 Break In 38 Burning 113 Button 34 Fuel 33 Capacity Weight 51 A 50 51 Cargo Box Dumping 52 128 Changing Coolant 77 Changing 35 Changing Oil Front Gearcase 71 Middle Gearcase 72 Rear Gearcase 74 Transmission Main Gearcase 70 Chart Gearcase Specifications 68 Chart Periodic Maintenance 58 62 Checking Oil Front Gearcase 71 Middle Gearcase 72 Transmission Main Gearcase 69 Chrome Wheel Care 104 Cleaning and Storage 102
74. idly 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 87 MAINTENANCE Brakes Brake Inspection 1 2 Park Brake Inspection 1 2 Check the brake system for fluid leaks Check the brake pedal for excessive travel or a spongy feel Check the friction pads for wear damage and looseness Inspect the brake disc spline and pad wear surface for excessive wear Change pads when worn to 3 64 1 mm Slowly push the park brake pedal down with your foot After 8 to 12 clicks of pedal travel check the vehicle for movement The vehicle should not roll while parked If the vehicle moves adjust the park brake Park Brake Pedal Park Brake Adjustment 1 2 3 88 Position the vehicle level surface Shift the transmission to neutral Loosen or tighten the nuts on the pedal end of the park brake cable as needed MAINTENANCE Steering Wheel Inspection Check the steering wheel for specified freeplay and smooth operation at the intervals outlined in the Periodic Maintenance Chart beginning on page 58 1 Position the vehicle on level ground 2 Lightly turn the steering wheel left and right 3 There should be 0 8 1 0 20 25 mm of freeplay 4 If there is excessive freeplay or strange noises or the stee
75. ified service dealer inspect the entire vehicle for possible damage including but not limited to brakes throttle and steering systems WARNING Exhaust system components are very hot during and after use of the vehicle Hot components can cause serious burns and fire Do not touch hot exhaust system components Always keep combustible materials away from the exhaust system Use caution when traveling through tall grass especially dry grass 20 SAFETY Fuel Safety WARNING Gasoline is highly flammable and is explosive under certain conditions Always exercise extreme caution whenever handling gasoline Always stop the engine when refueling Always refuel outdoors or in a well ventilated area 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 Gasoline powered engine exhaust fumes are poisonous and can cause loss of consciousness and death in a short time 21 FEATURES AND CONTROLS Component Locations 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 108 Cab Frame if Equipped
76. ing Passengers can be thrown off This can cause serious injury or death e Never carry passengers in cargo box Maximum 2X4 Box Load 850 Ibs Maximum 4X4 Box Load 1000 Ibs Maximum 6X6 Box Load 1200 Ibs IMPROPER TIRE PRESSURE OR OVERLOADING can cause loss of control resulting in SEVERE INJURY OR DEATH TIRE PRESSURE PSI RANGER 2X4 and 4X4 FRONT 10 REAR 10 RANGER 6X6 FRONT 10 CENTER 10 REAR 10 MAXIMUM WEIGHT CAPACITY Gross Vehicle Weight INCLUDING MACHINE DRIVER AND CARGO RANGER 2X4 and 4X4 is 2750 LBS RANGER 6X6 is 2900 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 SAFETY Safety Decals and Locations Cab Frame Seat Belt Warning Clutch Cover lt Warning Clutch Cover Warning WARNING NO STEP Moving parts hazard under belt clutch guard To prevent serious injury do not operate vehicle with guard removed Do not modify engine or clutch Doing so can cause part failure possible imbalance and excessive engine RPM which can result in serious injury or death Cab Frame Seat Belt Warning
77. ing Arm Bushings 64 MAINTENANCE Engine Oil Always check and change the engine oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 58 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 112 for the part num bers of Polaris products Premium 4 possesses unsurpassed film strength over the widest possible temperature range It resists viscosity and frictional breakdown in ambi ent temperatures from 40 to 120 Its exceptional frictional prop erties 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 OW 40 Oil may need to be changed more frequently if Polaris Premium 4 is not used Follow the manufacturer s recommendations for ambient tem perature operation CAUTION Mixing brands or using a non recommended oil may cause serious engine damage We recommend the use of Polaris Premium 4 All Season synthetic oil or API certified SH oil OW 40 Never substitute or mix oil brands Use only OW 40 WARNING Vehicle operation with in
78. ion as proof of residence Upon residence verification the servicing dealer will be authorized to per form the warranty repair If You Move If you move to another country be sure to contact Polaris Customer Assistance and the customs department of the destination country before you move Vehicles importation rules vary considerably from country to country You may be required to present docu mentation of your move to Polaris Industries in order to continue your warranty cover age You may also be required to obtain documentation from Polaris Industries in order to register your vehicle in your new country If Purchased From A Private Party If you purchase a Polaris product from a private citizen outside of the country in which the vehicle was originally purchased all warranty coverage will be denied Notice If your vehicle is registered outside of the country where it was purchased and you have not followed the procedure set out above your vehicle will no longer be eligible for war ranty or service bulletin coverage of any kind Vehicles registered to Government offi cials or military personnel on assignment outside of the country where the vehicle was purchased will continue to be covered by the basic warranty For questions call Polaris Customer Assistance United States 1 763 417 8650 Canada 1 204 925 7100 119 WARRANTY U S A EPA Emissions Limited Warranty This All Terrain Vehicle ATV or Off Road Utility Vehicl
79. ion 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 18 SAFETY Operator Safety A WARNING POTENTIAL HAZARD Failure to follow the minimum age recommendations for this vehicle WHAT CAN HAPPEN Serious injury or death the child or others HOW TO AVOID THE HAZARD 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 5 Always maintain proper tire pressure as described on the decal and in the Owner s Manual See page 5 19 SAFETY Operator Safety A WARNING Leaving the keys in the ignition can lead to unauthorized use of the vehicle resulting in serious injury or death Always remove the ignition key when the vehicle is not in use WARNING After any overturn or accident have a qual
80. ions Maintenance intervals in the following chart are based upon average riding conditions and an average vehicle speed of approximately ten 10 miles per hour Vehicles subjected to severe use must be inspected and serviced more frequently Severe Use Definition Frequent immersion in mud water or sand Racing or race style high RPM use Prolonged low speed heavy load operation Extended idle e 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 crank case Change oil immediately if the oil level begins to rise Monitor the oil level and if it continues to rise discontinue use and determine the cause or see your dealer 58 MAINTENANCE Periodic Maintenance Chart Maintenance Chart Key gt Perform these operations more often for vehicles subjected to severe use E Emission Control System Service 4 Cycle California Have an authorized Polaris dealer perform these services WARNING Improperly performing the procedures marked with a could result in component failure and lead to serious injury or death Have an authorized Polaris dealer perform these services 59 MAINTENANCE Periodic Maintenance Chart Perform all services at whichever maintenance interval is reached first Item
81. is dealer perform these services 60 Periodic Maintenance Chart MAINTENANCE Item Maintenance Interval Remarks whichever comes first Hours Calendar Miles Km gt Engine breather 25H Monthly Inspect replace if necessary filter if equipped gt Engine oil change 25H 1M Perform break in change break in at one month gt General 50 H 3M Lubricate all fittings pivots lubrication cables etc Shift Linkage 50H 6M Inspect lubricate adjust E Steering 50H 6M Lubricate gt Front Suspension 50 H 6M Lubricate gt Rear Suspension 50 H 6M Lubricate E Throttle cable 50H 6M Inspect adjust lubricate switch replace if necessary Throttle body air 50H 6M Inspect duct for proper seal intake ducts flange ing air leaks Drive belt 50H 6M Inspect adjust replace as needed Cooling system 50H 6M Inspect coolant strength if applicable seasonally pressure test system yearly gt Engine oil change 100 H 6M Perform a break in change at one month gt Oil filter change 100 H 6M Replace with oil change Perform these procedures more often for vehicles subjected to severe use E Emission Control System Service 4 Cycle California Have an authorized Polaris dealer perform these services 61 MAINTENANCE Periodic Maintenance Chart
82. le to another consumer during the warranty period through a Polaris dealer REGISTRATION At the time of sale the Warranty Registration Form must be completed by your dealer and submitted to Polaris within ten days Upon receipt of this registration Polaris will record the registration for warranty No verification of registration will be sent to the purchaser as the copy of the Warranty Registration Form will be the warranty entitle ment If you have not signed the original registration and received the customer copy please contact your dealer immediately NO WARRANTY COVERAGE WILL BE ALLOWED UNLESS YOUR VEHICLE IS REGISTERED WITH POLARIS Initial dealer preparation and set up of your vehicle is very important in ensuring trou ble free operation Purchasing a machine in the crate or without proper dealer set up will void your warranty coverage WARRANTY COVERAGE AND EXCLUSIONS LIMITATIONS OF WARRANTIES AND REMEDIES The Polaris limited warranty excludes any failures that are not caused by a defect in material or workmanship This warranty does not cover accidental damage normal wear and tear abuse or improper handling This warranty also does not cover any vehicle that has been altered structurally modified neglected improperly maintained used for rac ing or used for purposes other than for which it was manufactured or for any damages which occur during trailer transit or as a result of unauthorized service or the use of unauthoriz
83. led spark plug wires See your dealer Incorrect ignition timing See your dealer Mechanical failure See your dealer Loose ignition connections Check all connections and tighten Water present in fuel Replace with fresh recommended fuel 114 Engine Pings Knocks TROUBLESHOOTING Possible Cause Poor quality or low octane fuel Solution Replace with recommended fuel Incorrect ignition timing See your dealer Incorrect spark plug gap or heat range Set gap to specs or replace plugs Engine Runs Irregularly Stalls or Misfires Possible Cause Fouled or defective spark plugs Solution Inspect clean and or replace spark plugs Worn or defective spark plug wires See your dealer Incorrect spark plug gap or heat range Set gap to specs or replace plugs Loose ignition connections Check all connections and tighten Water present in fuel Replace with new fuel Low battery voltage Recharge battery to 12 8 VDC Kinked or plugged fuel tank vent line Inspect and replace Incorrect fuel Replace with recommended fuel Clogged air filter Other mechanical failure Possible Lean Fuel Cause Low or contaminated fuel Inspect and clean or replace See your dealer Solution Add or change fuel clean the fuel system Low octane fuel Replace with recommended fuel Clogged fuel filter Replace filter Poss
84. lling up on the tailgate latch Stand clear and pull up on the cargo box release lever Lift the front of the cargo box to dump the cargo 99 Lower the cargo box push down securely to latch A WARNING If the weight distribution on the box is located toward the rear of the box when the release lever is pulled forward the box may dump unexpectedly and cause serious injury to the operator or bystanders Never operate the dump lever without ensuring that the load is positioned evenly or at the front of the box 52 Driving Safely Towing Loads 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 See page 50 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 108 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 Model Total Towed Total Towed Total Hitch Maximum Load Wei
85. manual This preventive maintenance program is designed to ensure that all critical components on your vehi cle are thoroughly inspected at specific intervals SAFETY Operator Safety The following signal words and symbols appear throughout this manual and on your vehicle Your safety is involved when these words and sym bols are used Become familiar with their meanings before reading the manual A The safety alert symbol on your vehicle or in this manual alerts you to the potential for injury 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 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 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 e Read this manual and all labels carefully Follow the operating proce dures described Never allow anyone without a valid driver s license to operate this vehicle e 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
86. minutes 5 Stop the engine Inspect for leaks 6 Re check the oil level on the dipstick and add oil as necessary to bring the level to the upper mark on the dipstick 7 Dispose of used filter and properly Gearcases Gearcase Specification Chart Gearcase Lubricant Capacity Fill Plug Drain Plug Torque Torque Main Gearcase Premium AGL 15 2 oz 14 ft Ibs 14 ft Ibs Transmission Synthetic 450 ml 19 4 Nm 19 4 Nm Gearcase Lube Front Gearcase Premium Demand 5 02 8 10 ft Ibs 11 ft Ibs Drive Hub Fluid 150ml 11 13 6 Nm 15 Nm Middle Gearcase Premium ATV 6 75 oz 14 ft Ibs 14 ft Ibs 6X6 Angle Drive Fluid 200 ml 19 4 Nm 19 4 Nm Rear Gearcase Premium ATV 18 oz 40 50 ft Ibs 30 45 in Ibs 4X4 Angle Drive Fluid 532 54 68 Nm 3 5 Nm Rear Gearcase Premium ATV 10 oz 14 ft Ibs 14 ft Ibs 6X6 Angle Drive Fluid 300 ml 19 4 Nm 19 4 Nm 68 Gearcases Transmission Main Gearcase Always check and change the transmission oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 58 Maintain the oil level even with the bottom of the fill plug hole Refer to the Gearcase Specifications Chart on page 68 for recommended lubricants capacities and torque specifications See page 112 for the part numbers of Polaris products The fill plug is located at the rear of the vehicle Oil Check 1 Position the vehicle on a level su
87. move the radi ator cap Radiator 3 View the coolant level through the opening 4 Usea 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 25 the radiator should also be inspected NOTE Use of anon standard pressure cap will not allow the recovery system to function properly See your dealer for the correct replacement part 79 MAINTENANCE Polaris Variable Transmission PVT System Belt slip is responsible for creating excessive heat that destroys belts wears clutch components and causes outer clutch covers to fail Switch to low range while operating at slower speeds to extend the life of the PVT components belt cover etc When To Use Low Range and High Range Condition Range to Use Operating at speeds less than 7 MPH 11 km h Low Towing heavy loads Low Operating in rough terrain swamps mountains etc Low Operating at speeds greater than 7 MPH 11 km h High 80 MAINTENANCE 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
88. n are in accordance with Polaris recommendations 118 WARRANTY Exported Vehicles EXCEPT WHERE SPECIFICALLY REQUIRED BY LAW THERE IS NO WAR RANTY OR SERVICE BULLETIN COVERAGE ON THIS VEHICLE IF IT IS SOLD OUTSIDE THE COUNTRY OF THE SELLING DEALER S AUTHORIZED LOCA TION This policy does not apply to vehicles that have received authorization for export from Polaris Industries Dealers may not give authorization for export You should consult an authorized dealer to determine this vehicle s warranty or service bulletin coverage if you have any questions This policy does not apply to vehicles registered to government officials or military per sonnel on assignment outside the country of the selling dealer s authorized location This policy does not apply to Safety 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 locat
89. n excessively slippery surfaces Always reduce speed and use additional caution when operating on slippery surfaces 43 Driving Safely Driving Uphill Whenever traveling uphill follow these precautions 1 Always travel straight uphill 2 Avoid steep hills 15 maximum 3 Keep both feet on the floor 4 Proceed at a 15 maximum steady rate of speed and throttle opening A WARNING Climbing hills improperly can cause loss of control or vehicle overturn Always check the terrain carefully before climbing a hill Braking and handling are greatly affected when operating in hilly terrain Improper 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 44 Driving Safely Driving on a Sidehill Sidehilling 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 ex
90. n use to pre vent unauthorized use or accidental starting FOR MORE INFORMATION ABOUT SAFETY call Polaris at 1 800 342 3764 12 SAFETY Operator Safety A 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 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 vehi cle create a substantial 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 po
91. nd instructions Removing Corrosion If light rust is found on the chrome finish use steel wool 0000 OTT grade to remove it Gently rub the affected areas with the steel wool until the corrosion has been removed Clean and polish the wheel as out lined above 104 Cleaning and Storage Storage Tips CAUTION Starting the engine during the storage period will disturb the protective film created by fogging and damage could occur Never start the engine during the storage period Clean the Exterior Make any necessary repairs and clean the vehicle as recommended See page 102 Stabilize the Fuel 1 Fill the fuel tank 2 Add Polaris Carbon Clean Fuel Treatment or Polaris Fuel Stabilizer Follow the instructions on the container for the recommended amount NOTE Carbon Clean removes water from fuel systems stabilizes fuel and removes carbon deposits from pistons rings valves and exhaust sys tems 3 Allow the engine to run for 15 20 minutes to allow the stabilizer to disperse through the entire fuel delivery system Oil and Filter Change the oil and filter See page 67 Air Filter Air Box Inspect and clean or replace the pre cleaner and air filter See page 83 Clean the air box Drain the sediment tube Fluid Levels Inspect the fluid levels Add or change fluids as recommended in the Periodic Maintenance Chart beginning on page 58 Front and rear gearcase fluid
92. ng unit securely with suitable straps or rope Do not attach tie straps to the front A arm bolt pockets 107 SPECIFICATIONS RANGER 4X4 EFI Gross Vehicle Weight 2750 Ibs 1247 kg Fuel Capacity 9 gal 341 Engine Oil Capacity 2 qts 2 1 1 Coolant Capacity 3 25 qts 3 1 Towing Capacity 1500 165 681 kg Hitch Tongue Capacity 150 165 68 kg Max Cargo Box Load 1000 Ibs 454 kg Overall Length 113 in 282 cm Overall Width box 60 in 152 4 cm Overall Width tires 58 in 147 3 cm Overall Height 75 in 190 5 cm Wheelbase 76 in 193 cm Cargo Box L x W x H 58 x 42 x 10 in 147 x 106 7 x 25 4 cm Ground Clearance 11 5 in 29 cm Min Turning Radius 132 in 335 3 cm Engine 4 valve 4 stroke twin cylinder with counter bal ance Displacement 683 cc Bore x Stroke 80 x 68 Alternator Output 500 W 3000 RPM Compression Ratio 9 40 1 Starting System Electric Fuel System Electronic Fuel Injection Ignition System ECU Spark Plug Gap RC7YC 035 in 0 9 mm Front Suspension MacPherson strut w 8 in 20 3 cm of travel Rear Suspension Independent w 9 0 in 22 9 cm of travel 108 Lubrication System SPECIFICATIONS RANGER 4X4 EFI Pressurized Wet Sump Engine Oil 0 40 Driving System Type PVT 4 wheel independent shaft lockable differ ential Shi
93. ntains minerals that are harmful to a battery 99 MAINTENANCE Battery Battery Charging Conventional Battery 1 Remove the battery from the vehicle to prevent damage from leak ing or spilled electrolyte during charging See page 97 2 Charge the battery with a charging output no larger than 1 10 of the battery s amp hr rating Charge as needed to raise the specific grav ity to 1 270 or greater 3 Reinstall the battery See page 98 Make sure the positive terminal is toward the front of the vehicle Battery Charging Sealed Battery The following battery charging instructions apply only to the installa tion of a sealed battery Read all instructions before proceeding with the installation of this battery The sealed battery is already filled with electrolyte and has been sealed and fully charged at the factory Never pry the sealing strip off or add any other fluid to this battery The single most important thing about maintaining a sealed battery is to keep it fully charged Since the battery is sealed and the sealing strip cannot be removed you must use a voltmeter or multimeter to measure DC voltage WARNING An overheated battery may explode causing severe injury or death Always watch charging times carefully Stop charging if the battery becomes very warm to the touch Allow it to cool before resuming charging For a refresh charge follow all instructions carefully 1 Check the battery v
94. oltage with a voltmeter or multimeter A fully charged battery will register 12 8 V or higher 2 Ifthe voltage is less than 12 8 volts recharge the battery at 1 2 amps or less until battery voltage is 12 8 or greater NOTE When using an automatic charger refer to the charger manufacturer s instructions for recharging When using a constant current charger use the guidelines on the next page for recharging 100 Battery MAINTENANCE Battery Charging Sealed Battery NOTE Always verify battery condition before and 1 2 hours after the end of charging State of Charge Voltage Action Using constant current Charge charger standard amps specified on top of battery 100 12 8 13 0 volts None check at 3 None required mos from date of manufacture 75 100 12 5 12 8 volts May need slight 3 6 hours charge if no charge given check in 3 months Needs charge 5 11 hours 50 75 12 0 12 5 volts At least 13 hours 25 50 11 5 12 0 volts Needs charge verify state of charge 0 25 11 5 volts or less Needs charge with desulfating charger At least 20 hours 101 MAINTENANCE Cleaning and Storage Washing the Vehicle Keeping your Polaris vehicle clean will not only improve its appearance but it can also extend the life of various components CAUTION High water pressure may damage components Polaris recommends washing the vehicle by hand or with a garden hose
95. on Electrical equipment can be used START Turn the key to the START position to engage the electric starter The key returns to the ON position when released Light Switch The ignition switch key must be in the ON RUN position to operate the headlights The light switch has three positions high beam low beam and off AWD Differential Lock Switch The AWD Differential Switch has three positions All Wheel Drive AWD Differential Lock Two Wheel Drive 2WD and Off 1 WD turf mode Press the top of the rocker switch to engage All Wheel Drive AWD See page 56 for AWD oper ating instructions Move the rocker switch to the center position 4X4 models to lock the differential and operate in two wheel drive 2WD See page 55 for Differ ential Lock operating instructions Press the bottom of the switch to unlock the differ ential and allow the rear drive wheels to operate independently 1 WD This mode of operation is well suited to turf driving or when active traction is not needed 37 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 the engine Perform the
96. on Control Warranty Statement 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 Owner s Manual POLARIS recommends that you retain all receipts covering maintenance 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 As the 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 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 an
97. 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 Man ual 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 having all scheduled inspection and mainte nance 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 war ranty 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 124 WARRANTY Perform these procedures more often for vehicles subjected to
98. porate any water that may have entered the engine or exhaust system Polishing the Vehicle Polaris recommends the use of common household aerosol furniture polish for polishing the finish on your Polaris vehicle Follow the instructions on the container Polishing Tips e Avoid the use of automotive products some of which can scratch the finish of your vehicle Always use clean cloths and pads for cleaning and polishing Old or reused cloths and pads may contain dirt particles that will scratch the finish 103 Cleaning and Storage Chrome Wheel Care if equipped Proper maintenance will protect chrome wheels from corrosion pre serve wheel life and ensure a like new appearance for many years NOTE Chrome wheels exposed to road salt or salt in the air in coastal areas are more susceptible to corrosion if not properly cleaned Clean chrome wheels more often if they re exposed to salt or other corrosive elements 1 Wash chrome wheels frequently Use a mild detergent Never use abrasive cleaners on plated or painted surfaces 2 Rinse well with clear water Soap detergents salt dirt mud and other elements can cause corrosion 3 Polish the clean chrome wheels periodically Use an automotive grade chrome polish 4 Routinely and liberally apply a weather resistant wax to each pol ished chrome wheel Choose a product suitable for chrome finishes Read and follow the product labels a
99. r enough to expose the end gt of the inline cable adjuster Bdot 4 Loosen the adjuster lock nut 5 Rotate the boot to turn the adjuster until 1 16 to 1 8 1 5 3 mm of freeplay is achieved at the throttle Fock pin Adjuster pedal See page 85 NOTE While adjusting lightly flip the throttle pedal up and down 6 Tighten the lock nut 7 Squeeze the end of the rubber boot and slide it over the cable adjuster to its original position 86 MAINTENANCE Brakes The front and rear brakes are hydraulic disc type brakes activated by the brake pedal See page 36 Brake Fluid Inspect the brake system rou Brake Fluid tinely Inspect the level of the Reservoir brake fluid before each opera tion Change the brake fluid every two years and any time the fluid becomes contaminated the fluid level is below the minimum or if the type and brand of the fluid in the reservoir are unknown 1 Position the vehicle on a level surface 2 View the brake fluid level at the reservoir under the hood The level should be between the upper MAX and lower MIN level lines 3 Ifthe fluid level is lower than the lower level line add brake fluid to the upper MAX line 4 Apply the brake forcefully for a few seconds and check for fluid leakage around the fittings A 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 rap
100. re when temperature is below freezing Wrong or missing belt Install the recommended belt Improper break in Always break in a new belt and or clutch See pages 38 and 80 113 TROUBLESHOOTING Engine Doesn t Turn Over Possible Cause Low battery voltage Solution Recharge the battery to 12 8 VDC Loose battery connections Check all connections and tighten Loose solenoid connections Check all connections and tighten Loose electronic control box connections Inspect clean reinstall connectors Engine Turns Over Fails to Start Possible Cause Out of fuel Solution Refuel Clogged fuel filter Inspect and clean or replace Water is present in fuel Drain the fuel system and refuel Old or non recommended fuel Replace with fresh recommended fuel Fouled or defective spark plugs Inspect plugs and replace if necessary No spark to spark plug Inspect plugs and replace if necessary Water or fuel in crankcase Immediately see your Polaris dealer Low battery voltage Mechanical failure Recharge the battery to 12 8 VDC See your dealer Engine Backfires Possible Cause Weak spark from spark plug Solution Inspect clean and or replace spark plugs Incorrect spark plug gap or heat range Set gap to specs or replace plugs Old or non recommended fuel Replace with fresh recommended fuel Incorrectly instal
101. rface 2 Remove the fill plug 3 Check the oil level 4 Add the recommended oil as needed 5 Reinstall the fill plug Torque to specification Fill Plug 69 MAINTENANCE Gearcases Transmission Main Gearcase Oil Change The drain plug 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 Place a drain pan under the drain plug Remove the drain plug Drain the oil Dispose of used oil properly 3 Wipe the magnetic end of the drain plug clean to remove accumulated metallic filings 4 After the oil has drained com pletely install a new sealing washer 5 Reinstall the drain plug Torque to specification 6 Add the recommended oil as needed Do not overfill 7 Reinstall the fill plug Torque to specification 8 Check for leaks Drain Plug 70 MAINTENANCE Gearcases Front Gearcases Always check and change the front gearcase oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 58 Maintain the oil level even with the bottom thread of the fill plug hole Refer to the Gearcase Specifications Chart on page 68 for recommended lubricants capacities and torque specifications See page 112 for the part numbers of Polaris products The front gearcase fill plug is located on the right side of the front gear case Oil Check 1 Position the vehicle on a level surface 2 Remove t
102. ring feels rough or catchy have the steering system inspected by an autho rized Polaris dealer Suspension Adjustment 4X4 The 4X4 rear suspension may be adjusted to provide a stiffer suspension if necessary 1 Remove the top shock mounting bolts from the inside mounting holes 2 Reposition the shocks to the outside mounting holes 3 Reinstall the shock mounting bolts Torque to 30 ft Ibs 40 Nm Outside Mounting Holes Inside Mounting Holes Rear Spring Adjustment The rear shock absorber springs are adjusted by rotating the adjustment cam either clockwise or counterclockwise to increase or decrease spring tension 89 MAINTENANCE 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 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 passengers before driv ing Although having the belt at 30 is typical for many peo ple it will not accommodate all body sizes and shapes Make sure the seat belt is adjusted to
103. s screen is for informational purposes only Please see your dealer for all major repairs Programmable service interval When the hours of engine operation equal the programmed service interval setting the wrench icon will flash for 5 seconds each time the engine is started When this feature is enabled it provides a convenient reminder to perform routine maintenance See page 30 NOTE The service interval is programmed at 50 hours at the factory 29 FEATURES AND CONTROLS Instrument Cluster Rider Information Center Diagnostic Mode Programmable service interval To enable or disable the service interval 1 Enter the diagnostic mode 2 Toggle to the service interval screen 3 Press and hold the mode button for about seven 7 seconds until either ON or OFF appears in the Rider Information Center depend ing on your preference To reset the service interval 1 Enter the diagnostic mode 2 Toggle to the service interval screen 3 Press and hold the mode button for 2 3 seconds until the wrench icon flashes Release the button 4 Press and release the mode button once to advance the setting by one hour Press and hold the mode button to advance the hours quickly NOTE If you scroll past the intended number press and hold the button until the hours cycle back to zero 5 When the desired setting is displayed wait until the wrench icon stops flashing The new service interval is now programmed Miles Kilomet
104. severe use E Emission Related Service Have an authorized Polaris dealer perform these services Item Maintenance Interval Remarks whichever comes first Hours Calendar Miles Km gt Air filter pre filter Daily Inspect clean often E gt Air box sediment Daily Drain deposits when visible tube gt Air filter Weekly Inspect replace as needed main element gt Engine breather 25H Monthly Inspect replace if necessary filter if equipped E Throttle Cable 50H 6M Inspect adjust lubricate Switch replace if necessary Throttle body air 50H 6M Inspect ducts for proper seal intake ducts flange ing air leaks Valve clearance 100 H 12M Inspect adjust E Fuel system 100 H 12M Check for leaks at tank cap E lines fuel valve filter pump throttle body replace lines every two years Spark plug 100 H 12M Inspect replace as needed 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 per formance 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 de
105. skin Always change the oil and filter at the intervals outlined in the Periodic Maintenance Chart beginning on page 58 Always change the oil filter whenever changing oil 1 2 3 4 5 6 Position the vehicle level surface Run the engine for two to three minutes until warm Stop the engine Clean the area around the drain plug Place a drain pan beneath engine crankcase and remove the drain plug Allow the oil to drain completely Reinstall the sealing washer on the drain plug NOTE The sealing surfaces on drain plug and crankcase should be clean and 10 11 free of burrs nicks or scratches Reinstall the drain plug Torque to 20 ft 165 27 Nm Place shop towels beneath the oil filter Using an oil filter wrench turn the filter counter clockwise to remove it Using a clean dry cloth clean the filter sealing surface on the crank case Lubricate the o ring on the new filter with a film of fresh engine oil Check to make sure the o ring is in good condition Install the new filter and turn by hand until the filter gasket contacts the sealing surface then turn and additional 1 2 turn 67 Engine Oil Oil and Filter Change 1 Remove the dipstick and fill the sump with two quarts 1 9 1 of rec ommended oil 2 Shift the transmission to neutral 3 Engage the park brake 4 Apply the brakes Start the engine Allow it to idle for one to two
106. sticks during operation Never start or operate this vehicle if it has a sticking or improperly operating throttle pedal Immediately contact your dealer for service if throttle problems arise Always check the pedal for free movement and return before starting the engine and occasionally during operation Throttle Freeplay If the throttle pedal has excessive play due to cable stretch or mis adjustment it will cause a delay in throttle response especially at low engine speed The throttle may also not open fully If the throttle pedal has no freeplay the throttle may be hard to control and the idle speed may be erratic Check the throttle pedal freeplay at the intervals outlined in the Periodic Maintenance Chart beginning on page 58 Adjust the freeplay if necessary Throttle Freeplay Inspection 1 Engage the park brake Shift the transmission to neutral 2 Apply the brakes Start the engine Allow it to warm up thoroughly 3 Measure the distance the throttle pedal moves before the engine begins to pick up speed Freeplay should be 1 16 to 1 8 inches 1 6 3 2 mm 85 MAINTENANCE Throttle System Throttle Body Idle RPM Idle RPM is preset by the manufacturer If the engine idle speed is not satisfactory please see your Polaris dealer for adjustment Throttle Freeplay Adjustment 1 Remove the seat 2 Locate the throttle cable adjuster 3 Squeeze the end of the rub ber boot and slide it fa
107. sufficient 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 65 MAINTENANCE Engine Oil Always check and change the oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 58 Always use the recommended engine oil Oil Check The oil dipstick and fill tube is located on the engine 1 Position the vehicle on a level surface 2 Apply the brakes Start the engine and allow it to idle for 20 30 seconds Stop the engine Dipstick 3 Lift the lever lock to remove the dipstick Wipe it dry with a clean cloth 4 Reinstall the dipstick completely but do not lock it The dipstick must be screwed completely in to keep the angle and depth of the stick consistent 5 Remove the dipstick and check the oil level Maintain the oil level in the safe range Do not overfill NOTE Due to the dipstick entry angle into the crankcase the oil level Check Level will read higher on the bottom on Top Side side of the dipstick Always read the level on the upper sur face of the dipstick 6 After reinstalling the dipstick be sure to seat the lever lock 66 Engine Oil Oil and Filter Change CAUTION Hot oil can cause serious burns to skin Do not allow hot oil to come into contact with
108. ter leaving water always dry the brakes by applying light pres sure to the pedal repeatedly until braking action is normal NOTE After running your vehicle in water it s critical that you perform the ser vices outlined in the Periodic Maintenance Chart beginning on page 58 Give special attention to engine oil transmission oil front and rear gearcases and all grease fittings CAUTION Immersion can result in major damage if the vehicle isn t serviced correctly and promptly After immersion always take the vehicle to your dealer 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 95 and take the vehicle to your dealer at the first opportunity 46 Driving Safely Driving Over Obstacles 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 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 47 OPERATION Driving Safely Driving in Reverse Follow these guidelines when operating in reverse Back slowly Apply the brakes lightly for stopping Avoid turning at sharp angles Always avoid backing downhill Never op
109. 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 mixture of high quality aluminum compatible anti freeze coolant and distilled water Polaris Premium 60 40 is already premixed and ready to use Do not dilute with water See page 112 for the part numbers of Polaris prod ucts NOTE Always follow the manufacturer s mixing recommendations for the freeze protection required in your area Any time the cooling system has been drained for maintenance or repair replace the coolant If the recovery bottle has run dry the level in the radiator should be inspected Add coolant as needed 77 MAINTENANCE Cooling System Radiator and Cooling Fan Always check and clean the screen and radiator fins at the intervals out lined in the Periodic Maintenance Chart beginning on page 58 Do not obstruct or deflect air flow through the radiator by installing unautho rized accessories in front of the radiator or behind the cooling fan Inter ference with the radiator air flow can lead to overheating and consequent engine damage CAUTION Washing the vehicle with a high pressure hose could damage the radiator fins and impair the radiator s effectiveness Using a high pressure system is not recommended Coolant Level Always check and ch
110. the lowest possible lap position before riding 1 To adjust loosen the bolts 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 A 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 90 MAINTENANCE Tires WARNING Operating your vehicle with worn tires will increase the possibility of skidding loss of control and an accident which could result in serious injury or death Always replace tires when the tread depth measures 1 8 3 mm or less Improper tire inflation or the use of non standard size or type of tires may adversely affect vehicle handling which could result in vehicle damage or personal injury Always maintain proper tire pressure When replacing tires always use original equipment size and type Tire Tread Depth Always replace tires 1 8 3 mm when tread depth is worn to 1 8 3 mm less or less A NS Axle and Wheel Nut Torque Specifications Inspect the following items occasionally for tightness and if they ve been loosened for maintenance service Nut Type Location Nut Torque Lug Nut Front and Rear 90 ft Ibs 122 Nm 2 Piece Fl
111. w Input 46 Barometric Pressure Sensor Circuit High Input 22 TPS Open or Short Circuit to Ground 22 TPS Short Circuit to Battery 23 RAM Error Defective ECU 42 Engine Temp Sensor Circuit Short to Ground 42 Engine Temp Sensor Circuit Open or Short to Battery 51 Injector 1 Open Load 51 Injector 1 Short Circuit to Ground 51 Injector 1 Short Circuit to Battery 52 Injector 2 Open Load 52 Injector 2 Short Circuit to Ground 52 Injector 2 Short Circuit to Battery 53 Rear Differential Open Load RANGER 4X4 only 53 Rear Differential Short Circuit to Ground RANGER 4X4 only 53 Rear Differential Short Circuit to Battery RANGER 4X4 only 54 Engine Temp Lamp Open Load 54 Engine Temp Lamp Short Circuit to Ground 54 Engine Temp Lamp Short Circuit to Battery 55 Diag Lamp Open Load 55 Diag Lamp Short Circuit to Ground 55 Diag Lamp Short Circuit to Battery 56 Pump Relay Open Load 56 Pump Relay Short Circuit to Ground 56 Pump Relay Short Circuit to Battery 57 Reverse Beeper Open Load 57 Reverse Beeper Short Circuit to Ground 57 Reverse Beeper Short Circuit to Battery 58 Cooling Fan Open Load 58 Cooling Fan Short Circuit to Ground 58 Cooling Fan Short Circuit to Battery 41 Intake Air Temp Sensor Open or Short Circuit to Sensor Voltage 41 Intake Air Temp Sensor Short Circuit to Ground 61 END 32 FEATURES AND CONTROLS Seat Removal Pull up on the front of the seat and slide it towar
112. wer NOTE The addition of certain accessories including but not limited to mow ers blades tires sprayers or large racks may change the handling characteristics of the vehicle Use only Polaris approved accessories and familiarize yourself with their function and effect on the vehicle 13 SAFETY Operator Safety A 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 Engage the park brake after fully stopped If you begin rolling backwards Never apply engine power Apply the brakes gradually When fully stopped engage the park 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 WARNING 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 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 14 SAFETY Operator Safety

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