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Pitco Frialator 5C+ Fryer User Manual

1. 22220 24 and 37 Operating Safety 46 55 Operation Warnings 10 19 Parking On An Incline 54 Premium 4 Synthetic Lubricant 37 PVT System 33 and 75 Rear Spring Adjustment 70 Recoil Starter 22222 gt 43 Riding On Slippery Surfaces 48 Spark Arrestor 00000 74 Spark Plugs 000005 73 Starting A Cold Engine 40 Starting A Warm Engine 42 Starting The Engine 40 42 Tire Inspection 2222 82 Tool Kit o opere Eus 75 Torque Specifications 69 Towing Capacities 45 Trail Obstacles 2 53 Transmission Gear Selector Operation 0 32 Transmission Oil Changing Procedure zie 67 Troubleshooting 89 Understanding Warnings 1 Vehicle Identification Numbers 20 Warranty ssessseesess 92 93 Wheel Installation 81 Wheel Removal 81
2. POLARIS RANGER Owner s Safety and Maintenance Manual A WARNING READ AND UNDERSTAND WARNINGS AND OWNER S MANUAL BEFORE OPERATION SEVERE INJURY OR DEATH CAN RESULT FROM IGNORING WARNINGS OR IMPROPER USE THIS VEHICLE SHOULD BE OPERATED ONLY BY PERSONS WITH A VALID DRIVER S LICENSE MINIMUM AGE RECOMMENDATION FOR PASSENGERS IS FIVE YEARS OLD THIS VEHICLE CAN BE HAZARDOUS TO OPERATE A collision or rollover can occur quickly even during routine maneuvers such as turning or driving on hills or over obstacles if you fail to take proper precautions TO REDUCE TIPOVER RISK BE ESPECIALLY CAREFUL WHEN ENCOUNTERING OBSTACLES AND SLOPES WHEN BRAKING ON HILLS OR DURING TURNS KEEP FEET ON FLOORBOARDS AT ALL TIMES ALWAYS FASTEN YOUR SEAT BELTS SECURELY AROUND YOU OPERATING ON HILLS IS DANGEROUS especially when loaded Vehicle stability is greatly reduced during operation on hills REDUCE SPEED when operating this vehicle on rough or hilly terrain or when carrying cargo OFF ROAD USE ONLY This vehicle is not built for legal operation on public roads NEVER OPERATE THIS VEHICLE AT EXCESSIVE SPEEDS HELMETS ARE RECOMMENDED WHENEVER DRIVING THIS VEHICLE IN AN AGGRESSIVE MANNER Eye protection is recommended at all times High speeds jumps and stunts are dangerous and could result in loss of control and other accidents NEVER PERMIT A GUEST TO OPERATE THIS VEHICLE unless the guest has read the Owner s Manual and all labels NEV
3. DO NOT ATTEMPT ENGINE OR CLUTCH MODIFICATION DOING SO CAN CAUSE IMBALANCE AND OR EXCESSIVE ENGINE RPM EXCESSIVE ENGINE RPM CAN CAUSE PART FAILURE RESULTING IN POSSIBLE SEVERE INJURY OR DEATH DO NOT MODIFY ENGINE OR CLUTCH 7077377 SAFETY WARNING AND OPERATION DECALS OPERATOR LOAD DISTRIBUTION WARNINGS VIOLATION OF ANY OF THE FOLLOWING NOU Ob Da WARNINGS COULD CAUSE LOBI DF CONTROL AND RESULT IN SEVERE MAKE STARTS STOPS TURNS ANO DIRECTION CHANGES IN A te SMOOTH MANNER so au not in shift the load or NE FOOT DAAE PEDAL CONTROLS THE PRIMARY BRAKING for thie vehlche THE PARK BMEPIOENCY BRAKE LEVER vli supply increased braking but should be used ac an EMERGENCY OR THE BOK DUMP LATCH MUST BE SECURELY LATCHED befon loading and operating Urirdentional Dok dumping esci weigh is pesad in ihe reas of fm Dex Bre Bw Ion je Pot sette E m ee ke JEHGLE MTH THE DUMP BOX IN THE RAISED PORTION The dump box could akoma iriver The rear tires will catch the ol the ee ee PERFORMANCE I8 REDUCED WHEN CARRYING LOADS Meduce speeds stopping dancas wien opener ht Edad or along cerca wo ste ener CHANCE OF VEHIOUE TIP OVER AMD PERDONAL INJURY always range reduced vehicle peace when carrying heavy loads or towing loaded trailer m LOADS MUST BE CARRIED AB LOW IN THE BOX AS POSIBLE Carrying loads in the box reisas the center of Savy of fe vehicte and oraninn a ites stable peior aeree Able ias SAFELY ARRANG
4. e This vehicle REQUIRES SPECIAL RIDING SKILLS due to its handling Ride within your skill e THIS VEHICLE SHOULD BE OPERATED ONLY BY PERSONS WITH A VALID DRIVER S LICENSE Operation by unlicensed operators increases the risk of severe injury or death e MINIMUM AGE RECOMMENDATION FOR PASSENGERS IF FIVE YEARS OLD Passengers under five years of age require special restraints which are not available with this vehicle Driver and passenger should wear their seat belts at all times e THIS VEHICLE CAN BE HAZARDOUS TO OPERATE A collision or rol lover can occur quickly even during routine maneuvers such as turning driv ing on hills or over obstacles if you fail to take proper precautions e TO REDUCE TIPOVER RISK BE ESPECIALLY CAREFUL WHEN EN COUNTERING OBSTACLES AND SLOPES WHEN BRAKING ON HILLS OR DURING TURNS KEEP FEET ON FLOORBOARDS AT ALL TIMES ALWAYS FASTEN YOUR SEATBELTS SECURELY AROUND YOU SAFETY WARNING AND OPERATION DECALS e OPERATION ON HILLS IS DANGEROUS especially when loaded This vehicle is designed for utility usage on moderate terrains Turning braking and uneven terrain can induce rollovers especially if a maneuver is abrupt Under no circumstances should you climb descend or traverse hills greater than 15 Z Vehicle stability is greatly reduced during operating on hills creating the possibility of vehicle rollover and serious injury including death or paralysis Extreme caution should be used when operating
5. pect clean pect daily lubricate Periodic inspection adjust when parts are replaced 6 mon Inspect lubricate tighten fasteners 6 mon Inspect tighten fasteners 36 months Replace monthly Check Terminals clean check fluid level Adjust if necessary MAINTENANCE Periodic Maintenance Schedule Cont Item Hours or Frequency Remarks Odometer Headlamp Inspection Daily Daily Check operation daily apply Polaris di electric grease to connector when re placed m Tail lamp inspection Check operation daily apply Polaris di el lectric grease to socket when replaced Brake System Pre ride Pre ride inspection item m Brake fluid 200 hrs 24 months Change every two years In C ki Parking Brake heck lever adjustment daily adjust Frame nuts bolts fasteners Pre ride inspection item mM CAUTION Due to the nature of these adjustments it is recommended that service be performed by an authorized Polaris dealer Do not attempt to perform this work unless you are familiar with mechanical repair More often under severe use such as dirty or wet conditions Emission Control System Service California 4 Cycle Brake pad wear 10 hrs 100 Monthly spect periodically miles 61 MAINTENANCE Lubrication Recommendations Tem ieee Weed I Femeey 1 Engine Oil Polaris Pre Add to proper level on dipstick Check level dai mium 4 Syn See page 37 ly thetic OW40 2 Brake Fluid DOT 3 Only Maintain l
6. 028 7mm Spark plug torque is 17 ft Ibs 2 3 kg m Use NGK BKR5ES spark plugs Proper electrode gap is 025 06 cm Spark plug torque is 17 ft Ibs 2 3 kg m for a used spark plug 11 ft Ibs 1 52 kg m for a new spark plug 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 1 Normal The insulator tip is gray tan or light brown There will be few combustion deposits The electrodes are not burned or eroded This indicates the proper type and heat range for the engine and the service NOTE The tip should not be white A white insulator tip indicates overheating caused by use of an improper spark plug or incorrect carburetion adjustments 2 Wet Fouled The 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 are excessive oil use of non recommended injection oil improper use of the choke or incorrect carburetion adjustments Spark Plug Removal and Replacement IN waRNING Never attempt to remove a spark plug while the engine is warm The exhaust system or engine could burn you causing severe injury The spark plug is removed by using the special wrench provided in the tool pouch under the seat Reach inside the right hand e
7. 100 hrs 12 months Inspect Adjust S Spark Plug 100 hrs 12 months pect replace if necessary Ignition Timing 100 hrs 12 months Inspect and adjust as needed 59 MAINTENANCE Periodic Maintenance Schedule Cont Item Hours or Odometer Fuel System 100 hours m Fuel Filter 100 hrs Eu Carburetor Float Bowl Idle Speed As Required G X Choke Enricher Cable Coolant Level Inspection Coolant strength pressure test 100 hrs system ee m eese m eme Tem o eemems 0 pem p Jemen am p ronen wee be renmeenusceeuw pue e remm qme gt Terms ante mm sme e m ewm mee mme Jam m eeen DL NM oem e e rsen um m Front wheel bearings 300 hrs 60 12 months Check for leaks at fuel cap lines fuel valve filter pump and carburetor Re place lines every two years 12 months Replace annually 6 months Drain bowl periodically and prior to stor age Inspect adjust lubricate replace if nec essary pre ride inspection item Inspect adjust lubricate replace if nec essary Replace engine coolant every two years Inspect strength seasonally pressure test system annually pect clean external surface pect Clean out Drain moisture out after driving in water 3 mon Lubricate all fittings pivots cables etc heck monthly heck monthly and change annually spect monthly change annually spect adjust hange lubricant every two years pect adjust replace if necessary
8. IN PERIOD eee 44 CARRYING LOADS ssssseeeee eens 45 OPERATION SAFETY 00 cece e 46 55 NOISE EMISSION CONTROL SYSTEM REGULATION 56 BATTERY Hase ne len 571 58 MAINTENANCE 2 22 2222er nenn 59 88 TROUBLE SHOOTING s eese 89 SPECIFICATIONS eeee e 90 91 WARRANTY 222 2 2 a2 a aa a MARS ELSE 92 93 UNDERSTANDING WARNINGS SAFETY ALERT The following precautionary signal words are used throughout this manual to con vey the following messages This is the safety alert symbol When you see this symbol on your machine or in this manual be alert to the potential for personal injury Your safety is involved Indicates a potential hazard AAWA R N N G which could result in serious injury or death Indicates a potential hazard which CAUTI O N may result in minor personal inju ry or damage to the vehicle N OT E The word NOTE in this manual will alert you to key information or instructions AWARNING HAZARD Failure to heed WARNINGS WHAT CAN HAPPEN WARNINGS identify special instructions or procedures which if not cor rectly followed could result in personal injury or loss of life HOW TO AVOID THE HAZARD Read all WARNINGS in this manual carefully and for your safety be sure to follow their instructions SAFETY WARNING AND OPERATION DECALS A WARNING VEHICLE ROLLOVER COULD CAUSE SEVERE INJURY OR DEATH This cab frame is no
9. Lift the battery out of the vehicle being careful not to tip it sideways and spill any electrolyte CAUTION If electrolyte spills immediately wash it off with a solution of one table spoon baking soda and one cup water to prevent damage to the RANGER Battery Installation WARNING To avoid the possibility of explosion always connect battery cables in the order specified Red positive cable first black negative cable last 1 Setthe battery in its holder 2 Install the battery vent tube It must be free from obstructions and securely installed If not battery gases could accumulate and cause an explosion The tube should be routed away from the frame and body to prevent corrosion Avoid skin contact with electrolyte severe burns could result First connect and tighten the red positive cable Second connect and tighten the black negative cable Verify that cables are properly routed Reinstall battery cover and attach the hold down strap NOTE e When your RANGER is placed in storage for three months or more the battery should be removed charged to proper level and stored in a cool dry place oos e Before reusing take the battery to your dealer for testing and recharging 58 MAINTENANCE Periodic Maintenance Schedule Careful periodic maintenance will help keep your vehicle in the safest most reliable condition Inspection adjustment and lubrication intervals of important compo nents are explai
10. adding coolant to the recovery bottle Polaris recommends the use of Polaris Pre mium 60 40 anti freeze coolant or a 50 50 mixture of high quality aluminum com patible anti freeze coolant and distilled water NOTE Polaris Premium 60 40 is already premixed and ready to use Do not dilute with water NOTE Always follow the manufacturer s mixing recommendations for the freeze protection required in your area 34 CONTROL AND PARTS FUNCTIONS Engine Cooling System Radiator Coolant Level Inspection NOTE This procedure is only required if the cooling system has been drained for maintenance and or repair However if the recovery bottle has run dry the level in the radiator should be inspected and coolant added if necessary A WARNING Never remove the pressure cap when the engine is warm or hot Escaping steam can cause severe burns The engine must be cool before remov ing the pressure cap Lift the hood and locate the radiator cap NOTE Use of a non standard pressure cap will not allow the recovery system to function properly If the cap should need replacement contact your dealer for the correct replacement part Drain Plug Locations The oil should be changed annu ally especially before off season storage If the machine is used in wet conditions the oil should be checked more frequently If the oil has a milky appearance it should be changed as soon as possible Failure to properly maintain this important area can resul
11. and make a mark on the wall at the same height 3 Start the engine and turn the headlight switch to high beam 4 Observe headlight aim The most intense part of the headlight beam should be aimed 2 5 1 cm below the mark placed on the wall in step 2 NOTE Rider weight must be included on the seat Loosen pivot bolts and adjust beam to desired position 6 Tighten nut and bolt Torque to 60 in Ibs Indicator Lamp Replacement 1 Unplug light from harness depress lock ing tabs and remove from pod 2 Install new light and reassemble pod Depress locking tabs to remove 84 MAINTENANCE AWARNING Gasoline is highly flammable and explosive under certain conditions e Always exercise extreme caution whenever handling gasoline e Always refuel with the engine stopped and outdoors or in a well venti lated area Do not smoke or allow open flames or sparks in or near the area where refueling is performed or where gasoline is stored Do not over fill the tank If you should get gasoline 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 pow ered engine exhaust fumes are poisonous and can cause loss of con sciousness and death in a short time Shut off fuel valve whenever the vehicle is stored or parked ZNWARNING The engine exhaust from this product contains chemicals known to cause cancer birth d
12. components Extensive engineering and testing has been con ducted to insure the safety of this product However as the owner you have the following responsibilities to make sure this system remains safe e Do not modify any component of the PVT system Doing so may reduce its strength so that a failure may occur at high speeds This system has been precision balanced Any modification will cause the system to be out of balance creating vibration and additional loads on components Routine maintenance is the responsibility of the owner Always follow recommended maintenance procedures See your dealer e This PVT system is intended for use on Polaris products only e The PVT housing must be securely in place during operation Failure to comply with this warning can result in severe injury or death 75 MAINTENANCE Throttle Pedal If the throttle pedal 1 has exces sive play due to cable stretch or cable misadjustment it will cause a delay in throttle response especial ly at low engine speed Also the throttle may not open fully If the throttle pedal has no play the throttle may be hard to control and the idle speed may be erratic Check the throttle pedal play period ically in accordance with the Period ic Maintenance Chart and adjust the play if necessary Throttle Freeplay Inspection 1 Apply the parking brake 2 Put the gear shift lever in the N Neutral position 3 Start the engine and warm it up th
13. seri ous accident HOW TO AVOID THE HAZARD No one without a valid driver s license should operate a Polaris RANGER OPERATION WARNINGS AWARNING POTENTIAL HAZARD Operating this vehicle on paved surfaces WHAT CAN HAPPEN 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 HOW TO AVOID THE HAZARD Always avoid operating the vehicle on any paved surfaces including sidewalks driveways parking lots and streets A WARNING Safe operation of this vehicle requires good judgement and physical skills Persons with cognitive or physical disabilities who operate this vehicle have an increased risk of overturns and loss of control which could result in serious injury or death A WARNING POTENTIAL HAZARD Operating this vehicle on public streets roads or highways WHAT CAN HAPPEN You can collide with another vehicle HOW TO AVOID THE HAZARD Never operate this vehicle on any public street road or highway in cluding dirt or gravel In many states it is illegal to operate vehicles of this type on public streets roads and highways 11 OPERATION WARNINGS 12 AWARNING POTENTIAL HAZARD Operating this vehicle after consuming alcohol or drugs WHAT CAN HAPPEN Could seriously affect your judgment Could cause you to react more s
14. this vehicle on any side hill conditions Effectiveness of brakes is significantly reduced on hills Some hills are too steep to safely stop or recover from an unsuccessful climbing attempt If vehicle slides backwards down hill apply brakes with gradual even pressure and do not apply the throttle Sudden or aggressive application of brakes may cause loss of control e REDUCE SPEED when operating this vehicle on rough or hilly terrain or when carrying cargo e OFF ROAD USE ONLY Never operate on public roads as severe injury or death may occur this vehicle is not built for legal operation of public roads Always avoid paved surfaces e NEVER OPERATE THIS VEHICLE AT EXCESSIVE SPEEDS You in crease your risk of losing control if you operate this vehicle at speeds too fast for the terrain visibility conditions or your experience e HELMETS ARE RECOMMENDED WHENEVER DRIVING THIS VEHICLE IN AN AGGRESSIVE MANNER Eye protection is recommended at all times See Owner s Manual e REVERSE OPERATION CAN BE DANGEROUS Steering control becomes difficult When backing up proceed slowly and apply brakes carefully aggressive braking may result in loss of control Avoid backing downhill avoid turning at sharp angles in reverse e STOPPING DISTANCE MAY INCREASE WITH WET BRAKES OR ON WET SURFACES e VEHICLE DESIGNED MAINLY FOR WARM WEATHER USE Throttle link age and brakes may stick if operated in freezing weather causing loss of control Dirt mud
15. used oil properly Clean and reinstall the drain plug Add Polaris Premium Syn thetic Gearcase Lubricant PN 2871478 to full mark on the fill plug dipstick Check for leaks MAINTENANCE Operating Range CAUTION Be careful not to allow any dirt or foreign materials to enter the trans mission case 67 MAINTENANCE Front Gearcase Lubrication Fill plug Dipstick Front Gearcase Lubrication The front gearcase fill plug is located on the right side of the front gearcase The front gearcase lubricant level should be checked every six months or 1000 miles 1600 km whichever comes first Front gearcase oil should be changed annually With the RANGER on a level surface remove fill plug and check the lubri cant level Lubricant should be kept at the bottom thread of the fill plug hole The correct gearcase lubricant to use is GL5 80 90 Weight Gear Lube Gearcase Oil Changing Procedure 1 Remove fender panel 2 Remove fill plug dipstick 3 Remove gearcase drain plug located on the bottom right hand side and drain the oil Catch and discard used oil properly 4 Clean and reinstall the drain plug 5 Add GL5 80 90 Weight Gear Lube to the bottom thread of the fill plug hole 6 Check for leaks 68 MAINTENANCE The following items should be checked occasionally for tightness or ifthey have been loosened for maintenance service Axle and Wheel Nut Torque Specifications Front Spindle Nut s Dealer Perfo
16. water or other contaminants can also affect operation of controls Check both frequently e High speeds jumps and stunts are dangerous and could result in loss of control and other accidents e NEVER PERMIT A GUEST TO OPERATE THIS VEHICLE unless the guest has read the Owner s Manual and all labels e NEVER USE ALCOHOL OR DRUGS before or while operating the vehicle They slow reaction time and impair judgement e SEVERE INJURY OR DEATH can result if you do not follow these instruc tions CAUTION Do not shift while vehicle is moving LABEL LOCATION Warning General Warning Vehicle roll over Warning Load Distribution Warning Cargo Bed Tire Pressure Towing Information NEBEN it DAILY PRE RIDE INSPECTION Inspect your vehicle each time before riding to ensure it is in proper working order If proper inspection is not done severe injury or death could result AWARNING If a proper inspection is not performed serious injury or death can result Always inspect your RANGER before riding following the checklist care fully Before riding your vehicle inspect all operating controls and parts Item Inspection Procedure Tires check condition and pressures Fuel and oil tanks fill both tanks to their proper levels All brakes check operation adjustment and fluid level includes emergency parking brake Throttle check for free operation and closing Headlight Taillight Brakelight check operation of a
17. will give you room to famil E iarize yourself with vehicle Maintain Oil Level In Normal Range operation and handling Vary the throttle positions Do not operate at sustained idle CAUTION Do not operate at full throttle or high speeds for extended periods during the first three hours of use Excessive heat can build up and cause damage to close fitted engine parts Perform regular checks on fluid levels controls and all important areas on the vehicle as outlined earlier on the daily pre ride inspection checklist found on page 9 Pull only light loads Break in oil and filter Change at 20 hours or 500 miles CARRYING LOADS The RANGER has been designed to carry ortow a certain amount of load Always read and understand the load distribution warnings listed on the warning labels Never exceed the following weights Maximum Capacities Cargo Box Level Ground RANGER 1500 Ibs 681 kg 1000 Ibs 454 kg Dumping the Cargo Box 1 Select a level site to dump the cargo box Do not attempt to dump or unload the vehicle while parked on an incline 2 Set the parking brake 3 Dismount the vehicle 4 Stand clear and pull the cargo box release mechanism lever forward Lift the front of the cargo box to dump Maximum Towing Capacities Level Ground Maximum towed load weight 1500 Ibs 681 kg on level ground only 850 Ibs 386 kg up to 15 grade Maximum vertical hitch weight 150 Ibs 68 1 kg Use of low f
18. 14 Battery under hood 15 Radiator under hood 16 Front Bumper Brush Guard 28 CONTROL AND PARTS FUNCTIONS VEHICLE NOMENCLATURE Rear View 17 18 19 20 21 Tail Gate Latches Top and Bottom Tail Gate Muffler Spark Arrester Trailer Hitch Receiver Taillight 29 CONTROL AND PARTS FUNCTIONS VEHICLE NOMENCLATURE Instrument Panel Choke Knob Ignition Switch Hour Meter Passenger Warning Decal Neutral Indicator Light Reverse Indicator Light Brake Light Coolant Temperature Warning Light Fuel Gauge 12V Accessory Plug Fog High Beam Light Switch AWD All Wheel Drive Switch c co BRD b D m O 30 CONTROL AND PARTS FUNCTIONS Demand 6 Drive Exclusive Demand 6 Drive System All Wheel Drive This Polaris AWD is equipped with a unique Polaris exclusive Demand 6 Drive AWD system which is activated by a switch on the dash When the switch is off the RANGER is in 4 wheel drive at all times When the switch is on the RANGER is in Demand 6 Drive and the front wheels will automatically engage anytime the rear wheels lose traction When the rear wheels regain traction the front wheels will automatically disengage The AWD button position and a red AWD light indicates when the vehicle is in De mand 6 Drive There is no limit to the length of time the vehicle may remain in De mand 6 Drive The AWD switch may be turned on or off while the vehi
19. Air Cleaner 00 eee eee 70 All Wheel Drive 4 31 Backing Up un ee 54 Battery Installation 58 Battery Maintenance 57 Battery Removal 58 Brake Front 000 78 Brake H8arc suci eee eS tas 79 Break In Period 44 Carburetor Adjustment 77 Carrying Loads 2 4 45 Cleaning Your RANGER 86 Control And Parts Functions 31 43 Control Parts And Functions 27 30 Coolant Level Luuuus 34 Coolant Level Inspection 35 Crossing Streams 52 Cylinder Head Torque 73 Daily Pre ride Inspection 9 Demand 6 Drive 31 Disengaging Wheel Hubs 33 Dumping Cargo Bed 45 55 Engine Cooling System 34 36 Engine Idle Rpm Adjustment 77 Filter Change 2 2 38 39 Front Gearcase Lubrication 68 Front Wheel Hub Tightening 69 Fuel Filter 222222ar 220 39 Fuel System 000005 24 Gearcase Oil Changing Procedure 68 Indicator Lamp Replacement 84 Load Distribution 46 47 Lubrication Recommendations 62 65 Maintenance 59 88 95 Maintenance Schedule 60 61 Noise Control System 56 Oil Change ssese 38 39 Oil Eilter m 28 Re Ee 39 Oil System
20. Drive slowly practice maneuvering and using the throttle and brakes on level surfaces WA R N l N G indicates a potential hazard which A could result in serious injury or death Load Distribution A WARNING When carrying cargo or towing a trailer remember that load weight will in crease braking distances Failure to allow for increased braking distance may result in accident and injury 1 Always load the cargo bed placing the load as far forward as possible 2 Always operate the vehicle with extreme care especially when hauling or tow ing loads 3 Slow down and drive in D 1 Gear only 4 The cargo box dump latch must be securely latched before loading and operat ing Unintentional box tilting can result if weight is placed in the rear of the box and the latch is not secured 5 Do not place loads on the cab frame WARNING Never operate this vehicle with the cargo box in the raised position The cargo box could close unexpectedly while driving severely injuring the driver or passenger The rear tires can catch the rear of the box damaging the vehicle and creating hazardous driving conditions 47 OPERATING SAFETY Riding On Slippery Surfaces Whenever driving on slippery surfaces such as wet trails or loose gravel or during cold freezing weather special attention must be paid to prevent vehicle turnover Always 1 Slow down when entering slippery areas 2 Maintain a high level of alertness reading the tr
21. ED LOADG Wien handing off centered loade which cannot curit r d securely faltan load and operate with extra caution ma with loade extending aides Stability iet Au A over the box and 7077683 Text found below OPERATOR LOAD DISTRIBUTION WARNINGS VIOLATION OF ANY OF THE FOLLOWING WARNINGS COULD CAUSE LOSS OF CONTROL AND RESULT IN SEVERE INJURY OR DEATH MAKE STARTS STOPS TURNS AND DIRECTIONS CHANGES IN A SMOOTH MANNER so as not to shift the load or overturn the vehicle THE FOOT BRAKE PEDAL CONTROLS THE PRIMARY BRAKING for this ve hicle THE PARK EMERGENCY BRAKE LEVER will supply increased braking but should be used as an EMERGENCY OR PARKING BRAKE ONLY THE BOX DUMP LATCH MUST BE SECURELY LATCHED before loading and op erating Unintentional box dumping will result if weight is placed in the rear of the box and the latch is not secured NEVER OPERATE THIS VEHICLE WITH THE DUMP BOX IN THE RAISED POSITION The dump box could close unexpectedly while driving severely injur ing the driver and passenger The rear tires will catch the rear of the box damaging the vehicle and creating hazardous driving conditions THE VEHICLE BRAKING PERFORMANCE IS REDUCED WHEN CARRYING LOADS Reduce speeds and allow for greater stopping distances when operating in a loaded or trailering condition 4 SAFETY WARNING AND OPERATION DECALS THE ABILITY TO STEER THIS MACHINE IS REDUCED WHEN OPERATING IN A LOADED CONDITION on rough or hill
22. ER USE ALCOHOL OR DRUGS before or while operating the vehicle Part No 9914648 Rev 03 PRINTED IN THE U S A WARNING The engine exhaust from this product contains chemicals known to cause cancer birth defects or other reproductive harm FOREWORD Congratulations and thank you from Polaris Industries Inc for purchasing one of our products Built with American engineering and manufacturing know how it is designed to provide superior comfort utility enjoyment and safety This manual is furnished to ensure that the operator is aware of safe operating pro cedures It also includes information about the general care and maintenance of your vehicle Carefully read the following pages If you have any questions regarding this ve hicle contact a Polaris dealer for assistance Remember Polaris dealers have the knowledge and facilities to provide you with the best service possible PROTECT YOUR SPORT Know all local state province off road vehicle laws Respect your vehicle Respect the environment and You will gain the respect of others We also advise you to strictly follow the recommended maintenance program as outlined This preventive maintenance program is designed to ensure that all criti cal components on this vehicle are thoroughly inspected at various intervals All information in this manual is based upon the latest product data and specifica tions available at the time of printing Polaris Industries Inc r
23. LY Ania ae Inia vehic ie nel bull for legal operation or jub iach Alma auch paved Surface FE THIS VEHICLE AT EXCESSIVE SPEEDS You increase your riak of losing control H you operate this vehicle t speeds too fast for the terrain SETS TECOMMENDED wt TENEVER DRIVING THIS VEHICLE IN AN AGGRESSIVE MANNER Special safety equipment Is required whenever driving OPERATION CAN B ee Drag ray Fade I iota of Kam BP Bede ten popes becomes aificuk When backing up proceed slowly and apply brakes STOPPING DISTANCE MAY INCREASE WITH WET BRAKES OA ON WET SURFACES VIICLE DENONED MAINLY FOR WARM WEATHER THER USE Patte hokage rd oranes may stick H operated in freezing weather causing loss of control Dirt High speeds jumps and trick maneuvers are dangerous and could reeuit In loss of control and other accidents NEVER PERMIT A GUEST TO OPERATE THIS VEHICLE uniess the guest has read the Owner s Manual and all labels NEVER UGE ALCOMOL OF DRUGS before or white operating the vehicle They slow reaction time and impair judgement 2 SEVERE INJURY OR DEATH can result you do not follow these instructions a CAUTION Do nat ahlft tranemiselon white vahicte Is moving 7077680 Text found below READ AND UNDERSTANDING WARNINGS AND OWNER S MANUAL BEFORE OPERATION SEVERE INJURY OR DEATH CAN RESULT FROM IGNORING WARNINGS OR IMPROPER USE If you do not have the Owner s Manual for this vehicle call 1 800 324 3674 to have one provided at no extra charge
24. PARTS FUNCTIONS Oil and Filter Change The recommended oil change interval is 100 hours 1000 miles or every six months whichever comes first Suggested break in oil change is at 20 hours 500 miles or one month whichever comes first Severe use operation requires more frequent service Severe use includes continuous duty in dusty or wet conditions and cold weather riding NOTE Severe use cold weather riding is all riding below 10 F and riding between 10 F and 30 F when most trips are slow speed and less than 5 miles Be sure to change the oil filter whenever changing oil Polaris PN 3084963 1 2 10 11 12 13 38 Place vehicle on a level surface Remove rear wheel well panel by cutting dart clips and removing screws Clean area around drain plug at the bottom of the oil tank Run engine for two to three minutes until warm Shut engine off Place a drain pan beneath the oil tank and remove the drain plug CAUTION Oil may be hot Do not allow hot oil to come into contact with skin as serious burns may result Allow oil to drain completely Install a new sealing washer PN 5850135 on oil drain plug NOTE The sealing surfaces on the drain plug and the oil tank should be clean and free of burrs nicks or scratches Reinstall drain plug and torque to 14 17 ft Ibs 1 93 2 35 kg m Place shop towels beneath oil filter Using an oil filter wrench turn filter 1 counterclockwise to remove Using a c
25. accessory may be con nected to these terminals Brake Pedal The brake pedal 2 is the left pedal on the foot board Depress the brake pedal to slow or stop the ve hicle WARNING Once a bottle of brake fluid is opened use what is neces sary and discard the rest Do not store or use a partial bottle of brake fluid Brake fluid is hygroscopic meaning it rapidly absorbs moisture from the air This causes the boiling temperature of the brake fluid to drop which can lead to early brake fade and the possibility of serious in jury Braking NOTE Practice starting and stopping using the brakes until you are 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 1 Release the throttle pedal completely 2 Press on the brake pedal evenly and firmly AWARNING Be sure to apply the parking brake before leaving the vehicle If the vehicle moves it might be damaged or cause injury CONTROL PARTS AND FUNCTIONS Seat Belts The vehicle is equipped with lap style seat belts for the operator and passenger AWARNING Seat belts reduce injury Always were your seat belt Minimum age recommen dation for passengers if five years old Passengers under five years of age re quire special restraints which are not available with this vehicle To wear the seat belt properly follow this proce
26. ail 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 Driving with Demand 6 Drive All Wheel Drive engaged can assist in control ling the vehicle in slippery areas CAUTION Never engage Demand Drive while wheels are spinning as severe damage to drive train may occur Before operating your vehicle on a frozen body of water be sure that the ice is thick enough to support the machine and its operator as well as the force that is created by a moving vehicle Severe injury or death can result if the vehicle and or its oper ator break through the ice A WARNING Failure to exercise care when operating on slippery surfaces can be dan gerous Loss of tire traction and vehicle control can result in an accident including an overturn e Never apply brakes during a skid Complete loss of control can result e Do not operate on excessively slippery surfaces if possible e Always reduce speed and use additional caution 48 OPERATING SAFETY Operating on Hills AWARNING Improperly crossing hills or turning on hills can be dangerous Loss of vehicle control or overturning of the vehicle could occur e Avoid crossing the side of a steep hill if possible Use extreme care when operating your RANGER in hilly terrain Whenever descending a hill always 1 Drive directly downhill 2 Slow down 3 Apply the brakes lightly to aid in slow
27. aintain stable operating conditions OPERATE ONLY WITH STABLE AND SAFELY ARRANGED LOADS When han dling off centered loads which cannot be centered securely fasten load and oper ate with extra caution EXTREME CAUTION MUST BE USED when operating with loads extending over the box sides Stability and maneuverability may be adversely affected causing the machine to overturn SEE YOUR OWNER S MANUAL SAFETY WARNING AND OPERATION DECALS A WARNING I p7 15 AND WARNINGS AND CWNER S MANUAL BEFORE OPERATION SEVERE INJURY OR DEATH CAN RESULT FROM KGNORING WARNINGS Thie Vehicle REQUIRES SPECIAL DRIVING SKILLS due to its handling Drive within your skill TBB VEHICLE SHOULD BE OPERATED ONLY BY PERSONS WITH A VALID DRIVER S LICENBE Operation by unlicensed operators Increases the risk of severe ete AOE RECOMMENDATION FOR PASSENGERS 1S FIVE YEARS OLD Passengers under five years of age require speciei restraints which are not lt Tae viral VAZARDOUA TO OPERATE A colision or roliover can ocour quicky even during routine manauvers such as fuming driving on hile or TO MIDUCE TIPOVER OK MMO BE ESPECIALLY CAREFUL WHEN ENCOUNTERING OBSTACLES AND SLOPES WHEN BRAKING ON HILLS OR DURING TURNS KERP FEET ON FLOORBOARDS AT ALL TIMES ALWAYS PASTEN YOUR SEATBELTS SECURELY AROUND YOU CERE mias EY ng cu a ctae P EIUS pue Dgs S smt e ros we da not soy DE do Pi ap REDUCE SPEED when ee Be ioe BE dap wis sa lt OPPF ROAD USE ON
28. at a failure may occur at high speeds This system has been precision balanced Any modification will cause the system to be out of balance creating vibration and additional loads on components Routine maintenance is the responsibility of the owner Always fol low recommended maintenance procedures See your dealer e This PVT system is intended for use on Polaris products only e The PVT housing must be securely in place during operation Failure to comply with this warning can result in severe injury or death 33 CONTROL AND PARTS FUNCTIONS Engine Cooling System Coolant Level The recovery bottle 1 located on the left side of the machine must be maintained between the minimum and maximum levels indicated on the recovery bottle The engine coolant level is con trolled or maintained by the re covery system The recovery system components are the re covery bottle radiator filler neck radiator pressure cap and con necting hose As coolant operating tempera ture increases the expanding heated excess coolant is forced out of the radiator past the pressure cap and into the recovery 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 machines is normal as the system is purg ing itself of trapped air Observe coolant levels and maintain as recommended by
29. ation with insufficient deteriorated or contaminated engine oil will cause accelerated wear and may result in engine seizure acci dent and injury Engine Oil In order for the engine to function properly maintain the engine oil at the proper level and change the oil and oil filter in accordance with the Period ic Maintenance Schedule Not only do dirt and metal particles collect in the oil but the oil itself loses its lubrica tive quality if used too long The transmission cover dipstick 1 is located on the right side of the ma chine inside the chassis Transmission Oil The transmission lubricant level should be checked monthly or 1000 miles 1600 km whichever comes first Transmission oil should be changed annually To check the transmission lubricant level you must first position the ve hicle on a level surface Remove the right engine access panel as de scribed on page 35 Reach inside the engine compartment in the direction indicated by the arrow 2 Remove fill plug dipstick 3 by pulling upward and check the lubricant level Lubricant should be kept at the full mark on the dipstick The correct transmission lu bricant to use is Polaris Premium Syn thetic Gearcase Lubricant PN 2871478 66 Transmission Oil Changing Procedure 1 Locate and remove fill plug dipstick Remove transmission drain plug located on the bottom right hand side and drain the oil Catch and discard
30. aw ALL IMPLIED WARRANTIES INCLUDING BUT NOT LIMITED TO THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE ARE LIMITED IN DURATION TO THE ABOVE SIX MONTH WAR RANTY PERIOD POLARIS FURTHER 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 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 War ranty Registration 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 Polar is 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 Engine Oil 1 Always use Polaris engine oil 2 Never substitute or mix oil brands as serious engine damage and voiding of war ranty can result 94 INDEX
31. c disc type brakes activated by the brake pedal The following checks are recom mended to keep the brake system in good operating condition How often they need checking depends upon the type of driving that has been done Inspect the level of the brake fluid before each ride Change the brake fluid according to the Periodic Maintenance Chart The brake fluid should also be changed if it becomes contami nated with dirt or water To check the fluid level the vehicle must be on level ground Inspect the brake fluid by looking at the remote reservoir 1 under the hood The level should be between the upper MAX and lower MIN level lines If the fluid level is lower than the lower level line add brake fluid to the upper MAX line Apply the brake forcefully for a few seconds and check for fluid leakage around the fittings WARNING Change the fluid in the brake system completely if the fluid level is low but the type and brand of the fluid already in the reservoir are unknown WARNING Once a bottle of brake fluid is opened use what is necessary and dis card the rest Do not store or use a partial bottle of brake fluid Brake fluid is hygro scopic meaning it rapidly absorbs moisture from the air This causes the boiling temperature of the brake fluid to drop which can lead to early brake fade and the possibility of serious injury WARNING If the brake pedal has a soft spongy feeling when it is applied there c
32. cargo box could close unexpectedly while driving severely injuring the driver The rear tires will catch the rear of the box damaging the vehicle and creating haz ardous driving conditions IN Do not carry more than 1000 Lbs in the cargo box Parking the RANGER 1 Stop the vehicle on a level surface CAUTION Avoid parking on steeply inclined surfaces 2 When the engine has stopped apply the parking brake to help prevent the ve hicle from rolling AWARNING Be sure to apply the parking brake before leaving the vehicle Ifthe vehicle should move it might be damaged or cause injury 3 Remove the ignition switch key to prevent unauthorized use NOTE When parking inside a garage or other structure be sure the structure is well ventilated and the vehicle is not close to any source of flame or sparks This includes any appliance with a pilot light AWARNING Gasoline is extremely flammable and can be explosive under certain condi tions 46 OPERATING SAFETY 1 Sit in the driver s seat with the seatbelt fastened 2 After starting the engine and allowing it to warm up shift the transmission into gear 3 Check your surroundings and determine your path of travel 4 Release the parking brake 5 Keeping both hands on the steering wheel slowly depress the throttle with your right foot and begin driving Vehicle speed is controlled by the amount of throttle opening and PVT shifting is done automatically 6
33. cated in the center console storage compartment A has three posi tions OFF For vehicle storage and whenever transporting ON For normal operation RES For reserve supply in the event of main supply exhaustion NOTE There is about a 7 to 10 mile 11 2 to 16 km range on re serve gas Always refill the gas tank as soon as possible after having used the reserve supply Always return valve to on posi tion after refueling machine Gasoline and Alcohol Blends Blends of gasoline and alcohol called gasohol can be used on an occasional basis however continued use is not recom mended Switch back immedi ately to gasoline which does not contain alcohol if you experience any operating irregularities Any deterioration of fuel system com ponents or degradation of perfor mance resulting from the use of gasohol will not be covered by Polaris Warranty 24 CONTROL PARTS AND FUNCTIONS AWARNING Gasoline is highly flammable and explosive under certain conditions e Always exercise extreme caution whenever handling gasoline e Always refuel with the engine stopped and outdoors or in a well venti lated area Do not smoke or allow open flames or sparks in or near the area where refueling is performed or where gasoline is stored Do not over fill the tank Do not fill the tank neck If you should get gasoline on your skin or clothing immediately wash it off with soap and wat
34. cle is moving If the switch is turned off when the front hubs are driving they will not release until the rear wheels regain traction CAUTION Do not switch on Demand 6 Drive if the rear wheels are spinning This may cause severe drive shaft and clutch damage Engage the Demand 6 Drive switch before getting into conditions where front wheel drive may be needed If the rear wheels are spinning release the throttle before turning the Demand 6 Drive switch on 31 CONTROL AND PARTS FUNCTIONS Transmission Gear Selector Operation The transmission gear selector is located to the right of the vehicle driver s seat The transmission selector lever has four posi Shift Pattern tions high forward D2 reverse neutral and low forward D1 Use of low forward gear D1 is recom mended in heavy pulling situations to extend belt life To change gears stop the vehicle and with the engine idling move the lever to the de sired gear Do not attempt to shift gears with engine speed above idle or while the vehicle is moving Always place the transmission in gear with the parking brake locked whenever the vehicle is left unattended Maintaining shift linkage adjustment is important to assure proper transmission function Should you experience any shifting problem see your dealer A WARNING 1 Do not attempt to shift the transmission while the vehicle is moving or while operating on hilly terrain D 2 Always place the tra
35. dure 1 Place the belt across your lap as low on your hips as possible taking care that the belt is not twisted 2 Push the latch plate into the buckle until it clicks 3 Release the strap it will self tighten To unfasten the belt press on the squared red button in the center of the buckle Steering Wheel The steering wheel position can be adjusted to suit the operator 1 Loosen the bolt and nut 1 on the steering column bracket and move the steering wheel up or down to desired height 2 Tighten the bolts and nuts Throttle Pedal The throttle pedal is the right pedal on the floor board Push the pedal down to in crease 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 In addition there must be adequate throttle pedal play Refer to page 76 for throttle pedal adjustment procedure Trailer Hitch Bracket This vehicle is equipped with a receiver hitch bracket for a trailer hitch Trailer tow ing equipment is not supplied with this vehicle To avoid injury and property damage observe the precautions on page 45 23 CONTROL PARTS AND FUNCTIONS Engine Fuel and Oil System The fuel tank filler cap 1 is lo cated on the left side by the driv ers seat Use either leaded or un leaded gasoline with a minimum pump octane number of 87 R M 2 octane Tr The fuel supply valve 2 lo
36. e fects or other reproductive harm 85 MAINTENANCE Cleaning Your RANGER Keeping your vehicle clean will not only improve its appearance but it can also ex tend the life of various components With a few precautions your vehicle can be cleaned much like an automobile Washing If a high pressure type car wash system is used extreme care must be taken to avoid water damage to the wheel bearings transmission seals body panels brakes headlights and warning labels Many expensive repair bills can result from using high pressure detergent systems NOTE If a high pressure car wash is used grease all zerk fittings immediately af ter washing Also run the vehicle to evaporate any water that might have entered the engine or exhaust system The best and safest way to clean your vehicle is with a garden hose and a pail of mild soap and water Use a professional type washing mitten cleaning the upper body first and the lower parts last Rinse with water frequently and dry with a cham ois to prevent water spots NOTE If warning labels are damaged contact your a Polaris dealer for free replacement 86 MAINTENANCE Storage If your vehicle is to be placed in extended or off season storage the following steps should be taken to preserve its condition 1 2 co o0 11 Perform all necessary repairs and thor oughly clean the vehicle Turn the fuel valve to off and drain the carburetor Drain tub
37. e Remove the spark plug and pour attached approximately one ounce of Pre here mium 4 oil into the cylinder Oper ate the starter for a few seconds and reinstall the spark plug Remove the battery Store it in a cool dry place out of the sun Lubricate suspension pivot points lower steering post and rear axle fittings Drain the recoil housing Block the vehicle so all tires are suspended off the ground Spray oil on all unpainted metal surfaces to prevent rusting Avoid getting oil on rubber parts or in the brakes Lubricate all cables Tie a plastic bag over the exhaust pipe and air cleaner inlet to prevent moisture or small animals from entering Cover the vehicle with a canvas cover Do not use plastic or coated materials since they do not allow ventilation of the vehicle Removal from Storage 1 i dm Check the battery electrolyte level charge the battery if necessary and install itin the vehicle Take care the battery vent hose is not pinched and routed prop erly Make sure the spark plug is tight Fill the fuel tank with fuel Check all the points listed in the Daily Safety Checks section Lubricate per periodic maintenance chart 87 MAINTENANCE AWARNING Do not run the engine in a closed area Exhaust gases contain carbon monoxide a colorless odorless poisonous gas Breathing exhaust gas leads to carbon monoxide poisoning asphyxiation and death Bolt and Nut Tightening Tightnes
38. e The parking brake is located on the left side of the center console Activate by pulling up on the lever Release by pressing the button on the end of the handle and lowering the lever Always activate the foot pedal brake before releasing the park brake Always shut off the engine before refueling Make sure the area is well venti lated and free of any source of flame or sparks Gasoline is very flammable See page 24 for refueling instructions FOR MORE INFORMATION ABOUT SAFETY call Polaris at 1 800 342 3764 T WA R N l N G indicates a potential hazard which could result in serious injury or death Additional Important Information Due to our concern for the safety of our customers and the general public Polaris hereby strongly recommends and requests that consumers not have installed on a Polaris RANGER any equipment which is intended to increase the speed or pow er of the vehicle or make any other modifications to the vehicle for these purposes Any modifications to the original equipment of the RANGER substantially increase the risk of bodily injury Please be aware that these modifications may create a sub stantial safety hazard Polaris hereby informs you that the warranty on your RANGER is terminated if any such equipment has been added to the vehicle or any modifications have been made to the vehicle which increase its speed or power We also advise you to strictly follow the recommended maintenance program out li
39. e right side of the machine will allow vehicle operation until repairs can be made 1 2 3 4 Be certain the parking brake is set See page 27 Remove right side engine access panel See page 35 Grasp the recoil starter tightly and pull slightly until the starter mechanism en gages Pull the rope abruptly to start the engine CAUTION Take care not to extend the starter rope so far that it stops causing damage to the recoil assembly CAUTION Never start the engine with the battery disconnected Damage to the electrical system and lamps may result 43 VEHICLE BREAK IN PERIOD The break in period for your new Polaris RANGER is defined as 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 treat ment of anew engine will result in more efficient performance and longer life for the engine Perform the following procedures carefully CAUTION Use only Polaris Premium 4 All Season synthetic oil or API certified SH oil Never substitute or mix oil brands Serious engine damage and voiding of warranty can result 1 44 Fill fuel tank with either unleaded or leaded fuel which has a minimum pump octane number of 87 R M 2 Check oil reservoir level in dicated on dipstick Add oil if necessary Drive slowly at first Select Cao soz gt norma FULL an area which is open and
40. ect the brake light first turn the ignition switch to the ON position Depress the brake pedal The brake light should go on after about 10mm 0 4 in of pedal travel If the light does not go on check the bulb 79 MAINTENANCE Parking Brake Lever The parking brake helps hold the vehicle from rolling while parked Make sure the parking brake lever is functioning properly before each ride Inspection e Pull the parking brake lever up and to the rear e After 8 to 12 clicks of lever travel the vehicle should not roll while parked e Ifthe vehicle moves adjust ment is necessary Adjustment Loosen the locknut 1 lower nut on the lower end of the parking brake lever cable and turn the nut next to the locknut 2 until the brake lever will only move 8 12 clicks upward e Tighten the locknut securely NOTE Be sure to hold the cable end with a wrench to prevent the cable from twist ing Steering Wheel Check the steering wheel for specified free play and smooth operation in accor dance with the periodic maintenance Chart Inspection e Park the vehicle on level ground Lightly turn the steering wheel left and right There should be 0 8 1 0 in 20 25 mm of free play If there is excessive free play or strange noises or the steering feels rough or catchy have the steering system checked by an authorized Polaris deal er 80 MAINTENANCE Wheel Removal Procedure 1 Stop the
41. elephone number is 1 800 473 0111 The chance to arrange travel through the Polaris Travel Center The toll free travel telephone number is 1 800 267 1915 The chance to apply to serve on PRO Consumer Councils that provide input into the Polaris vehicles of the future The chance to serve as a PRO Field Evaluator and provide feedback on your new vehicle The chance to purchase exclusive PRO Family merchandise 3 And more To order PRO merchandise you ll complete the order form you receive with your membership packet take the form to your Polaris dealer and pay for the merchan dise The merchandise will be shipped directly to your home from the PRO mer chandise fulfillment center Watch for your PRO membership packet and the next issue of PRO Spirit maga zine This quarterly magazine will keep you informed about Polaris news and events and special PRO merchandise travel and ride opportunities Enjoy your new Polaris vehicle and welcome to the family The Polaris PRO Fami ly CONTENTS UNDERSTANDING WARNINGS 0 2 eee nennen 1 SAFETY WARNING AND OPERATION DECALS 2 7 LABEL LOCATIONS 0 0 cece eee eens 8 DAILY PRE RIDE INSPECTION 0 0 eee eee eee 9 OPERATION WARNINGS 0 neran 10 19 VEHICLE IDENTIFICATION NUMBERS 20 CONTROL AND PARTS FUNCTIONS 21 39 STARTING THE ENGINE 0 eee eee eee 40 43 VEHICLE BREAK
42. emoved or rendered inoperative by any person AMONG THOSE ACTS PRESUMED TO CONSTITUTE TAMPERING ARE THE ACTS LISTED BELOW 1 Removal or alteration or the puncturing of the muffler or any engine component which conducts removal of engine exhaust gases 2 Removal or alteration or the puncturing of any part of the engine air induction system 3 Replacement of any vehicle parts with parts not in compliance with federal reg ulations 4 Lack of proper maintenance CAUTION Remember exhaust system components are very hot during and after use of the vehicle e Do not touch hot exhaust system components Serious burns can result e Be especially careful when traveling through tall grass The potential for fire exists USFS Approved Spark Arrestor The muffler on this vehicle was tested and approved in accordance with the USFS Forest Service Standard 5100 1A 56 BATTERY Battery A CAUTION Whenever removing the battery discon nect the negative black cable first When reinstalling the battery connect the nega tive black cable last Replenishing the Battery Fluid an A poorly maintained battery will deteriorate upper and rapidly Check the battery fluid level often lower level The fluid level should be kept between the marks upper and lower level marks A To refill use only distilled water Tap water contains minerals which are harmful to a battery Battery Connections Battery terminals and c
43. engine place the transmission in gear and lock the parking brake 2 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 remove the wheel Wheel Installation 1 With the transmission in gear and the parking brake locked place the wheel in the correct position on the wheel hub Be sure the valve stem is toward the outside and rotation arrows on the tire point toward forward rotation 2 Attach the wheel nuts and finger tighten them 3 Lower the vehicle to the ground Securely tighten the wheel nuts according to the chart found on page 69 CAUTION If wheels are improperly installed it could affect vehicle han dling and tire wear 81 MAINTENANCE AWARNING Operating your vehicle with worn tires will increase the possibility of the vehicle skidding easily with possible loss of control Worn tires can cause an accident Always replace tires when the tread depth measures 1 8 3 cm or less Tire Inspection CAUTION Maintain proper tire pressure according to charts below Improper tire inflation may affect vehicle maneuverability When replacing a tire always use original equipment size and type CAUTION The use of non standard size or type tires may affect vehicle handling Tire Tread Depth Always replace tires when tread depth is worn to 1 8 3 cm or less Please refer to your Owner s Manual Supplement for tire s
44. er and change clothing Never start the engine or let it run in an enclosed area Gasoline pow ered engine exhaust fumes are poisonous and can cause loss of con sciousness and death in a short time Shut off fuel valve whenever the vehicle is stored or parked 25 CONTROL PARTS AND FUNCTIONS ZAWARNING The engine exhaust from this product contains chemicals known to cause cancer birth de fects or other reproductive harm rN Never use gasohol with an octane rating lower than the minimum octane rat ing specified for this product rN Never use gasohol containing more than 10 ethanol grain alcohol A Never use gasohol containing more than 5 methanol wood alcohol Gas oline containing methanol must also be blended with cosolvents and corrosion in hibitors PN use gasohol for extended periods and never store this vehicle with gasohol in the fuel system IN Gasoline containing alcohol can cause paint damage Be extra careful not to spill gasohol during refueling 26 CONTROL AND PARTS FUNCTIONS VEHICLE NOMENCLATURE Left View Cab Frame Cab Frame Hand Hold Dashboard Steering Wheel Gear Shift Lever Seat Cargo Box Seat Belts Parking Brake Engine Compartment Access Panel Hood Latches attached to hood left and right sides under dash DON ER DT o 27 CONTROL AND PARTS FUNCTIONS VEHICLE NOMENCLATURE Front View 12 Headlights 13 Air Box under hood
45. eserves the right to make product changes and improvements which may affect illustrations or ex planations No part of this manual shall be reproduced or used without the written permission of Polaris Industries Inc THIS VEHICLE IS NOT A TOY AND CAN BE HAZARDOUS TO OPERATE This vehicle handles differently from other vehicles including motor cycles and cars A collision or rollover can occur quickly even during rou tine maneuvers such as turning and driving on hills or over obstacles if you fail to take proper precautions SEVERE INJURY OR DEATH can result if you do not follow these instructions Read this manual and all labels carefully and follow the operating procedures described Never allow anyone without a valid driver s license to operate this vehicle Minimum age recommendation for passengers is five years old Passengers under five years of age require special restraints which are not available with this vehicle Driver and passenger should wear their seatbelts 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 when braking on hills or during turns Always fasten your seatbelts securely around you This vehicle is for off road use only Never operate on public roads as severe injury or death may occur Always avoid paved surfaces Helmets are rec
46. evel between fill lines As required See page 78 change every two years or 200 hours 3 Transmission Polaris Pre Add to FULL level on dipstick Change annually Oil mium Syn See page 66 or at 100 hours thetic chain case lube 4 Front Gear GL5 80 90 Fill to bottom thread of filler hole Change annually case Oil Weight Gear Make certain machine is on level Lube surface 5 Center Half Grease Locate Fittings and Grease Every 3 months shafts or 50 hours 6 Front Prop Grease Locate Fittings and Grease Every 3 months Shaft U joints or 50 hours 7 Front Prop Grease Locate fittings and grease 3 Every 3 months shaft Yoke pumps maximum or 50 hours Premium Remove set screw in hubs Ro Annually or at Hub Lube tate wheels to 4 O clock position 100 hrs If lubricant is not visible add more Reinstall set screw 8 Demand 6 Hubs All Wheel Drive 9 Front Drive Grease Locate grease fitting and grease Every 3 months Axle U Joint with grease gun or 50 hours 10 Ball Joint Grease Locate fitting on back side of Every 3 months struts and grease with grease or 50 hours gun 62 Lubrication Recommendations 3 Transmission Operating Range 6 Front Prop Shaft U Joint TG REN j SS 9 Axle Cardan Front Drive Models da 4 O 4 or MAINTENANCE 7 Propshaft Yoke Center Halfshaft oint 8 Demand Hubs 8 4 O clock 63 MAINTENANCE Lubrication Recommenda
47. fter the engine has been run The exhaust system becomes very hot and can cause severe burns 1 Open hood and locate the airbox 1 2 Follow right hand breather line out of the back of the airbox and locate filter 2 3 Inspect filter for debris Blow through gently in direction of arrow on filter to check for clogging Replace as needed 4 Check hoses for cracks deterioration abrasion or leaks Replace as needed 5 Reinstall filter and clamps with arrow pointing toward engine Radiator and Cooling Fan Check and clean the grille screen and radiator fins for obstruction by insects or mud in accordance with the Periodic Maintenance Chart CAUTION Using high pressure water as from a car wash facility could damage the radiator fins and impair the radiator s effectiveness Do not obstruct or deflect airflow through the radiator by installing unauthorized ac cessories in front of the radiator or behind the cooling fan Interference with the radiator airflow can lead to overheating and consequent engine damage Coolant absorbs excessive heat from the engine and transfers it to the air at the radiator If the coolant level becomes low the engine overheats and may suffer damage Check the coolant level each day before operating the vehicle and re plenish coolant if the level is low Change the coolant in accordance with the Peri odic Maintenance Chart 71 MAINTENANCE Coolant Level Inspection NOTE C
48. fully before you start up any hill Never climb hills with ex cessively slippery or loose surfaces Shift your weight forward Never open the throttle suddenly or make sudden gear changes Never go over the top of any hill at high speed Always follow proper procedures for going down hills and for braking on hills as described in this manual Check the terrain carefully before you start down any hill Never go down a hill at high speed Avoid going down a hill at an angle which would cause the vehicle to lean sharply to one side Go straight down the hill where possible Always follow proper procedures for crossing the side of a hill as described in this manual Avoid hills with excessively slippery or loose surfaces Never at tempt to turn the vehicle around on any hill until you have mastered the turning technique described in this manual on level ground Avoid crossing the side of a steep hill if possible Always use proper procedures if you stall or roll backwards when climbing a hill To avoid stalling maintain a steady speed when climbing a hill If you stall or roll backwards follow the special procedure for braking described in this manual Dismount on the uphill side or to either side if pointed straight uphill Turn the vehicle around and remount following the procedure described in this manual Always check for obstacles before operating in a new area Never attempt to operate over large obstacles such as large rocks or fallen tree
49. heck the coolant level when the engine is cold room or atmospheric temperature 1 Situate the vehicle on level ground 2 Check the coolant level through the coolant level gauge on the reserve tank lo cated Behind the left hand en gine compartment panel The coolant level should be be tween the F Full and L Low marks 3 If the amount of coolant is not within the operating range un screw the cap from the reserve tank Using a funnel add cool ant through the filler opening to the F Full mark Install the cap NOTE Polaris recommends the use of Polaris Premium 60 40 anti freeze coolant or a 50 50 mixture of high quality aluminum compat ible anti freeze coolant and dis tilled water IMPORTANT Polaris Premium 60 40 is already pre mixed and ready to use Do not di lute with water IMPORTANT Al ways follow the manufacturer s mixing recommendations for the freeze protection required in your area Radiator Cap Coolant Bottle NOTE In an emergency you can add water alone to the coolant reserve tank how ever it must be returned to the correct mixture ratio by the addition of antifreeze con centrate as soon as possible CAUTION If coolant must be added often or the reserve tank completely runs dry it is possible there is a leak in the system Have the cooling system inspected by your Polaris RANGER dealer 72 MAINTENANCE Spark Plugs e Proper electrode gap is
50. hills improperly can cause loss of control or cause vehicle to over turn Always check the terrain carefully before you start up any hill Never climb hills with excessively slippery or loose surfaces Never open the throttle suddenly The vehicle could go out of control Never go over the top of any hill at high speed An obstacle a sharp drop or another vehicle or person could be on the other side of the hill 51 OPERATING SAFETY Crossing Streams Your Polaris RANGER can operate through water up to depths reaching the floor boards Before fording streams always 1 Determine water depths and current 2 Choose a crossing where both banks have gradual inclines 3 Proceed slowly avoiding rocks and obstacles if possible 4 After crossing dry the brakes by applying light pressure to the lever until brak ing action is normal Should your vehicle become immersed it will be necessary to take it to your dealer as soon as possible Do not start the engine Immersion of the vehicle can cause major damage if not correctly repaired A WARNING Never try to cross any deep or fast flowing streams The large tires can cause the vehicle to float resulting in loss of control e Determine stream depth and speed before crossing 52 OPERATING SAFETY Trail Obstacles Keep Alert Look ahead and learn to read the trail as you ride Stay on the right side of the trail if possible and be constantly alert for hazards such as
51. ing A WARNING Loss of vehicle control due to excessive speed can occur Loss of control may result in serious injury or death Whenever traveling uphill always travel straight uphill and 1 Avoid steep hills 2 Keep both feet on the footrests 3 Proceed at a steady rate of speed and throttle opening 49 OPERATING SAFETY PN RUD C on serous injury or death AWARNING Braking and handling are greatly affected whenever operating in hilly ter rain Loss of vehicle control or overturning of the vehicle could occur e Avoid climbing steep hills 15 maximum Use extreme care when operating your vehicle in hilly terrain A WARNING Avoid climbing steep hills Loss of vehicle control or overturning of vehicle could occur Use extreme care when operating your RANGER in hilly terrain A WARNING Improperly crossing hills or turning on hills could cause loss of control or cause the vehicle to overturn If at all possible avoid crossing the side of a steep hill Avoid hills with ex cessively slippery or loose surfaces 50 OPERATING SAFETY AWARNING Going down a hill improperly could cause loss of control or cause the ve hicle to overturn Always check the terrain carefully before you start down any hill Never go down a hill at high speed Avoid going down a hill at an angle which would cause the vehicle to lean sharply to one side Go straight down the hill where possible A WARNING Climbing
52. ing a hill WHAT CAN HAPPEN Could result in vehicle overturning HOW TO AVOID THE HAZARD Maintain steady speed when climbing a hill If you lose all forward speed Apply the brakes Lock parking brake after you are stopped If you begin rolling backwards Never apply engine power Apply the brake gradually When fully stopped lock parking brake In the event of an accident have a qualified service dealer check the com plete machine including but not limited to brakes throttle and steering for possible damage 18 OPERATION WARNINGS A WARNING POTENTIAL HAZARD Overloading this vehicle or carrying or towing cargo improperly WHAT CAN HAPPEN Could cause changes in vehicle handling which could lead to an accident HOW TO AVOID THE HAZARD Never exceed the stated load capacity for this vehicle Cargo should be properly distributed and securely attached Reduce speed when carrying cargo or pulling a trailer Allow greater dis tance for braking Always follow the instructions in the Owner s Manual for carrying cargo or pulling a trailer See page 45 A WARNING Never carry passengers in the box If the weight distribution on the box is located toward the rear of the box and the release lever is pulled forward the box will want to dump on its own Never operate the dump lever without checking the position of the load This will prevent unexpected dumping of the cargo box A WARNING In
53. k the vehicle in a side hill position 54 OPERATING SAFETY Dumping the Cargo Box 1 Select a level site to dump the cargo box Do not attempt to dump or unload the vehicle while parked on an incline 2 Setthe parking brake 3 Dismount the vehicle 4 Stand clear and pull the cargo box release mechanism lever 1 forward Lift the front of the cargo box to dump A WARNING If the weight distribution on the box is located toward the rear of the box and the release lever is pulled forward the box will want to dump on its own Never operate the dump lever without checking the position of the load This will prevent unexpected dumping of the cargo box A WARNING Never carry passengers in the box A WARNING In the event of an accident have a qualified service dealer check the complete machine including but not limited to brakes throttle and steering for possible damage 55 NOISE EMISSION CONTROL SYSTEM REGULATION TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED U S Federal law prohibits the following acts or the causing thereof 1 The removal or rendering inoperative by any person other than for purposes of maintenance repair or replacement of any device or element of design incorpo rated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use or 2 the use of the vehicle after such device or element of design has been r
54. k the wheels Make sure the machine is in neutral and repeat steps 2 and 3 WARNING SEE BELOW Repeat steps 2 through 5 until no more particles are expelled when the engine is revved Stop the engine and allow the arrestor to cool Reinstall the arrestor plugs A WARNING Because exhaust system temperatures can reach 1000 F do not perform this operation immediately after the engine has been run because the ex haust system becomes very hot Because of the increased fire hazard make sure that there are no com bustible materials in the area when purging the spark arrestor Wear eye protection Do not stand behind or in front of the vehicle while purging the carbon from the spark arrestor Never run the engine in an enclosed area The exhaust contains poison ous carbon monoxide gas e Do not go under the machine while it is inclined Failure to heed these wamings could result in serious personal injury or death MAINTENANCE Tool Kit To help you perform routine maintenance a tool kit is provided in the storage compartment under the seat Items included in the kit are screwdriver open end wrench 8 10 mm open end wrench 12 14 mm tire pressure gauge spark plug wrench and handle NOTE Other tools are also necessary to perform maintenance work They are called out later in this manual PVT System AWARNING The PVT system rotates at high speeds creating large amounts of force on clutch
55. lean dry cloth clean filter sealing surface on crankcase Lubricate O Ring on new filter with a film of new engine oil Check to make sure the O Ring is in good condition Also make sure the O ring from the old filter is not still on the engine Install new filter and tighten by hand 1 2 to 3 4 turn after gasket contact Approximately 1 cup of engine oil will remain in the crankcase To drain remove drain plug found on lower right side of crankcase NOTE The sealing surfaces on the drain plug and crankcase should be clean and free of burrs nicks or scratches CONTROL AND PARTS FUNCTIONS Oil and Filter Change Cont 14 Reinstall drain plug 15 Remove dipstick 2 and add 2 quarts 1 9 I of Polaris Premium 4 synthetic oil Reinstall dipstick NOTE If sump is not drained add about 1 3 4 quarts initially 16 Place gear selector in neutral and set parking brake 17 Start engine and let it idle for one to two minutes Stop engine and inspect for leaks 18 Re check oil level on the dipstick and add oil as necessary to bring the level to the upper mark on the dipstick 19 Dispose of used filter and oil properly Fuel Filter and Oil Filter Your Polaris RANGER is equipped with a unique in line fuel filter These filters should be replaced by your dealer after every 100 hours of operation or annually Do not attempt to clean these filters 39 STARTING THE ENGINE Stopping the Engine 1 Release the thr
56. ling This warranty also does not cover any vehicle that has been altered structurally neglected improperly maintained used for racing or used for purposes other than for which it was manufactured or for any damages which occur during trailer transit or as a result of unauthorized service or the use of unauthorized parts In addition this warranty does not cover physical damage to paint or finish stress cracks tearing or puncturing of uphol stery 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 de fective 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 DESCRIPTION WHETHER ARISING OUT OF EXPRESS OR IMPLIED 93 WARRANTY WARRANTY OR ANY OTHER CONTRACT NEGLIGENCE OR OTHER TORT OR OTHERWISE Some states do not permit the exclusion or limitation of inciden tal or consequential damages or implied warranties so the above limitations or ex clusions may not apply to you if inconsistent with controlling state l
57. ll indicator lights and switches Engine ignition switch check for proper function Wheels check for tightness of wheel nuts and axle nuts check that axle nuts are secured by cotter pins Air cleaner element check for dirt clean or replace Steering check for free operation noting any unusual looseness in any area Loose parts visually inspect vehicle for any damaged or loose nuts bolts or fasteners Operator and passenger should be properly dressed Engine coolant check for proper level at the recovery bottle Check condition and operation of the dump box bed latch mecha nism OPERATION WARNINGS 10 AWARNING POTENTIAL HAZARD Operating this vehicle without proper instruction WHAT CAN HAPPEN The risk of an accident is greatly increased ifthe operator does not know how to operate the vehicle properly in different situations and on differ ent types of terrain HOW TO AVOID THE HAZARD Read and understand the Owner s Manual and all warning and instruc tion labels on the vehicle A WARNING POTENTIAL HAZARD Failure to follow the age recommendations for this vehicle WHAT CAN HAPPEN Use of this vehicle by a child can lead to severe injury or death of the child or others 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 judg ment needed to operate the vehicle safely and may be involved in a
58. logs rocks and low hanging branches A WARNING Hidden or unseen hazards on the trail can be dangerous Personal injury or the vehicle overturning can occur from unseen obstacles e Keep alert and constantly look for obstacles on the trail WA R N i N G indicates a potential hazard which A could result in serious injury or death 53 OPERATING SAFETY Backing Up When backing up always avoid backing downhill Back slowly When in reverse apply the brakes lightly for stopping Avoid turning at sharp angles in reverse Never open the throttle suddenly while backing Always inspect left and right fields of vision before backing A WARNING oa Pron Backing your RANGER can be dangerous You could hit an obstacle or person behind you or the vehicle could tip over on a steep incline e Always back slowly avoiding excessive speed Avoid backing on steep inclines Parking On An Incline Whenever the Vehicle is Parked 1 Place the transmission in gear 2 Set the parking brake 3 Avoid parking on an incline If it is necessary to park on an incline always block the rear wheels on the down hill side 4 Shut off fuel supply A WARNING Always check to be sure that the parking brake has been disengaged before operating the vehicle An accident could result if the parking brake is left on while the vehicle is operated Always block the downhill side of the wheels if leaving the vehicle on a hill or par
59. lowly Could affect your balance and perception Could result in an accident HOW TO AVOID THE HAZARD Never consume alcohol or drugs before or while driving this vehicle A WARNING POTENTIAL HAZARD Operating this vehicle at excessive speeds WHAT CAN HAPPEN Increases your chances of losing control of the vehicle which can result in an accident HOW TO AVOID THE HAZARD Always travel at a speed which is proper for the terrain visibility and operating conditions and your experience OPERATION WARNINGS AWARNING POTENTIAL HAZARD Failure to inspect the vehicle before operating Failure to properly maintain the vehicle WHAT CAN HAPPEN Increases the possibility of an accident or equipment damage HOW TO AVOID THE HAZARD Always inspect your RANGER each time you use it to make sure it is in safe operating condition Always follow the inspection and maintenance procedures and schedules described in the Owner s Manual AWARNING POTENTIAL HAZARD Attempting jumps and other stunts WHAT CAN HAPPEN Increases the chance of an accident including an overturn HOW TO AVOID THE HAZARD Never attempt stunts such as jumps Don t try to show off A WARNING POTENTIAL HAZARD Failure to use extra care when operating this vehicle on unfamiliar terrain WHAT CAN HAPPEN You can come upon hidden rocks bumps or holes without enough time to react Could result in the vehicle overturning
60. ned in the following chart Maintenance intervals are based upon average riding conditions and a vehicle speed of approximately 10 miles per hour Vehicles subjected to severe use such as operation in wet or dusty areas should be inspected and serviced more fre quently If you are not familiar with safe service and adjustment procedures have a qualified dealer perform these operations Inspect clean lubricate adjust or replace parts as necessary mM CAUTION Due to the nature of these adjustments it is recommended that service be performed by an authorized Polaris dealer Do not attempt to perform this work unless you are familiar with mechanical repair More often under severe use such as dirty or wet conditions Emission Control System Service California NOTE Inspection may reveal the need for replacement parts Always use genu ine Polaris parts available from your Polaris dealer Item Hours or Frequency Remarks Odometer pr Engine Oil Level Change 100 hrs 1000 6 months Check Level Daily Break in Service at 4 Cycle miles 1 month Change oil more often in cold weather use Oil Filter 100 hrs 1000 Replace with oil change miles Engine breather filter Monthly Inspect replace annually and as need ed er Er ns Engine Cylinder Head and 25 hrs 3 months Inspect re torque required at first ser Cylinder Base Fasteners vice only Air Filter Main Element Weekly Weekly Inspect Replace if necessary Valve Clearance
61. ned in this manual This preventive maintenance program is designed to ensure that all critical components on the vehicle are thoroughly inspected by your dealer at various mileage intervals NOTE The addition of certain accessories including but not limited to mowers blades tires sprayers or large racks may change the handling characteristics of the ve hicle Be certain any accessories added to this vehicle have been approved by Polaris Familiarize yourself with their function and affect on the vehicle The Polaris Preferred Registered Owners PRO Family Your Owners Program As the owner of a new Polaris vehicle you are entitled to a FREE two year mem bership in the Polaris PRO Family the Preferred Registered Owners Family It s an owners program for Polaris owners like you people who have chosen the finest recreational vehicle available people who share an interest in Polaris and its prod ucis Once your new vehicle s warranty is registered you will receive aPRO Family membership packet that will include A letter of welcome to the PRO Family 3 A PRO Family card with your name and membership number A colorful sticker of the PRO logo 3 A PRO merchandise brochure and order form As a PRO Family member you re entitled to opportunities such as A free subscription to PRO Spirit the official magazine of the PRO Family The chance to buy insurance for you Polaris vehicle The toll free insurance t
62. ng WHAT CAN HAPPEN You may lose control of the vehicle You may also regain traction unexpectedly which may cause the vehicle to overturn HOW TO AVOID THE HAZARD On slippery surfaces such as ice go slowly and be very cautious in order to reduce the chance of skidding or sliding out of control A WARNING POTENTIAL HAZARD Riding on frozen lakes and rivers WHAT CAN HAPPEN Severe injury or death can result if the vehicle and or the operator break through the ice HOW TO AVOID THE HAZARD Never ride your RANGER on a frozen body of water before you are sure the ice is thick enough and sound enough to support the machine and its operator as well as the force that is created by a moving vehicle OPERATION WARNINGS AWARNING POTENTIAL HAZARD Operating this vehicle through deep or fast flowing water WHAT CAN HAPPEN Tires may float causing loss of traction and loss of control which could lead to an accident HOW TO AVOID THE HAZARD Never operate this vehicle in fast flowing water or in water deeper than that specified in your Owner s Manual See page 52 Remember that wet brakes may have reduced stopping ability Test your brakes after leaving water If necessary apply them several times to let friction dry out the pads A WARNING POTENTIAL HAZARD Improperly operating in reverse WHAT CAN HAPPEN You could hit an obstacle or person behind you resulting in serious injur
63. ngine access panel and then back for access Remove the spark plug cap and then the spark plug by rotating coun terclockwise Reverse the procedure for spark plug installation Torque to 17 ft Ibs 2 3 kg m Never deviate from the recommended spark plug as engine damage can occur Cylinder Head Cylinder Base Fastener Torque Have your dealer check the RANGER cylinder head and cylinder base fasteners for proper torque at the first service or after 25 hours 73 MAINTENANCE Spark Arrestor The exhaust pipe must be period ically purged of accumulated car bon as follows 1 74 Remove the clean out plugs located on the bottom of the muffler as shown above Place the transmission in neutral and start the engine Purge accumulated carbon from the system by momen tarily revving the engine sev eral times If some carbon is expelled cover the exhaust outlet and rap on the pipe around the clean out plugs while revving the engine several more times If particles are still suspected to be in the muffler back the machine onto an in cline so the rear of the machine is one foot higher than the front Setthe parking brake and block the wheels Make sure the machine is in neutral and repeat steps 2 and 3 WARNING SEE BELOW If particles are still suspected to be in the muffler drive the machine onto the incline so the front of the machine is one foot higher than the rear Set the park ing brake and bloc
64. nsmission in gear with the parking brake applied and turn the vehicle off whenever the ve hicle is left unattended 32 CONTROL AND PARTS FUNCTIONS Disengaging Wheel Hubs When backing uphill while in Demand 6 Drive and then going forward downhill one or both hubs may remain engaged If one or both hubs remain engaged they can be disengaged by stopping shifting to and moving in reverse Then proceed in forward again You can tell if only one front hub is engaged if the steering pulls to one side If both front wheel hubs are engaged steering effort increases but remains balanced from left to right and vehicle speed is somewhat restricted A N warnine If both hubs were engaged and only one released during opera tion loss of control could result If you experience hub engaging symptoms use the above disengaging technique before proceeding Failure to disengage front hubs as directed above could result in severe injury or death If the hubs remain engaged after following these instructions return the vehicle to your dealer for service PVT System A WARNING The PVT system rotates at high speeds creating large amounts of force on clutch components Extensive engineering and testing has been con ducted to insure the safety of this product However as the owner you have the following responsibilities to make sure this system remains safe e Do not modify any component of the PVT system Doing so may reduce its strength so th
65. ommended whenever driving this vehicle in an aggressive man ner Eye protection is recommended at all times Never consume alcohol or drugs before or while operating this vehicle Never operate at excessive speeds Always travel at a speed which is proper for the terrain visibility and operating conditions and your experience Never attempt wheelies jumps or other stunts Always inspect your vehicle each time you use it to make sure it is in safe operat ing condition Always follow the inspection and maintenance procedures and schedules described in this manual Always keep both hands on the steering wheel and both feet on the floorboards of the vehicle during operation Always go slowly and be extra careful when operating on unfamiliar terrain Al Ways be alert to changing terrain conditions when operating this vehicle Never operate on excessively rough slippery or loose terrain Always follow proper procedures for turning as described in this manual Prac tice turning at low speeds before attempting to turn at faster speeds Do not turn at excessive speed 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 care
66. onnections should be kept 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 rags Coat the terminals with dielectric grease or petro leum jelly A Do not allow cleaning solution or tap water to enter the battery It will shorten the life of the battery IN venice lamps may burn out if battery is disconnected during vehicle opera tion Also the reverse speed limiter can be damaged AWARNING Battery electrolyte is poisonous It contains sulfuric acid Serious burns can result from contact with skin eyes or clothing Antidote External Flush with water Internal Drink large quantities of water or milk Follow with milk of magne sia 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 57 BATTERY Battery Removal 1 Disconnect hold down straps holding the battery 1 in position and remove battery retainer 2 Remove the battery vent tube from the battery 3 Disconnect the black negative battery cable first 4 Disconnect the red positive bat tery cable next 5
67. or going out of control HOW TO AVOID THE HAZARD Go slowly and be extra careful when operating on unfamiliar terrain Always be alert to changing terrain conditions when operating the vehicle 13 OPERATION WARNINGS 14 AWARNING POTENTIAL HAZARD Failure to use extra care when operating on excessively rough slip pery or loose terrain WHAT CAN HAPPEN Could cause loss of traction or vehicle control which could result in an accident including an overturn HOW TO AVOID THE HAZARD Do not operate on excessively rough slippery or loose terrain until you have learned and practiced the skills necessary to control the ve hicle on such terrain Always be especially cautious on these kinds of terrain A WARNING POTENTIAL HAZARD Operating on excessively steep hills WHAT CAN HAPPEN The vehicle can overturn more easily on extremely steep hills than on level surfaces or small hills HOW TO AVOID THE HAZARD Never operate the RANGER on hills too steep for the vehicle or for your abilities Practice on smaller hills before attempting large hills Never operate vehicle on hills steeper than 15 OPERATION WARNINGS AWARNING POTENTIAL HAZARD Climbing hills improperly WHAT CAN HAPPEN Could cause loss of control or cause vehicle to overturn HOW TO AVOID THE HAZARD Always check the terrain carefully before you start up any hill Never climb hills with excessively slippery or loo
68. oroughly 4 Measure the distance the throttle pedal moves before the engine begins to pick up speed Free play should be 1 16 1 8 inches Adjustment If adjustment is necessary adjust the throttle freeplay using the follow ing procedure 1 Loosen jam nut on cable where it connects to the throttle brack et 2 Adjust cable to specified free play 3 Tighten jam nuts securely 76 MAINTENANCE Carburetor The idle speed adjustment should be performed in accordance with the Periodic Maintenance Chart or whenever the idle speed is changed The following proce dure covers the idle speed adjustment Carburetor Engine Idle RPM Adjustment Recommended engine idle RPM is 1200 200 If the engine idle speed is not satisfactory and all other conditions are favorable the carburetor can be adjusted as follows 1 Apply the parking brake 2 Put the gear shift lever in the N Neutral position 3 Warm up the engine by running the vehicle approximately five minutes 4 Remove the right hand engine compartment access panel and locate the idle screw 5 Place the transmission in gear with the parking brake applied 6 Adjust the carburetor idle screw in or out until the desired idle RPM is reached Turning the screw in clockwise will raise RPM Turning the screw out counterclockwise will lower RPM Idle Screw 77 MAINTENANCE Front and Rear Brakes The front and brakes are hydrauli
69. orward is recommended in heavy pulling situations to extend belt life Maximum grade while trailer towing 15 do not tow any trailer on a grade steeper than 15 Total Towed Total Towed Total Hitch Towing Load Weight Load Weight 15 Vertical Weight Speed level ground grade 1500 Ibs 681 kg 850 Ibs 386 kg 150 Ibs 68 1 kg 10 mph 16 kph or less N Do not carry more than 1000 Lbs 454 kg in the cargo box AWARNING Never carry a passenger in a trailer 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 Remem ber that towing a trailer increases braking distance Do not tow more than 1500 Ib 681 kg trailer weight trailer plus cargo weight Attach a trailer to the trailer hitch bracket only Do not attach a trailer to any oth er location or you may lose control of the vehicle and have an accident 45 OPERATING SAFETY Load Distribution 1 Always load the cargo box placing the load as far forward as possible 2 Always operate the vehicle with extreme care whenever hauling or towing loads 3 Slow down and drive in D 1 only 4 The cargo box dump latch must be securely latched before loading and operat ing Unintentional box tilting will result if weight is placed in the rear of the box and the latch is not secured WARNING Never operate this vehicle with the cargo box in the raised position The
70. ottle pedal completely 2 Put the gear shift lever into N Neutral 3 Apply the parking brake to help prevent the vehicle from rolling 4 Turn the ignition switch key to the OFF position Procedure for Starting a Cold Engine AWARNING Do not start or operate this vehicle with sticking or improperly operating throttle pedal A stuck or improperly operating throttle could cause an ac cident resulting in severe injury or death Always contact your dealer for service repairs whenever throttle prob lems arise Failure to check or maintain proper operation of the throttle system can result in the throttle pedal sticking during driving and cause an accident Always check the pedal for free movement and return before starting the engine and occasionally during driving Place the transmission in neutral and move the vehicle to a level surface Lock the parking brake Turn the fuel tank valve to ON Sit in the vehicle in the driver s seat Tug iut OFF Choke Lever Side View 5 Move the choke lever to the FULL position 6 Turn the ignition key to START 40 STARTING THE ENGINE 7 If engine does not start release ignition switch and wait five seconds then turn the ignition switch to start for another five seconds Repeat this procedure until engine starts NOTE Do not press the throttle pedal while starting the engine After the Engine Starts 1 Ifthe engine slows or stops use of the choke lever at i
71. ould be air in the brake lines or the brake may be defective Do not operate the vehicle under these conditions Have the brake system ser viced by an authorized Polaris dealer immedi ately 78 Check brake system for fluid leaks Check brake for excessive travel or spongy feel Check friction pads for wear damage 3 64 1 cm and looseness Check security and surface condition of the disc Pads should be changed when worn to 3 64 1 cm or about the thickness of a dime MAINTENANCE Rear Brake The rear brake is a hydraulic disc type brake which is activated by the same pedal which activates the front brake system The rear brake sys tem is self adjusting and requires no maintenance other than periodic checks of the pads for wear Wear Line e Pads should be changed when worn to 3 64 1 cm which is 3 64 1 cm about the thickness of a dime e Inspect the brake disc spline and pad wear surface for excessive wear A WARNING Due to the nature of this type of vehicle and where it is operated headlight and taillight lenses may become dirty Frequent washing is necessary to maintain lighting quality Poor lighting while riding can result in severe injury or death CAUTION Do not service while lights are hot Serious burns may result Brake Light Switch When the brake pedal is depressed the brake light goes on Check the brake light switch before each ride To insp
72. pecifications Minimum Tread Depth 1 8 Tire Specifications RANGER 6x6 Front 25 x 10 00 12 Inflation Pressure Min 5 Max 12 Rear 25 x 11 00 10 Inflation Pressure Min 5 Max 10 Cargo Box Load Capacity 1000 Ibs 454 kg Gross Vehicle Weight 3020 Ibs 1327 kg including vehicle driver passenger and cargo Vehicle weighs 1520 Ibs 690 kg Center 25 x 11 00 10 Inflation Pressure Min 5 Max10 82 MAINTENANCE Seat Belts Make certain each seat belt functions properly before each ride Push the latch plate into the buckle until it clicks The latch plate must slide smoothly into the buckle The click sound shows it is securely latched Push the red button in the middle of the buckle to make sure it releases freely Also check the belt webbing for wear cuts or damage If any irregularities are found have the seat belt system checked or replaced by an authorized Polaris dealer THIS GENERAL PURPOSE OFF ROAD UTILITY VEHICLE DUES NOT MEET FEDERAL MOTOR VEHICLE SAFETY STANDARDS FOR ON ROAD VEHICLES e NEVER USE ON PUBLIC ROADS FOR MAXIMUM SAFETY PROTECTION ALWAYS WEAR YOUR SAFETY BELT NEVER USE WITH 7077646 DRUGS OR ALCOHOL 83 MAINTENANCE Headlight Beam The headlight beam can be adjusted up and down 1 Place the vehicle on a level surface with the headlight approximately 25 7 6 m from a wall 2 Measure the distance from the floor to the center of the headlight
73. remium 4 possesses unsurpassed film strength over the widest possible temper ature range It resists viscosity and frictional breakdown in ambient temperatures from 40 F to 120 F Its exceptional frictional properties result in more efficient operation more power output and lower fuel consumption Although Polaris Premium 4 is the only oil recommended for use in this engine use of any API certified SH oil is allowable Oil may need to be changed more fre quently if Polaris Premium 4 is not used You will also need to follow the manufac turers recommendations for ambient temperature operation Oil System The oil tank is located on the left side of the vehicle To check the oil 1 Set machine on a level surface 2 Start the engine and let it idle for 20 30 seconds 3 Stop the engine remove dipstick 1 and wipe dry with a clean cloth 4 Screw in the dipstick completely remove it and read the oil level NOTE The dipstick must be screwed in to keep the angle and depth of stick consistent 5 Remove dipstick and check to see that the oil level is between the full and add marks Add oil as indicated by the level on the dipstick Do not overfill Premium 4 All Season synthetic Cops oz ef vorm oil PN 2871271 or API certified SH oil Never substitute or mix Maintain Oil Level In Normal Range oil brands Serious engine dam age and voiding of warranty can result 37 CONTROL AND
74. ris RANGER against defects in material or workmanship This warranty cov ers the parts and labor charges for repair or replacement of defective parts which are covered by this warranty This warranty begins on the date of purchase This warranty is transferrable to another consumer during the warranty period through a Polaris dealer There is a charge of 35 00 payable to Polaris Industries Inc 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 war ranty entitlement If you have not signed the original registration and received the customer copy please contact your dealer immediately NO WARRANTY COV ERAGE WILL BE ALLOWED UNLESS YOUR VEHICLE IS REGISTERED WITH POLARIS Initial dealer preparation and set up of your vehicle is very important in ensuring trouble free operation Purchasing a machine in the crate or without proper dealer set up will void your warranty coverage WARRANTY COVERAGE AND EXCLUSIONS LIMITATIONS OF WARRANTIES AND REMEDIES The Polaris limited warranty excludes any failures that are not caused by a defect in material or workmanship This warranty does not cover accidental damage nor mal wear and tear abuse or improper hand
75. rmed Service Front Wheel Nuts 15 Ft Lbs Center and Rear Hub 120 Ft Lbs Retaining Nut s Rear Wheel Nuts 15 Ft Lbs Front Wheel Hub Tightening Front wheel bearing tightness and spindle nut retention are critical component op erations Service work must be performed by your authorized Polaris dealer 69 MAINTENANCE Rear Spring Adjustment The rear shock absorber springs are adjusted by rotating the adjuster in the direction required to increase or decrease spring tension Air Filter Service It is recommended that the air filter be replaced yearly When riding in ex tremely dusty conditions replace ment will be required more often 1 Open the hood 2 Remove the cover Inspect the gasket It should adhere tightly to the cover and seal all the way around Rear Spring Adjustment Cam 3 Remove the air filter Do not attempt to clean the main element 4 Install new air filter NOTE Apply a small amount of general purpose grease to the sealing edges of the filter before installing 5 Check air box If oil or water deposits are found drain them into a suitable con tainer NOTE Service more frequently if vehicle is operated in wet conditions or at high throttle openings for extended periods Air Filter 70 MAINTENANCE CAUTION Operation of your vehicle without a breather filter can cause engine damage Breather Filter and Hoses A WARNING Do not perform this operation immediately a
76. s Always follow proper procedures when operating over obstacles as described in this manual Always be careful of skidding or sliding On slippery surfaces such as ice go slowly and be very cautious in order to reduce the chance of skidding or sliding out of control Never operate vehicle in fast flowing water or in water deeper than that specified in this manual Remember that wet brakes may have reduced stopping ability Test your brakes after leaving water If necessary apply them lightly several times to let friction dry out the pads Always be sure there are no obstacles or people behind you when you operate in reverse When it is safe to proceed in reverse go slowly Avoid turning at sharp angles in reverse Always use the size and type tires specified in this manual Always maintain proper tire pressure as described on page 83 Never modify this vehicle through improper installation or use of accessories Never exceed the stated load capacity for this vehicle Cargo should be proper ly distributed and securely attached Reduce speed and follow instructions in this manual for carrying cargo or pulling a trailer Allow greater distance for brak ing Always wear the seat belts whenever the vehicle is operated This will reduce the severity of injury in case of a sudden stop or collision Always keep arms and legs inside of cab frame while the vehicle is in motion Always apply the parking brake before getting out of the vehicl
77. s of the bolts nuts and other fasteners should be checked by an autho rized Polaris dealer in accordance with the Periodic Maintenance Chart 88 TROUBLESHOOTING Procedures The following information is provided to help you identify probable causes for ques tions you may have about the operation of your vehicle See your Polaris dealer with any additional questions you may have ENGINE CRANKS BUT FAILS TO START Fuel Valve Off Water in Fuel Spark Plug No Spark to Spark Plug Contact Your Dealer ENGINE STOPS OR LOSES POWER Spark Plug Engine Fouled Overheated Fuel Vent Line Air Filter Clean Radiator Kinked or Clogged screen Contact Your Dealer Clogged Fuel Valve Overuse of Choke Plugged Water in Fuel Fuel Pump Faulty Contact Your Dealer Clean Engine Exterior Contact Your Dealer 89 SPECIFICATIONS CC CE om A OPFUSPO 90 SPECIFICATIONS N Type Foot pedal activated hydraulic front and rear Mechanical Parking Brake Hydraulic disc Floating caliper Rear Center Axle Hydraulic Disc floating Caliper Parking Brake Hand Lever Mechanical to center Axle Hood Headlight watts 4 x 35W Taillights watts 2 x 8 26W 91 WARRANTY 92 WARRANTY LIMITED WARRANTY Polaris Industries Inc 1225 Highway 169 North Minneapolis Minnesota 55441 5078 gives a SIX MONTH LIMITED WARRANTY on all components of the Pola
78. se surfaces Never open the throttle suddenly The vehicle could go out of control Never go over the top of any hill at high speed An obstacle a sharp drop or another vehicle or person could be on the other side of the hill A WARNING POTENTIAL HAZARD Going down a hill improperly WHAT CAN HAPPEN Could cause loss of control or cause vehicle to overturn HOW TO AVOID THE HAZARD Always check the terrain carefully before you start down any hill Never go down a hill at high speed Avoid going down a hill at an angle which would cause the vehicle to lean sharply to one side Go straight down the hill where possible A WARNING POTENTIAL HAZARD Improperly crossing hills or turning on hills WHAT CAN HAPPEN Could cause loss of control or cause vehicle to overturn HOW TO AVOID THE HAZARD Be very careful when turning on any hill Avoid crossing the side of a steep hill if possible When crossing the side of a hill Avoid hills with excessively slippery or loose surfaces 15 OPERATION WARNINGS 16 AWARNING POTENTIAL HAZARD Improperly operating over obstacles WHAT CAN HAPPEN Could cause loss of control or a collision Could cause vehicle to overturn HOW TO AVOID THE HAZARD Before operating in a new area check for obstacles Use extreme caution when riding over large obstacles such as large rocks or fallen trees AWARNING POTENTIAL HAZARD Skidding or slidi
79. t designed or intended to provide rollover protection in the event of vehicle overturning See Owner s Manual 7077478 Riders can be thrown off This can cause serious in jury or death Never carry riders in cargo box 7077681 TRAILER MAX WEIGHT 1500 LBS HITCH MAX VERTICAL WEIGHT 150 LBS 977682 A WARNING IMPROPER TIRE PRESSURE OR OVER LOADING CAN CAUSE LOSS OF CONTROL LOSS OF CONTROL CAN RESULT IN SEVERE INJURY OR DEATH TIRE PRESSURE PSI FRONT MIN 5 MAX 12 CENTER amp REAR MIN 5 MAX 10 MAXIMUM WEIGHT CAPACITY Gross Vehicle Weight INCLUDING MACHINE PASSENGER AND CARGO IS 2920 LBS SEE OWNER S MANUAL FOR PROPER TIRE INFLATION FOR DIFFERENT VEHICLE APPLICATIONS 7077475 SAFETY WARNING AND OPERATION DECALS HEADLAMPS ARE NOT SEALED DO NOT SUBMERGE OR APPLY WATER PRESSURE DIRECTLY ONTO SERVICE OPENING Recoil handle must be firmly seated to prevent water entry Drain starter motor if water enters See owner s manual 7075741 WARNING AVERTISSEMENT This vehicle is designed for operator and ONE passenger only Ce Vehicule est concu pour ne transporter que le conducteur et UN SEUL passager 7075439 THIS GENERAL PURPOSE OFF ROAD UTILITY VEHICLE DUES NOT MEET FEDERAL MOTOR VEHICLE SAFETY STANDARDS FOR ON ROAD VEHICLES NEVER USE ON FOR MAXIMUM SAFETY PROTECTION ALWAYS WEAR YOUR SAFETY BELT NEVER USE WITH PUBLIC ROADS 7077646 DRUGS OR ALCOHOL AWARNING
80. t in premature wear or pos sible failure of the engine com ponents Always use Polaris Recoil OW 40 oil Drain Engine Access Panel Removal and Installation Crankcase Drain Engine access panels are re moved by pulling handle out and then up no tools are required Install by firmly placing the bot tom pins in the grommets and pushing the top pins 1 into the grommets 2 35 CONTROL AND PARTS FUNCTIONS Engine Cooling System To insure that the coolant maintains its ability to protect the engine it is recom mended that the system be completely drained every two years and a fresh mixture of antifreeze and water be added Polaris recommends the use of Polaris Pre mium 60 40 anti freeze coolant or a 50 50 mixture of high quality aluminum com patible anti freeze coolant and distilled water NOTE Polaris Premium 60 40 is already premixed and ready to use Do not dilute with water IMPORTANT Al ways follow the manufacturer s mixing recommendations for the freeze protection required in your area Using a funnel slowly add coolant as necessary 36 CONTROL AND PARTS FUNCTIONS 4 Cycle Premium 4 Synthetic Lubricant Polaris Premium 4 All Season Synthetic engine oil has been specially formulated for use in Polaris 4 cycle engines It is a fully synthetic high performance multi vis cosity oil designed to provide the ultimate in lubrication performance and protec tion P
81. ter is engaged by holding ignition switch key in this position Upon release the key will return to the ON position A Do not operate the starter continuously for more than 5 seconds or the start er will overheat and the battery power will drop temporarily Wait at least 5 seconds between each operation of the starter to let it cool and the batter power recover Do not turn the ignition switch key to the START position with the engine run ning or damage to the starter can result Light Switch Lever Turn on headlights and taillights by flipping the light switch lever up with the ignition Switch key in the ON position The lights go off when the lever is pushed down 4WD AWD Rocker Switch This vehicle can be operated in either 4WD or AWD The 4WD AWD is operated by a rocker switch located on the console Flipping the lever up will engage the AWD 21 CONTROL PARTS AND FUNCTIONS Parking Brake Lever The parking brake lever is located at the right side of the driver s seat Pull the lever up and to the rear to apply the parking brake To release push in and hold the knob on the end of the lever and push the lever all the way down Spring pressure helps return the lever to the released position Auxiliary Lighting Electrical Accessory Terminals The auxiliary lighting electrical ac cessory 12 volt terminals 1 are lo cated under the instrument panel An auxiliary light or other optional light or an
82. the event of an accident have a qualified service dealer check the complete machine including but not limited to brakes throttle and steering for possible damage 19 VEHICLE IDENTIFICATION NUMBERS Important Record these numbers from your vehicle in the spaces provided 1 Frame VIN 2 Vehicle Model Number 3 Engine Serial Number Right front side of engine crankcase Remove the spare key and store in a safe place Record your ignition key num ber here It is a four digit number found stamped on the key In the event the key is lost replacement can be made by supplying your dealer with this number Ignition Key Number The vehicle frame and engine serial numbers are important for model identifica tion when registering your vehicle obtaining insurance or whenever replace ment parts are required In the event your vehicle were stolen these numbers are essential to the recovery and identification of your vehicle Dealer Imprint 20 CONTROL PARTS AND FUNCTIONS Fuel Gauge The fuel gauge on the instrument panel shows the amount of fuel in the fuel tank When the red indicator needle comes near the E empty mark refuel at the earliest opportunity Ignition Switch This is a three position key operated switch The key can be removed from the switch when it is in the OFF position Engine off All electrical circuits off except Acc 12V All electrical equipment can be used Electric star
83. tions 11 Front A Arm Pivot Shaft 12 Swing Arm Bushings 13 Upper Control Arms 14 Lower Control Arms 15 Center Wheel Hub Bearing Car rier 16 Tail Shaft Coupler 17 Center and rear angle drives Grease A Grease Grease A Grease A Grease A Grease A GL5 80 90 weight gear lube Locate fitting on pivot shaft and grease with grease gun Locate fittings on swing arm and grease with grease gun Locate fittings and grease Locate fittings and grease Locate fitting and grease Locate Fitting and grease Fill to bottom thread of filler hole Make certain machine is on a level surface More often under severe use such as wet or dusty conditions Polaris Premium all Season Grease or grease conforming to NLGI No 2 such as Conoco Superlube M or Mobilegrease Special Grease every 500 miles or after submerging in water or before long periods of storage or after pressure washing Always use Polaris Premium U Joint Lube for maximum service of these driveline components PN 2871515 3 oz PN 2871551 14 oz A When suspension action becomes stiff or after washing NOTE Hours are based on 10 mph average 64 Every 3 months or 50 hours Monthly or at 20 hours Semi annually Semi annually Semi annually Monthly or at 20 hours Monthly or at 20 hours MAINTENANCE Lubrication Recommendations 13 Upper Control Arm 65 MAINTENANCE AWARNING Vehicle oper
84. ts HALF position will allow proper engine warm up 2 Vary the engine RPM slightly with the throttle to aid in warm up until the engine idles smoothly Then move the choke to OFF CAUTION Proper engine warm up is essential each time before driving to avoid engine damage A WARNING Carbon monoxide exhaust gas is poisonous Always start the vehicle outdoors Never run the engine in an enclosed area 41 STARTING THE ENGINE Procedure for Starting a Warm Engine Warm engines do not normally require the use of the choke since the spark plug can easily become wet fouled 1 ar oN 42 Place the transmission in neutral and move the vehicle to a level surface Lock the parking brake Turn the fuel tank valve to ON Sit in the vehicle in the driver s seat Turn the ignition key to START HALF 24 7777 a OFF Choke Lever Side View If the engine has cooled to a point where it does not readily start intermittent use of the choke lever in its HALF position is permitted If the engine is over choked by mistake when warm depress the throttle lever fully while cranking to aid in starting Release the throttle lever immediately after the engine starts If the engine does not start and all conditions are favorable change the spark plug STARTING THE ENGINE Recoil Starter Recoil Starter If the battery is weak and cannot start the engine use of the recoil starter located on th
85. y HOW TO AVOID THE HAZARD Before you select reverse gear make sure there are no obstacles or people behind you When it is safe to proceed go slowly Always avoid backing down hill A WARNING POTENTIAL HAZARD Operating this vehicle with improper tires or with improper or uneven tire pressure WHAT CAN HAPPEN Use of improper tires on this vehicle or operation of this vehicle with improper or uneven tire pressure may cause loss of control and in creases the risk of an accident HOW TO AVOID THE HAZARD Always use the size and type tires specified in the Owner s Manual for this vehicle See page 91 Always maintain proper tire pressure as described in the Owner s Manual See page 2 OPERATION WARNINGS A WARNING POTENTIAL HAZARD Operating this vehicle with improper modifications WHAT CAN HAPPEN Improper installation of accessories or modification of this vehicle may cause changes in handling which in some situations could lead to an accident HOW TO AVOID THE HAZARD Never modify this vehicle through improper installation or use of accessories All parts and accessories added to this vehicle should be genuine Polaris In dustries Inc or equivalent components designed for use on this vehicle and should be installed and used according to instructions If you have questions consult an authorized Polaris dealer A WARNING POTENTIAL HAZARD Stalling rolling backwards while climb
86. y terrain When climbing hills always hav ing the cargo in the rear box securely fastened and located as far forward in the box as possible Loaded vehicles will experience reduced steering and front brake ef fectiveness when operating on hills TO REDUCE THE CHANCE OF VEHICLE TIP OVER AND PERSONAL INJURY always use D 1 Gear and reduced vehicle speeds when carrying heavy loads or towing a loaded trailer Correct loading of this vehicle is necessary to maintain proper stability and operat ing characteristics Overloading or incorrect positioning of the load effects the ve hicles turning stopping distance and stability Failure to follow loading require ments could cause severe injury or death REDUCE SPEED AND ALLOW GREATER DISTANCE FOR BRAKING WHEN CARRYING CARGO MAXIMUM CARGO CAPACITY IS 1000 LBS ON LEVEL TERRAIN When oper ating over rough or hilly terrain reduce speed and cargo to maintain stable driving conditions When operating at maximum cargo capacity the cargo weight must be evenly distributed in the rear box ALL LOADS MUST BE SECURED BEFORE MOVING VEHICLE Unsecured loads can create unstable operating conditions which could result in loss of control of the vehicle LOADS MUST BE CARRIED AS LOW IN THE BOX AS POSSIBLE Carrying loads high in the box raises the center of gravity of the vehicle and creates a less stable operating condition When cargo loads are carried high in the box the weight of the loads must be reduced to m

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