Polaris RANGER XP 900, 2013 RANGER XP 900 Owner's Manual

PMS 419

Owner's Manual

for Maintenance and Safety

RANGER XP® 900

WARNING

Read, understand, and follow all of the instructions and safety precautions in
this manual and on all product labels.

Failure to follow the safety precautions could result in serious injury or death.

WARNING

The engine exhaust from this product contains chemicals known to the State

of California to cause cancer, birth defects or other reproductive harm.

The text is printed on 100% recycled

with 40% post-consumer waste (PCW).

PMS 419

WARNING

Improper vehicle use can result in SEVERE INJURY or DEATH

NEVER Operate:

• At speeds too fast for your skills or the conditions.

• If you are under age 16 and without a valid driver’s license.

• After or while using Alcohol or Drugs.

• On hills steeper than 15 degrees.

• On public roads, a collision can occur with another vehicle.

• With more than two passengers, or passengers under age
twelve or who cannot comfortably reach the floor and hand holds.

ALWAYS:

• Secure cab nets and keep hands and feet inside vehicle at all times.

• Wear a helmet, eye protection, gloves, long-sleeve shirt, long pants and
over-the-anke boots.

• Wear your seat belt. Vehicle rollover can cause severe injury or death.

• Reduce speed and use extra caution when carrying passengers.

• Avoid sharp turns or turns while applying heavy throttle.

• Make sure passengers read and understand all safety labels.

• Operate slowly in reverse - avoid sharp turns or sudden braking.

READ OWNER’S MANUAL.

FOLLOW ALL INSTRUCTIONS AND WARNINGS.

• On paved surfaces - pavement may seriously affect handling and control.

• With non-Polaris approved accessories - they may seriously affect stability.

For your nearest Polaris dealer,
call 1-800-POLARIS
or visit www.polarisindustries.com
Polaris Sales Inc.
2100 Hwy. 55
Medina, MN 55340
Phone [phone]
Part No. 9924098 Rev 02
Printed in USA

1

WELCOME

Thank you for purchasing a POLARIS vehicle, and welcome to our world-wide family of
POLARIS enthusiasts. Be sure to visit us online at www.polarisindustries.com for the latest
news, new product introductions, upcoming events, career opportunities and more.

Here at POLARIS we proudly produce an exciting line of utility and recreational products.

• Snowmobiles

• All-terrain vehicles (ATVs)

• RANGER® utility vehicles

• Victory Motorcycles®

• Low Emission Vehicles (LEVs)
We believe POLARIS sets a standard of excellence for all utility and recreational vehicles

manufactured in the world today. Many years of experience have gone into the engineering,
design, and development of your POLARIS vehicle, making it the finest machine we’ve ever
produced.

For safe and enjoyable operation of your vehicle, be sure to follow the instructions and rec­ommendations in this owner’s manual. Your manual contains instructions for minor mainte­nance, but information about major repairs is outlined in the POLARIS Service Manual and
should be performed only by a Factory Certified Master Service Dealer® (MSD) Technician.

Your POLARIS dealer knows your vehicle best and is interested in your total satisfaction. Be
sure to return to your dealership for all of your service needs during, and after, the warranty
period.

2

POLARIS, RANGER and RANGER XP are registered trademarks of POLARIS Industries Inc.
Copyright 2012 POLARIS Sales Inc. All information contained within this publication is based on the latest

product information at the time of publication. Due to constant improvements in the design and quality of produc­tion components, some minor discrepancies may result between the actual vehicle and the information presented
in this publication. Depictions and/or procedures in this publication are intended for reference use only. No liabil­ity can be accepted for omissions or inaccuracies. Any reprinting or reuse of the depictions and/or procedures
contained within, whether whole or in part, is expressly prohibited.

The original instructions for this vehicle are in English. Other languages are provided as translations of the origi­nal instructions.

Printed in U.S.A.
2013 RANGER XP 900 Owner’s Manual
P/N 9924098

3

TABLE OF CONTENTS

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Features and Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Emission Control Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

POLARIS Products. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

Maintenance Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87

Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88

4

INTRODUCTION

Failure to follow the warnings contained in this manual can result in severe injury or death.
A POLARIS RANGER is not a toy and can be hazardous to operate. This vehicle handles differently

than other vehicles, such as motorcycles and cars. A collision or rollover can occur quickly, even during
routine maneuvers like turning, or driving on hills or over obstacles, if you fail to take proper
precautions.

• Read this owner’s manual. Understand all safety warnings, precautions and operating procedures
before operating the vehicle. Keep this manual with the vehicle.

• This vehicle is an ADULT VEHICLE ONLY. You MUST be at least age 16 and have a valid driver’s
license to operate this vehicle.

• No person under the age of 12 may ride as a passenger in this vehicle. Any passenger must be able
to comfortably reach the floor and hand holds.

• Never permit a guest to operate this vehicle unless the guest has read this manual and all product
labels.

• Always use the cab nets while riding in this vehicle.

• Always wear a helmet, eye protection, gloves, long-sleeve shirt, long pants and over-the-ankle
boots.

• Always keep hands and feet inside the vehicle at all times.

WARNING

5

INTRODUCTION

The RANGER is an off-road vehicle. Familiarize yourself with all laws and regulations con-
cerning the operation of this vehicle in your area.

The following signal words and symbols appear throughout this manual and on your vehicle.
Your safety is involved when these words and symbols are used. Become familiar with their
meanings before reading the manual.

The safety alert symbol indicates a potential personal injury hazard.

DANGER

A DANGER indicates a hazardous situation that, if not avoided, will result in death or serious injury.

WARNING

A WARNING indicates a hazardous situation that, if not avoided, could result in death or serious injury.

CAUTION

A CAUTION indicates a hazardous situation that, if not avoided, could result in minor or moderate
injury.

NOTICE

A NOTICE indicates a situation that could result in property damage.

The Prohibition Safety Sign indicates an action NOT to take in order to avoid a hazard.

The Mandatory Action Sign indicates an action that NEEDS to be taken to avoid a hazard.

6

INTRODUCTION

Vehicle Identification Numbers

Record your vehicle's identification numbers and key number in the spaces provided.
Remove the spare key and store it in a safe place. An ignition key can be duplicated only by
ordering a POLARIS key blank (using your key number) and mating it with one of your
existing keys. The ignition switch must be replaced if all keys are lost.

Vehicle Model Number: ________________________________________________________________________

Frame VIN: _________________________________________________________________________________

Engine Serial Number: ________________________________________________________________________

Key Number: ________________________________________________________________________________

Engine Serial Number

Key Number

VIN

####

7

INTRODUCTION

European Vibration and Noise

The driver-perceived noise and hand/arm and whole body vibration levels of this machinery
is measured per prEN 15997.

The operating conditions of the machinery during testing:

The vehicles were in like-new condition. The environment was controlled as indicated by the
test procedure(s).

The uncertainty of vibration exposure measurement is dependent on many factors, including:

• Instrument and calibration uncertainty

• Variations in the machine such as wear of components

• Variation of machine operators such as experience or physique

• Ability of the worker to reproduce typical work during measurements

• Environmental factors such as ambient noise or temperature

8

SAFETY

Safety Labels and Locations

Warning labels have been placed on the vehicle for your protection. Read and follow the
instructions of the labels on the vehicle carefully. If any of the labels depicted in this manual
differ from the labels on your vehicle, always read and follow the instructions of the labels
on the vehicle.

If any label becomes illegible or comes off, contact your POLARIS dealer to purchase a
replacement. Replacement safety labels are provided by POLARIS at no charge. The part
number is printed on the label.

Clutch Cover Warning

WARNING
Improper service or maintenance of this PVT system can result in vehicle damage, SEVERE INJURY

or DEATH.
Always look for and remove debris inside and around clutch and vent system when replacing belt.
Read owner’s manual or see authorized POLARIS dealer.

7177469

Age 16 Warning

Operating this vehicle if you are under the age of 16 increases your chance of severe injury or death.
NEVER operate this vehicle if you are under age 16 and NEVER operate this vehicle without a valid

driver’s license.

7175566

Discretionary

Warning

Age 16

Warning

Shift

Caution

Clutch Cover

Warning

9

SAFETY

Safety Labels and Locations

Shift Caution

CAUTION
To avoid transmission damage, shift only when vehicle is stationary and at idle. When vehicle is

stopped, place shift in parked position.

• APPLY BRAKE TO START

• If total payload is greater than 500 lbs. the vehicle must be operated in LOW range.

7178545

Discretionary Warning

WARNING
Improper vehicle use can result in Severe Injury or Death.

NEVER Operate:

• At speeds too fast for your skills or the conditions.

• After or while using Alcohol or Drugs.

• On hills steeper than 15 degrees 15°.

• On public roads, a collision can occur with a another vehicle.

• With more than two passengers (five for CREW), or passengers under the age of twelve or who

cannot comfortably reach the floor and hand holds.

• On paved surfaces - pavement may seriously affect handling and control.

• With non-POLARIS approved accessories - they may seriously affect stability.

ALWAYS:

• Wear your seat belt. Vehicle rollover could cause severe injury or death.

• Secure cab nets and keep hands and feet in vehicle at all times.

• Wear a helmet and eye protection.

• Reduce speed and use extra caution when carrying passengers.

• Avoid sharp turns or turns while applying heavy throttle.

• Operate slowly in reverse - avoid sharp turns or sudden braking.

• Make sure passengers read and understand all safety labels.
LOCATE AND READ OWNER’S MANUAL. FOLLOW ALL INSTRUCTIONS AND WARNINGS.

7178544

10

SAFETY

Safety Labels and Locations

Load/Passenger/Tire Pressure Warning

Storage Box Load 250 lbs. (113 kg)

WARNING

• Passengers can be thrown off. This can cause serious
injury or death.

• Never carry passengers in cargo box.

IMPROPER TIRE PRESSURE OR OVERLOADING
CAN CAUSE LOSS OF CONTROL RESULTING IN
SERIOUS INJURY OR DEATH.

• Reduce speed and allow greater distance for braking
when carrying cargo.

• Overloading or carrying tall, off-center, or unsecured
loads will increase your risk of losing control. Loads
should be centered and carried as low as possible in
box.

• For stability on rough or hilly terrain, reduce speed and cargo.

• Be careful if load extends over the side of the box.

7178618

RANGER 4 x 4

MAXIMUM CARGO BOX LOAD 1000 lbs.

(454 kg)

TIRE PRESSURE IN PSI (KPa) FRONT 10 (69)

REAR 12 (83)

MAXIMUM WEIGHT CAPACITY

INCLUDES WEIGHT OF OPERATOR, PASSENGER, CARGO
AND ACCESSORIES

1500 lbs.

(682 kg)

Read Operation and Maintenance Manual for more detailed loading information.

11

SAFETY

Safe Riding Gear

Always wear appropriate clothing when
riding a POLARIS vehicle. Wear
protective clothing for comfort and to
reduce the chance of injury.

Helmet

Wearing a helmet can prevent a severe
head injury. Whenever riding this
POLARIS vehicle, always wear a helmet
that meets or exceeds established safety
standards.

Approved helmets in the USA and
Canada bear a U.S. Department of
Transportation (DOT) label.

Approved helmets in Europe, Asia and Oceania bear the ECE 22.05
label. The ECE mark consists of a circle surrounding the letter E,
followed by the distinguishing number of the country which has granted
approval. The approval number and serial number will also be displayed
on the label.

Eye Protection

Do not depend on eyeglasses or sunglasses for eye protection. Whenever riding a POLARIS
vehicle, always wear shatterproof goggles or use a shatterproof helmet face shield.
POLARIS recommends wearing approved Personal Protective Equipment (PPE) bearing
markings such as VESC 8, V-8, Z87.1, or CE. Make sure protective eye wear is kept clean.

Gloves

Wear gloves for comfort and for protection from sun, cold weather and other elements.

Boots

Wear sturdy over-the-ankle boots. Do not ride a POLARIS vehicle with bare feet.

Clothing

Wear long sleeves and long pants to protect arms and legs.

Helmet

Eye

Protection

Gloves

Over-the-Ankle Boots

Long

Pants

Long

Sleeves

E

4

051039

0006.31

12

SAFETY

Operator Safety

Serious injury or death can result if you do not follow these instructions and procedures, which are
outlined in further detail within your owner's manual.

• Read this manual and all labels carefully. Follow the operating procedures described.

• Never allow anyone under age 16 to operate this vehicle and never allow anyone without a
valid driver's license to operate this vehicle.

• Do not carry a passenger until you have at least two hours of driving experience with this
vehicle.

• No person under the age of 12 may ride as a passenger in this vehicle. Any passenger must
be able to comfortably reach the floor and hand holds.

• The driver and all passengers must wear helmet, eye protection, gloves, long-sleeve shirt,
long pants, over-the-ankle boots and seat belt at all times.

• Always use the cab nets while riding in this vehicle.

• Always keep hands and feet inside the vehicle at all times.

• Always keep both hands on the steering wheel and both feet on the floorboards of the
vehicle during operation.

• Never permit a guest to operate this vehicle unless the guest has read this manual and all
product labels.

• To reduce tipover risk, be especially careful when encountering obstacles and slopes and
when braking on hills or during turns.

• This vehicle is for off road use only. Never operate on public roads. Always avoid paved
surfaces.

• Never consume alcohol or drugs before or while operating this vehicle.

• Never operate at excessive speeds. Always travel at a speed proper for the terrain, visibil­ity and operating conditions, and your experience.

• Never attempt jumps or other stunts.

• Always inspect the vehicle before each use to make sure it's in safe operating condition.
Always follow the inspection procedures described in this manual.

• Always travel slowly and use extra caution when operating on unfamiliar terrain. Be alert
to changing terrain.

• Never operate on excessively rough, slippery or loose terrain.

• Always follow proper procedures for turning. Practice turning at slow speeds before
attempting to turn at faster speeds. Never turn at excessive speeds.

• Always have this vehicle checked by an authorized POLARIS dealer if it has been
involved in an accident.

• Never operate this vehicle on hills too steep for the vehicle or for your abilities. Practice
on smaller hills before attempting larger hills.

WARNING

13

SAFETY

Operator Safety

• Always follow proper procedures for climbing hills as described in this manual. Check the

terrain carefully before attempting to climb a hill. Never climb hills with excessively slip­pery or loose surfaces. Never apply throttle suddenly. Never make sudden gear changes.
Never go over the top of a hill at high speed.

• Always follow the proper procedures outlined in this manual for traveling downhill and

for braking on hills. Check the terrain carefully before descending a hill. Never travel
downhill at high speed. Avoid going downhill at an angle, which would cause the vehicle
to lean sharply to one side. Travel straight down the hill where possible.

• Always check for obstacles before operating in a new area. Never attempt to operate over

large obstacles such as rocks or fallen trees. Always follow the proper procedures outlined
in this manual when operating over obstacles.

• Always be careful of skidding or sliding. On slippery surfaces such as ice, travel slowly

and exercise caution to reduce the chance of skidding or sliding out of control.

• Never operate your vehicle in fast-flowing water or in water deeper than that specified in

this manual. Wet brakes may have reduced stopping ability. Test your brakes after leaving
water. If necessary, apply them lightly several times to let friction dry out the pads.

• Always be sure there are no obstacles or people behind your vehicle when operating in

reverse. When it's safe to proceed in reverse, move slowly. Avoid turning at sharp angles
in reverse.

• Always use the proper size and type of tires specified in this manual. Always maintain

proper tire pressure as specified on safety labels.

• Never modify this vehicle through improper installation or use of accessories.

• Never exceed the stated load capacity for this vehicle. Cargo should be properly distrib-

uted and securely attached. Reduce speed and follow the instructions in this manual for
hauling cargo or pulling a trailer. Allow a greater distance for braking.

• Always place the transmission in PARK before getting out of the vehicle.

• Always stop the engine before refueling. Remove flammable material containers from the

box before filling them with fuel. Make sure the refueling area is well ventilated and free
of any source of flame or sparks. Gasoline is extremely flammable. See page 14 for fuel
safety warnings.

• Always remove the ignition key when the vehicle is not in use to prevent unauthorized use

or accidental starting.

FOR MORE INFORMATION ABOUT SAFETY, call

POLARIS at 1-800-342-3764.

14

SAFETY

Operator Safety

Equipment Modifications

We strongly recommend that consumers do not install on a POLARIS RANGER any equip­ment that may increase the speed or power of the vehicle, or make any other modifications to
the vehicle for these purposes. Any modifications to the original equipment of the vehicle
create a substantial safety hazard and increase the risk of bodily injury.

The warranty on your POLARIS RANGER is terminated if any equipment has been added to
the vehicle, or if any modifications have been made to the vehicle, that increase its speed or
power.

The addition of certain accessories, including (but not limited to) mowers, blades, tires,
sprayers, or large racks, may change the handling characteristics of the vehicle. Use only
POLARIS-approved accessories, and familiarize yourself with their function and effect on
the vehicle.

Handling Gasoline

Gasoline is highly flammable and explosive under certain conditions.

• Always exercise extreme caution whenever handling gasoline.

• Always stop the engine when refueling.

• Always refuel outdoors or in a well ventilated area.

• Remove flammable material containers from the box before filling them with fuel.

• Do not smoke or allow open flames or sparks in or near the area where refueling is performed or
where gasoline is stored.

• Do not overfill the tank. Do not fill the tank neck.

• If gasoline spills on your skin or clothing, immediately wash it off with soap and water and change
clothing.

Hot Exhaust Systems

Exhaust system components are very hot during and after use of the vehicle. Hot components can
cause burns and fire. Do not touch hot exhaust system components. Always keep combustible
materials away from the exhaust system. Use caution when traveling through tall grass, especially dry
grass.

15

SAFETY

Operator Safety

Failure to operate the RANGER properly can result in a collision, loss of control, accident or overturn,
which may result in serious injury or death. Heed all safety warnings outlined in this section of the
owner’s manual. See the OPERATION section of the owner’s manual for proper operating procedures.

Age Restrictions

This vehicle is an ADULT VEHICLE ONLY. NEVER operate this vehicle if
you are under age 16 and NEVER operate without a valid driver’s license.

No person under the age of 12 may ride as a passenger in this vehicle. Any
passenger must be able to comfortably reach the floor and hand holds.

Operating Without Instruction

Operating this vehicle without proper instruction increases the risk of an
accident. The operator must understand how to operate the vehicle properly
in different situations and on different types of terrain.

All operators must read and understand the Owner's Manual and all
warning and instruction labels before operating the vehicle.

Using Alcohol or Drugs

Operating the vehicle after consuming alcohol or drugs could adversely
affect operator judgment, reaction time, balance and perception.

Never drink alcohol or use drugs or medications before or while operating
this vehicle.

Seat Belts

Riding in this vehicle without wearing the seat belt increases the risk of
serious injury in the event of an accident or sudden stop. Riders must wear
seat belts at all times. Seat belts reduce the severity of injury in the event of
a sudden stop or accident. Always make sure the seat belts are secured for both the operator and
passenger before riding.

Protective Apparel

Riding in this vehicle without wearing an approved helmet and protective eyewear increases the risk of
a serious injuries in the event of an accident.

Operator and all passengers must always wear an approved helmet that fits properly and eye
protection (goggles or face shield).

Cab Nets

Riding in this vehicle without using the cab nets increases the risk of serious injury or death in the event
of an accident or overturn. Always use the cab nets while riding in this vehicle. Always keep hands and

feet inside the vehicle at all times.

Failure to Inspect Before Operating

Failure to inspect and verify that the vehicle is in safe operating condition before operating increases
the risk of an accident. Always inspect your RANGER before each use to make sure it's in safe
operating condition. Always follow all inspection and maintenance procedures and schedules
described in the owner's manual.

WARNING

16

SAFETY

Operator Safety

Operating With a Load on the Vehicle

The weight of both cargo and passengers impacts vehicle operation. For your safety and the safety of
others, carefully consider how your vehicle is loaded and how to safely operate the vehicle. Follow the
instructions in this manual for loading, tire pressure, gear selection and speed.

• Do not exceed vehicle weight capacities. The vehicle’s maximum weight capacity is listed in the

specifications section of this manual and on a label on the vehicle. When more passenger weight is
added, cargo weight may need to be reduced accordingly.

• The recommended tire pressures are listed in the specifications section of this manual and on a label

on the vehicle.

Always follow these guidelines:

Exposure to Exhaust

Engine exhaust fumes are poisonous and can cause loss of consciousness or death in a short time.
Never start the engine or let it run in an enclosed area.

The engine exhaust from this product contains chemicals known to cause cancer, birth defects or other
reproductive harm. Operate this vehicle only outdoors or in well-ventilated areas.

Operating a Damaged Vehicle

Operating a damaged vehicle can result in an accident. After any overturn or accident, have a qualified
service dealer inspect the entire machine for possible damage, including (but not limited to) brakes,
throttle and steering systems.

Operating at Excessive Speeds

Operating this vehicle at excessive speeds increases the operator's risk of losing control. Always
operate at a speed that's appropriate for the terrain, the visibility and operating conditions, your skills
and your passenger’s skills.

Operating on Pavement

This vehicle's tires are designed for off-road use only, not for use on pavement. Operating this vehicle
on paved surfaces (including sidewalks, paths, parking lots and driveways) may adversely affect the
handling of the vehicle and could result in loss of control and accident or overturn. Avoid operating the
vehicle on pavement. If it's unavoidable, travel slowly and avoid sudden turns or stops.

Operating on Public Roads

Operating this vehicle on public streets, roads or highways could result in a collision with another
vehicle. Never operate this vehicle on any public street, road or highway, including dirt and gravel
roads. In some areas it's unlawful to operate this vehicle on public streets, roads and highways.

Under ANY of these conditions: Do ALL of these steps:

Passenger and/or cargo exceeds half the maximum weight capacity 1. Slow down.

2. Verify tire pressure.

3. Use extra caution when
operating.

Operating in rough terrain

Operating over obstacles

Climbing an incline

Towing

17

SAFETY

Operator Safety

Turning Improperly

Turning improperly could cause loss of traction, loss of control, accident or overturn. Always follow
proper procedures for turning. Never turn abruptly or at sharp angles. Never turn at high speeds.
Practice turning at slow speeds before attempting to turn at faster speeds.

Operating in Unfamiliar Terrain

Failure to use extra caution when operating on unfamiliar terrain could result in an accident or overturn.
Unfamiliar terrain may contain hidden rocks, bumps, or holes that could cause loss of control or
overturn. Travel slowly and use extra caution when operating on unfamiliar terrain. Always be alert to
changing terrain conditions.

Jumps and Stunts

Attempting wheelies, jumps and other stunts increases the risk of an accident or overturn. Never
attempt wheelies, jumps, or other stunts. Avoid exhibition driving.

Operating on Slippery Terrain

Failure to use extra caution when operating on excessively rough, slippery or loose terrain could cause
loss of traction, loss of control, accident or overturn. Do not operate on excessively slippery surfaces.
Always reduce speed and use additional caution when operating on slippery surfaces.

Improper Hill Climbing

Climbing hills improperly can cause loss of control or vehicle overturn. Always follow proper procedures
for climbing hills as described in the owner's manual. See page 37.

Stalling While Climbing a Hill

Stalling or rolling backwards while climbing a hill could cause an overturn. Always maintain a steady
speed when climbing a hill.

If all forward speed is lost:

• Apply the brakes.

• Place the transmission in reverse and slowly allow the vehicle to roll straight downhill while applying
light brake pressure to control speed.

If you begin rolling downhill:

• Never apply engine power.

• Apply the brakes gradually until the vehicle is fully stopped.

• Place the transmission in reverse and slowly allow the vehicle to roll straight downhill while applying
light brake pressure to control speed.

Improper Tire Maintenance

Operating this vehicle with improper tires or with improper or uneven tire pressure could cause loss of
control or accident. Always use the size and type of tires specified for your vehicle. Always maintain
proper tire pressure as described in the owner's manual and on safety labels.

Operating on Frozen Bodies of Water

Severe injury or death can result if the vehicle and/or the operator fall through the ice. Never operate
the vehicle on a frozen body of water unless you have first verified that the ice is sufficiently thick to
support the weight and moving force of the vehicle, you and your passengers, and your cargo, together
with any other vehicles in your party. Always check with local authorities and residents to confirm ice
conditions and thickness over your entire route. Vehicle operators assume all risk associated with ice
conditions on frozen bodies of water.

Unauthorized Use of the Vehicle

Leaving the keys in the ignition can lead to unauthorized use of the vehicle, which could result in an
accident or overturn. Always remove the ignition key when the vehicle is not in use.

18

FEATURES AND CONTROLS

Component Locations

Your vehicle is equipped with cab nets on both sides of the vehicle. Cab nets must be used by
both operator and passengers at all times. Any illustrations without cab nets are only to allow
component identification. Always use the cab nets.

Not all models come with all features. Refer to the specifications section on page 76.

Headlights

Front Bumper/Brush Guard

Radiator

ROPS Cab

Frame

Console

Cargo Box

Fuel Tank Cap

Cab Net

Receiver

Hitch

CV Boot/Rear

Caliper

Muffler (Spark Arrester)

Tailgate

Intake Screens (both sides)

19

FEATURES AND CONTROLS

Console

Auxiliary Outlets

The 12-volt receptacles have spade connections on the back that may be used to power an
auxiliary light or other optional accessories or lights. The connections are behind the con­sole, under the dash.

Gear Selector

H: High Gear
L: Low Gear
N: Neutral
R: Reverse
P: Park

Low gear is the primary driving range for the RANGER. High gear is intended for use on
hard-packed surfaces with light loads.

To shift gears, brake to a complete stop. When the engine is idling, move the lever to the
desired gear.

NOTICE: Shifting gears with the engine speed above idle or while the vehicle is moving could cause

transmission damage. Always shift when the vehicle is stationary and the engine is at idle.

Tip: Maintaining shift linkage adjustment is important to assure proper transmission function. See your

dealer if you experience any shifting problems.

Using Low Range

Always shift into low gear for any of the following conditions.

• Operating in rough terrain or over obstacles

• Loading the vehicle onto a trailer

• Towing heavy loads

Cup Holder

12V Auxiliary

Outlets

Storage

Tray

Instrument

Cluster

Gear Selector

(Shifter)

Storage

Compartment

20

FEATURES AND CONTROLS

Switches

Ignition Switch

The ignition switch is a three-position, key-operated
switch. The key can be removed from the switch
when it is in the OFF position.

Mode Button

The MODE button is located on the instrument cluster.
Use the MODE button to toggle through mode options
available in the instrument cluster. See pages 26-30.

Light Switch

The ignition switch key must be in the ON/RUN position
to operate the headlights. Press the top of the rocker
switch toward the dash to place the headlights on high
beam. Move the rocker switch to the center position to
place the headlights on low beam. Press the bottom of
the rocker switch to turn off the headlights.

AWD/Differential Lock Switch

The AWD/Differential Switch has three positions:

• All Wheel Drive (AWD)

• Differential Lock (2WD)

• Differential Unlock
Press the top of the rocker switch to engage All Wheel

Drive (AWD). See page 44 for operating instructions.
Move the rocker switch to the center position to lock the

differential and operate in rear wheel drive. Press the bot­tom of the switch to unlock the differential and allow the
two rear drive wheels to operate independently. See page
45 for differential lock operating instructions.

OFF The engine is off. Electrical circuits are off,

except Acc, 12V.

ON Electrical circuits are on. Electrical equip-

ment can be used.

START Turn the key to the START position to

engage the electric starter. The key returns to
the ON position when released.

Ignition Switch

Mode

Button

HIGH

OFF

LOW

AWD

Differential Lock

Differential Unlock

21

FEATURES AND CONTROLS

Trailer Hitch Bracket

This vehicle is equipped with a receiver hitch bracket for a trailer hitch. To avoid injury and
property damage, always heed the warnings and towing capacities outlined on pages 41-42.

Brake Pedal

Depress the brake pedal to slow or stop the vehicle. Apply
the brakes while starting the engine.

Throttle Pedal

Push the throttle pedal down to increase engine speed. Spring
pressure returns the pedal to the rest position when released.
Always check that the throttle pedal returns normally before
starting the engine.

Tip: If the throttle pedal and brake pedal are applied simultaneously,

engine power may be limited.

Adjustable Steering Wheel

The steering wheel can be tilted upward or downward
for rider preference.

Lift and hold the adjustment lever toward you while
moving the steering wheel upward or downward.
Release the lever when the steering wheel is at the
desired position.

Electronic Power Steering (EPS)

Electronic power steering (if equipped) engages when
the ignition key is turned to the ON position. EPS
remains engaged whether the vehicle is moving or idle.

To conserve battery power, the EPS will shut down 5
minutes after the engine is stopped if the key remains in the ON position. The EPS warning
indicator will illuminate to indicate the EPS has shut down. Turn the key off and on to reset
the unit.

See page 26 for EPS warning indicator information.

Throttle

Pedal

Brake
Pedal

Adjuster

22

FEATURES AND CONTROLS

Seat and Storage Compartments

The battery, fuses and storage compartments are located under the seats.
Pull the rear edge of a seat upward to release the latch pins from the grommets. Roll the seat

forward to access the under-seat area.
The fuses are located under the center portion of the seat. Never use this area for storage.
Storage compartments are located under both driver and passenger seats. Remove the storage

bin under the passenger seat to access the battery.
To completely remove a seat, roll the seat forward and lift the seat tabs from the seat base

mounts.
Always make sure all seats are properly installed and securely latched before operating. Push

down firmly on the rear of each seat until the latch pins are fully seated into the grommets.

Storage Compartment

(Under Driver’s Seat)

Battery

(Under Storage Bin)

Electrical/Fuse Compartment

(Not For Storage)

23

FEATURES AND CONTROLS

Fuel Cap

The fuel tank filler cap is located on the left side
of the vehicle near the driver’s seat. Use only
unleaded gasoline with a minimum pump octane
number of 87 R+M/2 octane. Unleaded fuel
blends with up to 10% ethanol can be used.

NOTICE: Never use fuel blends with more than 10%

ethanol. Engine damage could occur.

Hood Latches

Remove the hood to access the coolant
overflow bottle, the radiator cap and the
headlight adjustment screws.

To remove the hood, rotate the hood
latches 1/4-turn and lift the hood away
from the vehicle.

Latches

24

FEATURES AND CONTROLS

Rollover Protective Structure (ROPS)

The Rollover Protective Structure (ROPS) on this
vehicle meets OSHA 1928.53 rollover performance
requirements. Always have your authorized
POLARIS dealer thoroughly inspect the ROPS if it
ever becomes damaged in any way.

No device can assure occupant protection in the
event of a rollover. Always follow all safe operating

practices outlined in this manual to avoid vehicle
rollover.

WARNING! Vehicle rollover could cause severe injury or
death. Always avoid operating in a manner that could
result in vehicle rollover.

Cab Nets

Riding in this vehicle without using the cab nets increases the risk of serious injury or death
in the event of an accident or overturn. Cab nets must be used by both operator and passen­gers at all times. Make sure all latches are secure before operating the vehicle.

Always inspect cab nets for tightness, wear and damage before each use of the vehicle. Use
the strap adjusters to tighten any loose straps. Promptly replace worn or damaged cab nets
with new cab nets, available from your authorized Polaris dealer.

Securing a Net

1. After entering the vehicle, insert the lower net rod
into the net mount on the floor. Make sure the ball
at the end of the rod is properly secured in the
mount.

2. Connect the latch at the top edge of the net to the

receiver latch mounted on the front frame.

Opening a Net

1. To exit the vehicle, release the latch at the top front
edge of the cab net.

2. Rotate the net rearward and pull upward on the

lower net rod to remove it from the mount.

3. Allow the net to hang freely outside the vehicle

while dismounting.

ROPS

Latch

Rod

Net Mount

Ball

25

FEATURES AND CONTROLS

Seat Belts

This POLARIS vehicle is equipped with three-point lap and diagonal seat belts on all exter­nal seats.The center seat is equipped with a lap-style seat belt. Always make sure the seat
belts are secured for all riders before operating.

WARNING! Falling from a moving vehicle could result in serious injury or death. Always fasten your
seat belt securely before operating or riding in the RANGER.

To wear the seat belt properly, follow this proce­dure:

1. For 3-point belts, pull the seat belt latch down­ward and across your chest toward the buckle
at the inner edge of the seat. The belt should fit
snugly across your hips and diagonally across
your chest. Make sure the belt is not twisted.
For lap style belts, place the belt across your
lap as low on your hips as possible. Make sure
that the belt is not twisted.

2. Push the latch plate into the buckle until it

clicks.

3. Release the strap, it will self-tighten.

Tip: The center belt must be tightened manually by pull-

ing on the strap.

4. To release the seat belt, press the square red

button in the buckle's center.

Seat Belt Inspection

Inspect all seat belts for proper operation before each use of the vehicle.

1. Push the latch plate into the buckle until it clicks. The latch plate must slide smoothly
into the buckle. A click indicates that it's securely latched.

2. Push the red release latch in the middle of the buckle to make sure it releases freely.

3. Pull each seat belt completely out and inspect the full length for any damage, including

cuts, wear, fraying or stiffness. If any damage is found, or if the seat belt does not oper­ate properly, have the seat belt system checked and/or replaced by an authorized
POLARIS dealer.

4. To clean dirt or debris from the seat belts, sponge the straps with mild soap and water.

Do not use bleach, dye or household detergents.

Buckle

Latch Plate

26

FEATURES AND CONTROLS

Instrument Cluster

High water pressure may
damage components. Wash the
vehicle by hand or with a
garden hose using mild soap.
Do not use alcohol to clean the
instrument cluster. Do not
allow insect sprays to contact
the lens.

Speedometer

The speedometer displays
vehicle speed in either miles
per hour (MPH) or kilometers
per hour (km/h). See page 28.

Indicator Lamps

Lamp Indicates Condition

Vehicle Speed

When standard mode is selected, speed displays in miles per hour.

When metric mode is selected, speed displays in kilometers per hour.

Over Temperature This lamp illuminates to indicate an overheated engine. If the

indicator flashes, the overheating condition remains, and the system
will automatically reduce engine power.

EPS Warning (if
equipped)

This indicator illuminates briefly when the key is turned to the ON
position. If the light remains on, the EPS system is inoperative. See
your authorized POLARIS dealer for service.

Neutral This lamp illuminates when the transmission is in neutral and the

ignition key is in the ON position.

High Beam This lamp illuminates when the headlamp switch is set to high beam.

Helmet/Seat Belt This lamp flashes for several seconds when the key is turned to the

ON position. The lamp is a reminder to the operator to ensure all
riders are wearing helmets and seat belts before operating.

Check Engine This indicator appears if an EFI-related fault occurs. Do not operate

the vehicle if this warning appears. Serious engine damage could
result. See your dealer.

Rider

Information

Center

Speedometer

Indicator

Lamps

MODE
Button

27

FEATURES AND CONTROLS

Instrument Cluster

Rider Information Center

The rider information center is
located in the instrument cluster. All
segments will light up for one sec­ond at start-up. If the instrument
cluster fails to illuminate, a battery
over-voltage may have occurred
and the instrument cluster may have
shut off to protect the electronic
speedometer. If this occurs, take the
vehicle to your POLARIS dealer for
proper diagnosis.

The information center is set to dis­play standard units of measurement
and a 12-hour clock at the factory.
To change to metric and/or a 24­hour clock, see page 28.

1. Gear Indicator - This indicator displays gear shifter position.
H = High Gear
L = Low Gear
N = Neutral
R = Reverse Gear
P = Park

-- = Gear Signal Error (or shifter between gears)

2. Fuel Gauge - The segments of the fuel gauge show the level of fuel in the fuel tank.

When the last segment clears, a low fuel warning is activated. All segments including
the fuel icon will flash. Refuel immediately.

Tip: If the fuel icon fails to display, an open or short circuit has occurred in the fuel sensor circuit. See

your dealer.

3. Information Display Area - This area displays odometer, trip meter, tachometer, engine

temperature meter, engine hour meter and programmable service hour interval.

4. Under / Over Voltage - This warning usually indicates that the vehicle is operating at an

RPM too low to keep the battery charged. It may also occur when the engine is at idle
and high electrical load (lights, cooling fan, accessories) is applied. Drive at a higher
RPM or recharge the battery to clear the warning.

5. Clock - The clock displays time in a 12-hour or 24-hour format. See page 28 for reset-

ting instructions.

6. Service Indicator - A flashing wrench symbol alerts the operator that the preset service

interval has been reached. The vehicle should be brought to your dealer for scheduled
maintenance. See page 28 for resetting instructions.

7. 4X4 Indicator - This indicator illuminates when the 4X4 system is engaged (switch is

on 4X4).

8. Turf Mode Indicator - This indicator illuminates when the operator unlocks the differ-

ential. See page 45.

Trip 1

km

mi

RPM

FE

88

:

88

1

2

65

4

7

3

8

28

FEATURES AND CONTROLS

Instrument Cluster

Rider Information Center

Use the MODE button to toggle through the information area options.

Display Units (Standard/Metric)

The display can be changed to display either standard or metric units of measurement.

Tip: To exit the set-up mode at any time, wait 10 seconds.The display automatically exits and returns to

the odometer display.

1. Turn the key to the OFF position.

2. Press and hold the MODE button while turning the key to the ON position.

3. When the display flashes the distance setting, tap the MODE button to advance to the
desired setting.

4. Press and hold the MODE button to save the setting and advance to the next display
option.

5. Repeat the procedure to change remaining display settings.

Clock Mode

Tip: The clock must be reset any time the battery has been disconnected or discharged.

1. Turn the key to the ON position. Use the MODE button to toggle to the odometer dis-

play.

2. Press and hold the MODE button until the hour segment flashes. Release the button.

3. With the segment flashing, tap the MODE button to advance to the desired setting.

4. Press and hold the MODE button until the next segment flashes. Release the button.

5. Repeat steps 3-4 twice to set the 10-minute and 1-minute segments. After completing the

1-minute segment, step 4 will save the new settings and exit the clock mode.

6. Turn the key to the OFF position.

Standard Display Metric Display
Distance Miles Kilometers
Fuel U.S. Gallons Liters, Imperial Gallons
Tempera tur e Fahrenheit Celsius
Time 12-Hour Clock 24-Hour Clock

29

FEATURES AND CONTROLS

Instrument Cluster

Rider Information Center

Odometer Mode

The odometer records and displays the distance traveled by the vehicle.

Trip Meter Mode

The trip meter records the distance traveled by the vehicle if reset before each trip. To reset,
select the trip meter mode. Press and hold the MODE button until the meter resets to zero. In
the Rider Information Center, the trip meter display contains a decimal point, but the odome­ter displays without a decimal point.

Tachometer Mode

The engine RPM is displayed digitally.

Tip: Small fluctuations in the RPM from day to day may be normal because of changes in humidity,

temperature and elevation.

Engine Temperature Mode

This mode displays current temperature of the engine coolant.

Hour Meter Mode

This mode logs the total hours the engine has been in operation.

Programmable Service Interval

When the hours of engine operation equal the programmed service interval setting, the
wrench icon will flash for 5 seconds each time the engine is started. When this feature is
enabled, it provides a convenient reminder to perform routine maintenance. The service
interval is programmed at 50 hours at the factory. Use the following procedure to change the
service interval.

1. Press the MODE button until remaining service hours display.

2. Press and hold the MODE button.

3. When the service hours flash, press and release the MODE button to advance the hours
to the desired setting (including OFF). Press and hold the MODE button to set the new
service hour interval.

Diagnostic Display Mode

The EFI diagnostic display mode is for informational purposes only. Please see your
POLARIS dealer for all major repairs.

The diagnostic mode is accessible only when the check engine warning indicator activates
after the key has been turned on. Leave the key on if you want to view the active code (fail­ure code).

The diagnostic mode becomes inaccessible if the key is turned off and on and the warning
indicator is no longer active. This allows the determination of persistent as well as intermit­tent faults.

Inactive codes are stored in the history of the unit.

30

FEATURES AND CONTROLS

Instrument Cluster

Rider Information Center

Engine Error Codes

The error screen displays only when the
CHECK ENGINE light is on or when it goes
on and off during one ignition cycle. Error
codes are not stored. When the key is turned
OFF, the code and message is lost, but will
reappear if the fault reoccurs after restarting the
engine.

If the CHECK ENGINE light illuminates,
retrieve the error codes from the display.

1. If the error codes are not displayed, use the
MODE button to toggle until “Ck ENG”
displays on the main line of the display.

2. Press and hold the MODE button to enter
the diagnostics code menu.

3. Record the three numbers displayed in the gear position, clock and odometer displays.

4. Press the MODE button to advance to the next error code.

5. Press and hold the MODE button to exit the diagnostics code menu.

6. See an authorized POLARIS dealer for code details and diagnosis.

Suspect Parameter

Number (SPN)

Error Code

Number (0-9)

Failure Mode Indicator (FMI)

31

OPERATION

Failure to operate the vehicle properly can result in a collision, loss of control, accident or overturn,
which may result in serious injury or death. Read and understand all warnings outlined in the safety
section of this manual.

Break-In Period

The break-in period for your new RANGER is the first 25 hours of operation, or the time it
takes to use the first two tanks full of fuel. No single action on your part is as important as a
proper break-in period. Careful treatment of a new engine will result in more efficient perfor­mance and longer life for the engine. Perform the following procedures carefully.

NOTICE: Excessive heat build-up during the first three hours of operation will damage close-fitted

engine parts. Do not operate at full throttle or high speeds for extended periods during the
first three hours of use.

Engine and Drivetrain Break-in

1. Fill the fuel tank with clean, fresh fuel. Review the fuel warnings on page 14.

2. Check the oil level. Add the recommended oil as needed to maintain the oil level in the
normal (safe) operating range.

3. Drive slowly at first. Select an open area that allows room to familiarize yourself with
vehicle operation and handling.

4. Vary throttle positions. Do not operate at sustained idle.

5. Perform regular checks on fluid levels, controls and areas outlined on the daily pre-ride
inspection checklist. See page 32.

6. During the break-in period, change both the oil and the filter at 25 hours.

7. Check fluid levels of transmission and all gearcases after the first 25 hours of operation
and every 100 hours thereafter.

8. Pull only light loads.

PVT Break-in (Clutches/Belt)

A proper break-in of the clutches and drive belt will ensure a longer life and better perfor­mance. Break in the clutches and belt by operating at slower speeds during the break-in
period as recommended. Pull only light loads. Avoid aggressive acceleration and high speed
operation during the break-in period.

If a belt fails, always clean any debris from the duct and from the engine compartment.

WARNING

32

OPERATION

Pre-Ride Inspection

Failure to inspect and verify that the vehicle is in safe operating condition before operating
increases the risk of an accident. Always inspect the vehicle before each use to make sure it's
in safe operating condition.

Item Remarks Page

Brake system/pedal travel Ensure proper operation 21

62

Brake fluid Ensure proper level 62

Front suspension Inspect, lubricate if necessary 50

Rear suspension Inspect, lubricate if necessary 50

Steering Ensure free operation 63

Tires Inspect condition and pressure 65

Wheels/fasteners Inspect, ensure fastener tightness 65

Frame nuts, bolts, fasteners Inspect, ensure tightness -

Fuel and oil Ensure proper levels 27

51

Coolant level Ensure proper level 57

Coolant hoses Inspect for leaks -

Throttle Pedal Ensure proper operation -

Indicator lights/switches Ensure operation 20

Intake Screens (2) Inspect, clean 60

Air filter Inspect, clean 60

Headlamp Verify proper operation

Brake light/tail lamp Verify proper operation

Seat Belts Check length of belt for damage, check latches for

proper operation

25

Cab Nets Check for wear or damage, ensure proper installation 24

33

OPERATION

Starting the Engine

1. Always start the engine outdoors or in a well-ventilated area.

2. Sit in the driver's seat and fasten the seat belt. Secure the cab nets.

3. Place the transmission in PARK.

4. Apply the brakes. Do not press the throttle pedal while starting the engine.

5. Turn the ignition key past the ON/RUN position to START. Engage the starter for a max­imum of five seconds. Release the key when the engine starts.

6. If the engine does not start within five seconds, release the ignition switch and wait five
seconds. Repeat steps 5 and 6 until the engine starts.

Stopping the Engine

1. Release the throttle pedal completely and brake to a complete stop.

2. Place the transmission in PARK.

3. Turn the engine off.

WARNING! A rolling vehicle can cause serious injury. Always place the transmission in PARK when
stopping the engine.

Braking

1. Release the throttle pedal completely.

Tip: When the throttle pedal is released completely and the engine speed drops near an idle, the vehi-

cle has no engine braking.

2. Press on the brake pedal evenly and firmly.

Tip: If the throttle pedal and brake pedal are applied simultaneously, engine power may be limited.

3. Practice starting and stopping (using the brakes) until you're familiar with the controls.

34

OPERATION

Driving Procedure

1. Wear a helmet, eye protection, gloves, long-sleeve shirt, long pants and over-the-ankle
boots.

2. Perform the pre-ride inspection. See page 32.

3. Sit in the driver's seat and fasten the seat belt.

4. Always use the cab nets while riding in this vehicle.

5. Place the transmission in PARK.

6. Start the engine.

7. Apply the service brakes and shift the transmission into gear.

8. Check your surroundings and determine your path of travel.

9. Keeping both hands on the steering wheel, slowly release the brakes and slowly depress

the throttle with your right foot to begin driving.

10. Drive slowly. Practice maneuvering and using the throttle and brakes on level surfaces.

11. Do not carry a passenger until you have at least two hours of driving experience with this

vehicle.

35

OPERATION

Driving with a Passenger

1. Perform the pre-ride inspection. See page 32.

2. Make sure all passengers are at least 12 years of age and tall enough to comfortably and
safely sit in a passenger seat with the seat belt secured, put both feet on the floor and
grasp the hand hold.

3. Make sure all passengers are wearing helmet, eye protection, gloves, long-sleeve shirt,
long pants and over-the-ankle boots.

4. Make sure all passengers secure their seat belt.

5. Make sure all cab nets are properly secured.

6. Do not carry more than the recommended number of passengers for your vehicle. See
page 10.

7. Allow a passenger to ride only in a passenger seat.

8. Slow down. Always travel at a speed appropriate for your skills, your passengers’ skills,
and operating conditions. Avoid unexpected or aggressive maneuvers that could cause
discomfort or injury to a passenger.

9. Vehicle handling may change with a passenger and/or cargo on board. Allow more time
and distance for braking.

10. Always follow all operating guidelines as outlined on safety labels and in this manual.

Driving Over Obstacles

Follow these precautions when operating over obstacles:

1. Always check for obstacles before operating in a new area.

2. Look ahead and learn to read the terrain. Be constantly alert for hazards such as logs,
rocks and low hanging branches.

3. Travel slowly and use extra caution when operating on unfamiliar terrain. Not all obsta­cles are immediately visible.

36

OPERATION

Driving on Slippery Surfaces

Skidding or sliding can cause loss of control or overturn (if tires regain traction unexpectedly). When
operating on slippery surfaces such as ice or loose gravel, reduce speed and use extra caution to
reduce the chance of skidding or sliding out of control. Do not operate on excessively slippery surfaces.

Whenever riding on slippery surfaces such as wet trails or loose gravel, or during freezing
weather, follow these precautions:

1. Do not operate on excessively rough, slippery or loose terrain.

2. Slow down before entering slippery areas.

3. Maintain a high level of alertness, reading the trail and avoiding quick, sharp turns,
which can cause skids.

4. Engage all-wheel drive before wheels begin to lose traction.

NOTICE: Severe damage to the drive train may occur if the AWD is engaged while the wheels are

spinning. Always allow the wheels to stop spinning before engaging AWD.

5. Correct a skid by turning the steering wheel in the direction of the skid. Never apply the
brakes during a skid.

WARNING

Sideways

skid

Turn in

direction of

skid

37

OPERATION

Driving Uphill

Whenever traveling uphill, follow these precautions:

1. Always travel straight uphill.

2. Avoid steep hills (15° maximum).

3. Keep both feet on the floor.

4. Always check the terrain carefully before
ascending any hill.

5. Never climb hills with excessively slippery or
loose surfaces.

6. Proceed at a steady rate of speed and throttle
pedal position. Never apply throttle suddenly.

7. Never go over the crest of a hill at high speed.
An obstacle, a sharp drop, or another vehicle
or person could be on the other side of the hill.

Driving on a Sidehill (Sidehilling)

Driving on a sidehill is not recommended. Improper procedure could cause loss of control or
overturn. Avoid crossing the side of any hill unless absolutely necessary.

If crossing a sidehill is unavoidable, follow these precautions:

1. Slow down.

2. Exercise extreme caution.

3. Avoid crossing the side of a steep hill (15° maximum).

Driving Downhill

When driving downhill, follow these precau­tions:

1. Avoid steep hills (15° maximum).

2. Drive straight downhill. Avoid descending
a hill at an angle, which would cause the
vehicle to lean sharply to one side. Travel
straight downhill when possible.

3. Slow down.

4. Apply the brakes slightly to aid in slowing.

15° maximum

15° maximum

38

OPERATION

Driving Through Water

Your POLARIS RANGER can operate through water up to a maximum recommended depth
equal to the floorboards.

NOTICE: Immersion can result in major damage if the vehicle isn't serviced correctly and promptly.

After immersion, always take the vehicle to your dealer service. Do not start the engine! If it's
impossible to bring the vehicle to your dealer before starting the engine, perform the service
outlined on page 59, and take the vehicle to your dealer at the first opportunity.

Follow these procedures when operating
through water:

1. Determine water depths and current
before entering water.

2. Choose a crossing where both banks

have gradual inclines.

3. Proceed slowly, avoiding rocks and

obstacles.

4. Avoid operating through deep or fast-

flowing water.

WARNING! The large tires on your RANGER
may cause the vehicle to float in deep or fast­flowing water, which could result in loss of
control and lead to serious injury or death.
Never cross deep or fast-flowing water with
your RANGER.

5. After leaving water, always dry the

brakes by applying light pressure to
the pedal repeatedly until braking action is normal. Avoid applying brake and throttle at
the same time.

NOTICE: After running your vehicle in water, it's critical that you perform the services outlined in the

Periodic Maintenance Chart beginning on page 47. Give special attention to engine oil,
transmission oil, all gearcase fluids, and all grease fittings.

Floorboard

39

OPERATION

Driving in Reverse

Follow these precautions when operating in reverse:

1. Always check for obstacles or people behind the vehicle. Always inspect left and right
fields of vision before backing.

2. Always avoid backing downhill.

3. Back slowly.

4. Apply the brakes lightly for stopping.

5. Avoid turning at sharp angles.

6. Apply only light throttle. Never apply throttle suddenly.

40

OPERATION

Parking the Vehicle

1. Apply the brakes. Stop the vehicle on a level surface.

2. When parking inside a garage or other structure, be sure that the structure is well venti­lated and that the vehicle is not close to any source of flame or sparks, including any
appliance with pilot lights.

3. Place the transmission in PARK.

4. Turn the engine off.

5. Remove the ignition switch key to prevent unauthorized use.

Parking on an Incline

Avoid parking on an incline if possible. If it's
unavoidable, follow these precautions:

1. Apply the brakes.

2. Place the transmission in PARK.

3. Turn the engine off.

4. Block the rear wheels on the downhill
side.

15° maximum

41

OPERATION

Hauling Cargo

Hauling cargo improperly can alter vehicle handling and may cause loss of control or brake instability,
which can result in serious injury or death. Always follow these precautions when hauling cargo:

Never exceed the maximum weight capacity of the vehicle. When determining the weight you are
adding to the vehicle, include the weight of the operator, passenger, accessories, loads in the rack or
box and the load on the trailer tongue. The combined weight of these items must not exceed the
maximum weight capacity.

REDUCE SPEED AND ALLOW GREATER DISTANCES FOR BRAKING WHEN HAULING CARGO.
Always load the cargo box with the load as far forward and as low as possible.
When operating over rough or hilly terrain, reduce speed and cargo to maintain stable driving

conditions.
Always operate the vehicle with extreme care when hauling or towing loads.
Slow down and drive in the lowest gear available. Always use LOW gear when towing or hauling heavy

loads.
SECURE ALL LOADS BEFORE OPERATING. Unsecured loads can create unstable operating

conditions, which could result in loss of control of the vehicle.
OPERATE ONLY WITH STABLE AND SAFELY ARRANGED LOADS. When handling off-centered

loads that cannot be centered, securely fasten the load and operate with extra caution. Always attach
the tow load to the hitch point designated for your vehicle.

HEAVY LOADS CAN CAUSE BRAKING AND CONTROL PROBLEMS. Use extreme caution when
applying brakes with a loaded vehicle. Avoid terrain or situations that may require backing downhill.

USE EXTREME CAUTION when operating with loads that extend over the rack sides. Stability and
maneuverability may be adversely affected, causing the vehicle to overturn.

DO NOT TRAVEL FASTER THAN THE RECOMMENDED SPEEDS. Vehicle should never exceed 10
MPH (16 km/h) while towing a load on a level grass surface. Vehicle speed should never exceed 5
MPH (8 km/h) when towing loads in rough terrain, while cornering, or while ascending or descending a
hill.

Load Capacity

The RANGER has been designed to carry or tow specific capacities. Always read and under­stand the load distribution warnings listed on the warning labels. The total load (operator,
passenger, accessories, cargo and weight on hitch) must not exceed the maximum weight
capacity of the vehicle. See page 10.

WARNING! Driving with passengers in the
cargo box can result in severe injury or death.
Never allow passengers to ride in the cargo box.
Passengers must always ride in the cab with
seat belts fastened securely.

WARNING

42

OPERATION

Towing Loads

Towing improperly can alter vehicle handling and may cause loss of control or brake insta­bility. Always follow these precautions when towing:

1. Never load more than 150 lbs. (68.1 kg) tongue weight on the towing bracket.

2. Always shift to low gear for towing.

3. Do not operate the vehicle faster than 10 MPH (16 km/h) when towing. See page 41.
Towing a trailer increases braking distance.

4. Do not tow more than the recommended weight for the vehicle. See the towing capacity
chart below and the specifications charts beginning on page 76.

5. Attach a trailer to the trailer hitch bracket only. Do not attach a trailer to any other loca­tion or you may lose control of the vehicle.

6. Never tow a trailer on a grade steeper than 15°.

Belt Life

To extend belt life, use the lowest gear possible when hauling or towing heavy cargo.

Model Total Towed

Load Weight

(Level Ground)

Total Towed

Load Weight

(15° grade)

Total H itch

Vertical

Weight

Maximum

Towing

Speed

RANGER XP 900 2000 lbs. (907 kg) 850 lbs. (386 kg) 150 lbs. (68.1 kg) 10 MPH (16 km/h)

43

OPERATION

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. Apply the brakes. Place the transmission in

PARK .

3. Ensure that the cargo is positioned evenly or

toward the front of the cargo box.

4. Release the tailgate by pulling up on the tail-

gate latch.

WARNING! If the weight distribution on the box is
located toward the rear of the box when the release
lever is pulled forward, the box may dump unexpectedly
and cause serious injury to the operator or bystanders.
Never operate the dump lever without ensuring that the
load is positioned evenly or at the front of the box.

5. Stand clear and pull up on the cargo box

release lever. Lift the front of the cargo box to dump the cargo.

6. Lower the cargo box and push down securely to latch.

WARNING! Operating the vehicle while the cargo box is raised could result in severe injury. The box
could close unexpectedly and cause injury to the driver or passenger. The rear tires could also catch
the rear of a raised box, damaging the vehicle and creating hazardous driving conditions. Never
operate this vehicle with the cargo box in the raised position.

Release Lever

44

OPERATION

All Wheel Drive (AWD)

Engaging AWD

Press the top of the switch to engage All Wheel Drive
(AWD). The 4X4 indicator illuminates in the rider
information center to indicate that the vehicle is in
AWD. See page 27.

When the AWD switch is on, the front wheels will
automatically engage any time the rear wheels lose
traction. When the rear wheels regain traction, the
front wheels will automatically disengage. There is
no limit to the length of time the vehicle may remain
in AWD.

Tip: The AWD switch may be turned on or off while the vehicle is moving.

Engage the AWD before getting into conditions where front wheel drive may be needed. If
the rear wheels are spinning, release the throttle before switching to AWD.

NOTICE: Switching to AWD while the rear wheels are spinning may cause severe drive shaft and

clutch damage. Always switch to AWD while the rear wheels have traction or are at rest.

Disengaging AWD

Move the AWD switch to the center or bottom position to disengage AWD. If the switch is
turned off while the front hubs are driving, they will not release until the rear wheels regain
traction.

In some situations, the front gearcase may remain locked after turning the AWD switch off.
If this occurs, you may notice increased steering effort and some vehicle speed restriction.
Perform the following procedure to unlock the front gearcase.

1. Stop the vehicle.

2. Operate in reverse for at least 10 feet (3 m).

3. Stop completely.

4. Shift into low gear and drive forward.

5. If the front gearcase remains locked after following these instructions, see your dealer
for service.

AWD

Differential Lock

Differential Unlock

45

OPERATION

All Wheel Drive (AWD)

Locking the Differential

NOTICE: Damage to the differential can occur if it is

engaged while the vehicle is traveling at high
speeds or while the rear wheels are spinning.
Slow the vehicle to nearly stopped before
engaging the differential.

Locking the differential in slippery or low traction
conditions helps improve traction. Move the
rocker switch to the center position (2WD) to lock
the differential and operate in rear wheel drive.

Press the bottom of the switch to unlock the differ­ential and allow the rear drive wheels to operate
independently. This mode of operation is well
suited to turf driving or whenever aggressive trac­tion is not required.

46

EMISSION CONTROL SYSTEMS

Noise Emission Control System

Do not modify the engine, intake or exhaust components, as doing so may affect compliance
with U.S.A. EPA noise control requirements (40 CFR 205) and local noise level require­ments.

Operation on Public Lands in the U.S.A.

Your POLARIS vehicle has a spark arrester that was tested and qualified to be in accordance
with the USFS standard 5100-1c. Federal law requires that this spark arrester be installed and
functional when the vehicle is operated on public lands.

Operation of off-road vehicles on public lands in the U.S.A. is regulated by 43 CFR 420.
Violations are subject to monetary penalties. Federal regulations can be viewed online at
www.gpoaccess.gov/ecfr/.

Crankcase Emission Control System

This engine is equipped with a closed crankcase system. Blow-by gases are forced back to
the combustion chamber by the intake system. All exhaust gases exit through the exhaust
system.

Exhaust Emission Control System

Exhaust emissions are controlled by an electronic fuel
injection (EFI) system. The engine and EFI components
are set at the factory for optimal performance and are
not adjustable.

The emissions label is located on the main frame under
the driver’s seat and storage compartment.

Electromagnetic Interference

This spark ignition system complies with Canadian ICES-002.
This vehicle complies with the EMC requirements of European directives 97/24/EC and

2004/108/EC.
Non-ionizing Radiation: This vehicle emits some electromagnetic energy. People with active

or non-active implantable medical devices (such as heart monitoring or controlling devices)
should review the limitations of their device and the applicable electromagnetic standards
and directives that apply to this vehicle.

47

MAINTENANCE

Periodic Maintenance Chart

Careful periodic maintenance will help keep your vehicle in the safest, most reliable condi­tion. Inspection, adjustment and lubrication of important components are explained in the
periodic maintenance chart.

Inspect, clean, lubricate, adjust and replace parts as necessary. When inspection reveals the
need for replacement parts, use genuine POLARIS parts available from your POLARIS
dealer.

Record maintenance and service in the Maintenance Log beginning on page 87.

Tip: Service and adjustments are important for proper vehicle operation. If you're not familiar with safe

service and adjustment procedures, have a qualified dealer perform these operations.

Maintenance intervals in the following chart are based upon average riding conditions and an
average vehicle speed of approximately 10 MPH (16 km/h). Vehicles subjected to severe use
must be inspected and serviced more frequently.

Severe Use Definition

• Frequent immersion in mud, water or sand

• Frequent or prolonged operation in dusty environments

• Racing or race-style high RPM use

• Prolonged low speed, heavy load operation

• Extended idle

• Frequent short trip operation in cold weather (engine frequently does not operate long
enough to reach full operating temperature)

Pay special attention to the oil level. A rise in oil level during cold weather can indicate con­taminants collecting in the oil sump or crankcase. Change oil immediately if the oil level
begins to rise. Monitor the oil level, and if it continues to rise, discontinue use and determine
the cause or see your dealer.

Maintenance Chart Key

 Perform these operations more often for vehicles subjected to severe use.

E Emission-related service (Failure to conduct this maintenance will not void the emis­sions warranty but may affect emissions.)

D Have an authorized POLARIS dealer perform these services.

WARNING! Improperly performing the procedures marked with a “D” could result in component failure

and lead to serious injury or death. Have an authorized POLARIS dealer perform these services.

48

MAINTENANCE

Periodic Maintenance Chart

Perform all services at whichever maintenance interval is reached first.

 Perform these procedures more often for vehicles subjected to severe use.

E Emission-Related Service
D Have an authorized POLARIS dealer perform these services.

Item Maintenance Interval

(whichever comes first)

Remarks

Hours Calendar Miles (Km)

Steering

Pre-Ride Make adjustments as needed.

See Pre-Ride Checklist on page 32.

Front suspension

Rear suspension

Tires

Brake fluid level

Brake pedal travel

Brake system

Wheels/fasteners

Frame fasteners

Engine oil level

E Intake Screens - Daily - Inspect; clean often as needed

E Engine intake pre-filter - Daily - Inspect; clean often

Coolant - Daily - Check level daily, change coolant every

2 years

 Power steering unit (if equipped) - Daily - Inspect daily; clean often

Headlamp/tail lamp - Daily - Verify proper operation

DBrake pad wear 10 H Monthly 100 (160) Inspect periodically

Battery 25 H Monthly 200 (320) Check terminals; clean; test

EAir filter 25 H Monthly 200 (320) Inspect; replace as needed

 Front gearcase oil 25 H 1 M - Perform a break-in oil level check

 Transmission oil 25 H 1 M - Perform a break-in oil level check

 Engine oil change (break-in) 25 H - 500 (800) Perform a break-in oil change

 General lubrication 50 H 3 M 500 (800) Lubricate all fittings, pivots, cables, etc.

Shift Linkage 50 H 6 M 500 (800) Inspect, lubricate, adjust

D Steering 50 H 6 M 500 (800) Lubricate

 Front Suspension 50 H 6 M 500 (800) Lubricate

 Rear Suspension 50 H 6 M 500 (800) Lubricate

49

MAINTENANCE

Periodic Maintenance Chart

 Perform these procedures more often for vehicles subjected to severe use.

E Emission-Related Service
D Have an authorized POLARIS dealer perform these services.

Item Maintenance Interval

(whichever comes first)

Remarks

Hours Calendar Miles (Km)

DEThrottle pedal 50 H 6 M 500 (800) Inspect for free movement; replace

pedal as needed

E Throttle body air intake ducts/

flange

50 H 6 M 500 (800) Inspect duct for proper sealing/air leaks

Drive belt 50 H 6 M 500 (800) Inspect; adjust; replace as needed

Cooling system (if applicable) 50 H 6 M 500 (800) Inspect coolant strength seasonally;

pressure test system yearly

 Engine oil and filter change 100 H 6 M 1000 (1600) Change the oil and filter

 Front gearcase oil 100 H 12 M 1000 (1600) Change fluid

 Transmission oil 100 H 12 M 1000 (1600) Change fluid

DEFuel system 100 H 12 M 1000 (1600) Check for leaks at tank cap, lines, fuel

valve, filter, pump, throttle body; replace
lines every two years

 Radiator (if applicable) 100 H 12 M 1000 (1600) Inspect; clean external surfaces

 Cooling Hoses (if applicable) 100 H 12 M 1000 (1600) Inspect for leaks

 Engine mounts 100 H 12 M 1000 (1600) Inspect

Exhaust muffler/pipe 100 H 12 M 1000 (1600) Inspect

DESpark plug 100 H 12 M 1000 (1600) Inspect; replace as needed

 Wiring 100 H 12 M 1000 (1600) Inspect for wear, routing, security; apply

dielectric grease to connectors sub­jected to water, mud, etc.

DClutches (drive and driven) 100 H 12 M 1000 (1600) Inspect; clean; replace worn parts

D Front wheel bearings 100 H 12 M 1000 (1600) Inspect; replace as needed

D Brake fluid 200 H 24 M 2000 (3200) Change every two years

Spark arrester 300 H 36 M 3000 (4800) Clean out

DEValve clearance - - 5000 (8000) Inspect; adjust as needed

D Toe adjustment - Inspect periodically; adjust when parts

are replaced

DAuxiliary brake (if equipped) - Inspect daily; adjust as needed

Headlight aim - Adjust as needed

50

MAINTENANCE

Lubrication Recommendations

Check and lubricate all components at the intervals outlined in the Periodic Maintenance
Chart beginning on page 47, or more often under severe use, such as wet or dusty conditions.
Items not listed in the chart should be lubricated at the general lubrication interval.

Engine Oil

Always check and change the engine oil at the intervals outlined in the Periodic Maintenance
Chart beginning on page 47. Always change the oil filter whenever changing oil.

WARNING! Vehicle operation with insufficient, deteriorated, or contaminated engine oil will cause
accelerated wear and may result in engine seizure, accident, and injury. Always perform the
maintenance procedures as outlined in the Periodic Maintenance Chart.

Oil Recommendations

POLARIS recommends the use of POLARIS PS-4 PLUS Performance Synthetic 2W-50 4­cycle oil or a similar oil. Refer to the specifications section beginning on page 76 for capaci­ties. See page 78 for the part numbers of POLARIS products.

NOTICE: Mixing brands or using a non-recommended oil may cause serious engine damage. Always

use the recommended oil. Never substitute or mix oil brands.

Always check and change the oil at the intervals outlined in the Periodic Maintenance Chart
beginning on page 47. Always use the recommended engine oil.

Item Method Lube

Engine Oil Add to proper level on dipstick. See page 51. PS-4 PLUS 2W-50

Brake Fluid Maintain level between fill lines. See page 62. DOT 4

Main Gearcase Oil
(Transmission)

See page 53. AGL PLUS Transmission Fluid

Front Gearcase Oil See pages 53-54. Demand Drive Plus Fluid

Front Prop Shaft Yoke Locate fittings and grease (3 pumps

maximum).

POLARIS Premium U-Joint Lube

Front Control Arm Pivot
Bushings

Grease 3 fittings on each side of the vehicle.

POLARIS Premium all Season
Grease or grease conforming to
NLGI No. 2

Rear Control Arm Pivot
Bushings

Grease 4 fittings on each side of the vehicle.

Rear Stabilizer Bar Bushings Grease one fitting on each side of the vehicle.

51

MAINTENANCE

Engine Oil

Oil Check

Always check the oil when the engine is cold. If the engine is hot when the oil is checked, the
level will appear to be overfull.

CAUTION! Always remove all cargo from the cargo box before lifting the box to access engine
components.

Access the oil fill cap, dipstick and filter under
the cargo box.

1. Remove all cargo from the cargo box. See

page 43.

2. Position the vehicle on a level surface.

3. Place the transmission in PARK.

4. Stop the engine.

5. Stand clear and pull up on the cargo box

release lever. Lift the front of the cargo
box.

6. Remove the dipstick. Wipe it dry with a

clean cloth.

7. Reinstall the dipstick completely. Remove

the dipstick and check the oil level.

8. Remove the oil fill cap to add the recommended oil as needed. Maintain the oil level

between the minimum and maximum marks on the dipstick. Do not overfill.

9. Reinstall the fill cap. Reinstall the dipstick.

10. Lower the cargo box and push down securely to latch.

Oil and Filter Change

Always change the oil and filter at the intervals outlined in the Periodic Maintenance Chart
beginning on page 47. Always change the oil filter whenever changing oil.

The crankcase drain plug is located on the bottom of the crankcase. Access the drain plug
through the access hole in the skid plate under the crankcase (see next page).

CAUTION! Always remove all cargo from the cargo box before lifting the box to access engine
components.

Access the oil fill cap, dipstick and filter under the cargo box.

1. Remove all cargo from the cargo box. See page 43.

2. Position the vehicle on a level surface.

Oil Fill

Cap

Oil

Dipstick

Oil

Filter

52

MAINTENANCE

Engine Oil

Oil and Filter Change

3. Place the transmission in PARK.

4. Stand clear and pull up on the cargo box release lever. Lift the front of the cargo box.

5. Locate the crankcase drain plug access hole in the skid plate.

6. Clean the area around the crankcase drain plug.

CAUTION! Hot oil can cause burns to skin. Do not allow
hot oil to contact skin.

7. Place a drain pan under the engine crankcase and
remove the drain plug. Allow the oil to drain com­pletely.

8. Using an oil filter wrench, turn the filter counter­clockwise to remove it.

9. Using a clean dry cloth, clean the filter sealing
surface on the crankcase.

10. Lubricate the o-ring on the new filter with a film
of fresh engine oil. Check to make sure the o-ring
is in good condition.

11. Install the new filter and turn by hand until the fil­ter gasket contacts the sealing surface, then turn
an additional 1/2 turn.

12. Reinstall the drain plug. Torque the drain plug to
12 ft. lbs. (16 Nm).

13. Remove the oil fill cap and add 2.5 quarts (2.4 l)
of recommended oil. Reinstall the fill cap.

14. Start the engine and check for leaks.

15. Stop the engine and wait 15 seconds before
removing the dipstick.

16. Remove the dipstick. Wipe it dry with a clean
cloth.

17. Reinstall the dipstick completely. Remove the
dipstick and check the oil level.

18. Remove the oil fill cap and add oil as needed to bring the level to the upper mark on the
dipstick. Do not overfill.

19. Reinstall the fill cap. Reinstall the dipstick.

20. Lower the cargo box and push down securely to latch.

21. Dispose of used filter and oil properly.

Crankcase

Drain Plug

Access

Hole

Bottom View of Skid Plate

Oil Fill

Cap

Oil

Filter

Oil

Dipstick

53

MAINTENANCE

Gearcases

Gearcase Specification Chart

Transmission (Main Gearcase)

Always check and change the transmission oil at the
intervals outlined in the Periodic Maintenance Chart
beginning on page 47. Refer to the Gearcase
Specifications Chart for recommended lubricants,
capacities and torque specifications. See page 78 for
the part numbers of POLARIS products.

Oil Check

The level check/fill plug is located on the rear of the
gearcase. Maintain the oil level even with the bot­tom of the level check/fill plug hole threads.

1. Position the vehicle on a level surface.

2. Place the transmission in PARK.

3. Remove the level check/fill plug. Check the oil
level.

4. Add the recommended oil as needed.

5. Reinstall the fill plug. Torque to specification.

Oil Change

The drain plug is located near the bottom of the
gearcase.

1. Remove the level check/fill plug.

2. Place a drain pan under the gearcase.

3. Remove the drain plug. Allow the oil to drain completely.

4. Clean and reinstall the drain plug. Torque to specification.

5. Add the recommended oil.

6. Reinstall the fill plug. Torque to specification.

7. Check for leaks. Dispose of used oil properly.

RANGER XP 900 Gearcase Specifications

Gearcase Lubricant Capacity Fill Plug Torque Drain Plug Torque

Main Gearcase

(Transmission)

AGL PLUS

Transmission Fluid

34 oz.

(1000 ml)

12 ft. lbs.

(16.3 Nm)

12 ft. lbs.

(16.3 Nm)

Front Gearcase Demand Drive Plus

Fluid

7.6 oz.

(225 ml)

8-10 ft. lbs.

(11-13.6 Nm

8-10 ft. lbs.

(11-13.6 Nm

Gearcase

Drain Plug

Level

Check/Fill

Plug

Fill

Level

54

MAINTENANCE

Gearcases

Front Gearcase

Always check and change the front gearcase oil at the intervals outlined in the Periodic
Maintenance Chart beginning on page 47. Maintain the oil level even with the bottom thread
of the fill plug hole.

Refer to the Gearcase Specifications Chart on page 53 for recommended lubricants, capaci­ties and torque specifications. See page 78 for the part numbers of POLARIS products.

Oil Check

The front gearcase fill plug is located on the right
side of the front gearcase.

1. Position the vehicle on a level surface.

2. Place the transmission in PARK.

3. Remove the fill plug. Check the oil level.

4. Add the recommended oil as needed.

5. Reinstall the fill plug. Torque to specification.

Oil Change

1. Support the vehicle securely with a jackstand.

2. Remove the fill plug.

3. Place a drain pan under the drain plug.

4. Remove the drain plug. Allow the oil to drain
completely.

5. Clean and reinstall the drain plug. Torque to
specification.

6. Add the recommended oil.

7. Reinstall the fill plug. Torque to specification.

8. Check for leaks. Dispose of used oil properly.

Recessed

Drain Plug

Fill

Plug

Fill

Level

55

MAINTENANCE

Spark Plugs

Spark Plug Recommendations

Refer to the specifications section beginning on page 76 for the recommended spark plug
type for your vehicle. Always torque spark plugs to specification.

NOTICE: Using non-recommended spark plugs can result in serious engine damage. Always use

POLARIS-recommended spark plugs.

Spark Plug Gap/Torque

Spark Plug Inspection

Spark plug condition is indicative of engine operation. The spark plug firing end condition
should be read after the engine is warmed up and the vehicle is driven at higher speeds.
Immediately check the spark plug for correct color.

CAUTION! Always remove all cargo from the cargo box before lifting the box to access engine
components.

1. Lift the cargo box. Remove the spark plug
cap.

CAUTION! A hot exhaust system and engine can
cause burns. Wear protective gloves when
removing a spark plug for inspection.

2. Using the spark plug wrench provided in

the tool kit, remove the plug by rotating it
counter-clockwise.

3. Reverse the procedure for spark plug

installation. Apply anti-seize compound
to the spark plug threads.

4. Torque to specification.

Normal Plug

The normal insulator tip is gray, tan or light
brown. There will be few combustion depos­its. The electrodes are not burned or eroded. This indicates the proper type and heat range for
the engine and the service.

The tip should not be white. A white insulator tip indicates overheating, caused by use of an
improper spark plug or incorrect throttle body adjustments.

Wet Fouled Plug

The wet fouled insulator tip is black. A damp oil film covers the firing end. There may be a
carbon layer over the entire nose. Generally, the electrodes are not worn. General causes of
fouling are excessive oil, use of non-recommended oil or poor fuel quality.

Model Electrode Gap New Plug Torque Used Plug Torque

RANGER XP 0.7-0.8 mm 10 ft. lbs. (13.5 Nm) 10 ft. lbs. (13.5 Nm)

Spark Plugs

56

MAINTENANCE

Cooling System

The engine coolant level is controlled or maintained by the recovery system. The recovery
system components are the overflow bottle, radiator filler neck, radiator pressure cap and
connecting hose.

As coolant operating temperature increases, the expanding (heated) excess coolant is forced
out of the radiator, past the pressure cap, and into the overflow bottle. As engine coolant tem­perature decreases, the contracting (cooled) coolant is drawn back up from the tank, past the
pressure cap, and into the radiator.

Some coolant level drop on new vehicles is normal as the system is purging itself of trapped
air. Observe coolant levels and maintain as recommended by adding coolant to the overflow
bottle.

Adding or Changing Coolant

To ensure that the coolant maintains its ability to protect the engine, we recommend that the
system be completely drained every two years and a fresh mixture of antifreeze and water
added. POLARIS recommends the use of POLARIS Premium 60/40 anti-freeze/coolant or a
50/50 mixture of high quality aluminum compatible anti-freeze/coolant and distilled water.
POLARIS Premium 60/40 is already premixed and ready to use. Do not dilute with water.
See page 78 for the part numbers of POLARIS products.

Always follow the manufacturer's mixing recommendations for the freeze protection
required in your area.

Any time the cooling system has been drained for maintenance or repair, replace the coolant.
If the recovery bottle has run dry, the level in the radiator should be inspected. Add coolant
as needed.

Radiator and Cooling Fan

Always check and clean the screen and radiator fins at the intervals outlined in the Periodic
Maintenance Chart beginning on page 47. Do not obstruct or deflect air flow through the
radiator by installing unauthorized accessories in front of the radiator or behind the cooling
fan. Interference with the radiator air flow can lead to overheating and consequent engine
damage.

NOTICE: Washing the vehicle with a high-pressure hose could damage the radiator fins and impair

the radiator's effectiveness. Using a high-pressure system is not recommended.

57

MAINTENANCE

Cooling System

Overflow Bottle Coolant Level

Always check and change the coolant at the intervals outlined in the Periodic Maintenance
Chart beginning on page 47. Maintain the coolant level between the minimum and maximum
marks on the bottle (when the fluid is cool).

1. Position the vehicle on a level
surface.

2. Place the transmission in PARK.

3. Remove the hood. See page 23.

4. View the coolant level in the

overflow bottle.

5. If the coolant level is below the

safe operating range, use a funnel
to add coolant through the filler
opening. Reinstall the cap.

Tip: If coolant must be added often, or if

the overflow bottle runs completely
dry, there may be a leak in the sys­tem. Have the cooling system
inspected by your POLARIS dealer.

Radiator Coolant Level

1. Remove the hood. See page 23.

CAUTION! Escaping steam can cause burns. Never remove the pressure cap while the engine is
warm or hot. Always allow the engine to cool before removing the pressure cap.

2. Slowly remove the radiator cap.

3. View the coolant level through the opening.

4. Use a funnel and slowly add coolant as needed.

Tip: This procedure is required only if the cooling system has been drained for maintenance and/or

repair. But if the overflow bottle has run dry, the level in the radiator should also be inspected.

5. Reinstall the pressure cap. Use of a non-standard pressure cap will not allow the recov-

ery system to function properly. See your dealer for the correct replacement part.

MIN

MAX COLD

COOLANT ONLY

Maximum
Level
(Cold)

Minimum
Level

Radiator

Cap

58

MAINTENANCE

POLARIS Variable Transmission (PVT) System

Failure to comply with the instructions in this warning can result in severe injury or death.

Do not modify any component of the PVT system. Doing so may reduce its strength so that a failure
may occur at a high speed. The PVT system has been precision balanced. Any modification will cause
the system to be out of balance, creating vibration and additional loads on components.

The PVT system rotates at high speeds, creating large amounts of force on clutch components.
Extensive engineering and testing has been conducted to ensure the safety of this product. However,
as the owner, you have the following responsibilities to make sure this system remains safe:

• Always follow all recommended maintenance procedures. Always look for and remove debris inside
and around the clutch and vent system when replacing the belt.

• See your dealer as outlined in the owner's manual.

• This PVT system is intended for use on POLARIS products only. Do not install it in any other product.

• Always make sure the PVT housing is securely in place during operation.

Belt Replacement/Debris Removal

If a belt fails, always clean any debris from the
duct and from the clutch and engine compart­ments when replacing the belt.

WARNING! Failure to remove ALL debris when
replacing the belt could result in vehicle damage and
severe injury or death.

1. Remove the clutch cover screws and open

the clutch cover. Remove all debris wrapped
in and around the PVT system.

2. Remove all debris from the entire clutch air

duct passage.

3. Check for signs of damage to seals on the

transmission and engine. See your dealer
promptly for service if any seals appear to
be damaged.

Tip: Belt slip is responsible for creating excessive heat that destroys belts, wears clutch components

and causes outer clutch covers to fail. Switch to low range while operating at slower speeds to
extend the life of the PVT components (belt, cover, etc.).

WARNING

Remove ALL Debris

59

MAINTENANCE

POLARIS Variable Transmission (PVT) System

PVT Drying

There may be some instances when water is accidently ingested into the PVT system. Use
the following instructions to dry it out before operating.

1. Position the vehicle on a level surface. Place the transmission in PARK. Stop the engine.

2. Remove the clutch cover drain plug. Allow the
water to drain completely. Reinstall the drain plug.

3. Start the engine.

4. Apply varying throttle for 10-15 seconds to expel
the moisture and air-dry the belt and clutches. Do
not apply heavy throttle for more than 10 seconds.

5. Allow the engine RPM to settle to idle speed.
Apply the brakes. Shift the transmission to the
lowest available range.

6. Test for belt slippage. If the belt slips, repeat the
process.

7. Take the vehicle to your dealer for service as soon as possible.

Vehicle Immersion

NOTICE: If your vehicle becomes immersed, major engine damage can result if the machine is not

thoroughly inspected. Take the vehicle to your dealer before starting the engine.

If it's impossible to take your RANGER to a dealer before starting it, follow the steps outlined
below.

1. Move the vehicle to dry land or at the very least, to water below the floorboard.

2. Dry any water present in the air box. Filter replacement is required if water is present.

3. Dry any water present in the intake manifold.

4. Remove the spark plugs. Turn the engine over several times using the electric start.

5. Dry the spark plugs and reinstall, or replace with new plugs.

6. Attempt to start the engine. If necessary, repeat the drying procedure.

7. Take the vehicle to your dealer for service as soon as possible, whether you succeed in
starting it or not.

8. If water has been ingested into the PVT, follow the PVT Drying procedure.

Drain Plug

60

MAINTENANCE

Filter Systems

Air Filter

Always change the air filter at the
intervals outlined in the Periodic
Maintenance Chart beginning on
page 47. Service the air filter more
frequently if the vehicle is operated
in wet conditions or at high throttle
for extended periods.

1. Lift the cargo box to access the
air box.

2. Release the five (5) air box

cover latches and lower the bot­tom to expose the air filter.

3. Remove the air filter.

4. Inspect the air box for oil or water deposits. Wipe away any deposits with a clean cloth.

5. Install a new filter if needed. Do not attempt to clean the air filter.

Intake Screens

An engine intake screen is located on the
driver’s side of the vehicle. A clutch
intake screen is located on the passenger
side of the vehicle.

Inspect the screens before each use of the
vehicle. Remove the screens and clean
them frequently with warm soapy water
to ensure adequate air flow.

Left Side View

Air

Filter

Right Side

View

5 Latches

Intake Screens

(both sides)

61

MAINTENANCE

Spark Arrester

Failure to heed the following warnings while servicing the spark arrester could result in serious injury or
death.

• Do not perform clean-out immediately after the engine has been run, as the exhaust system
becomes very hot. Serious burns could result from contact with the exhaust components. Allow
components to cool sufficiently before proceeding.

• Wear eye protection and gloves.

• Never run the engine in an enclosed area. Exhaust contains poisonous carbon monoxide gas that
can cause loss of consciousness or death in a very short time.

Periodically clean the spark arrestor to remove accumulated carbon.

1. Place the transmission in PARK.

2. Remove the retaining screw and remove the

arrester from the end of the muffler.

3. Use a non-synthetic brush to clean the

arrester screen. A synthetic brush may melt
if components are warm. If necessary, blow
debris from the screen with compressed air.

4. Inspect the screen for wear and damage.

Replace a worn or damaged screen.

5. Reinstall the arrester.

6. Torque the bolts to 5-7 ft. lbs. (7-9 Nm).

WARNING

Screen

Arrester

Retaining

Screw

Muffler

62

MAINTENANCE

Brakes

The front and rear brakes are hydraulic disc type brakes activated by the brake pedal. See
page 21.

Brake Fluid

Inspect the brake system routinely. Inspect the level of the brake fluid before each operation.

WARNING! After opening a bottle of brake fluid, always discard any unused portion. Never store or
use a partial bottle. Brake fluid is hygroscopic, meaning it rapidly absorbs moisture from the air. The
moisture causes the boiling temperature of the brake fluid to drop, which can lead to early brake fade
and the possibility of accident or severe injury.

Change the brake fluid every two years and any time the fluid becomes contaminated, the
fluid level is below the minimum, or if the type and brand of the fluid in the reservoir are
unknown.

1. Position the vehicle on a level surface.

2. Place the transmission in PARK.

3. View the brake fluid level at the reservoir in the driver’s
side wheel well.

4. The level should be between the upper (MAX) and
lower (MIN) level lines.

5. If the fluid level is lower than the upper level line, add
brake fluid to the upper (MAX) line.

6. Apply the brake forcefully for a few seconds and check
for fluid leakage around the fittings.

Maximum

Minimum

63

MAINTENANCE

Brakes

Brake Inspection

1. Check the brake system for fluid leaks.

2. Check the brake pedal for excessive travel or a spongy
feel.

3. Check the friction pads for wear, damage and looseness.

4. Check brake discs for signs of cracks, excessive corro­sion, warping or other damage. Clean any grease using
an approved brake cleaner or alcohol.

NOTICE: Do not apply WD-40 or any petroleum product to brake

discs.

5. Inspect the brake disc spline and pad wear surface for
excessive wear. Change pads when worn to 3/64" (1 mm).

Steering Wheel Inspection

Check the steering wheel for specified freeplay and smooth operation at the intervals out­lined in the Periodic Maintenance Chart beginning on page 47.

1. Position the vehicle on a level surface.

2. Place the transmission in PARK.

3. Lightly turn the steering wheel left and right. There should be 0.8"-1.0" (20-25 mm) of
freeplay.

4. If there is excessive freeplay or strange noises, or the steering feels rough or “catchy,”
have the steering system inspected by an authorized POLARIS dealer.

3/64" (1mm)

64

MAINTENANCE

Suspension Adjustments

The front and rear suspensions can be adjusted to provide a stiffer suspension, if necessary.

1. Remove the top shock mounting bolts from the inside mounting positions.

2. Reposition the shocks to the outside mounting holes.

3. Reinstall the shock mounting bolts. Torque to 40 ft. lbs. (54.2 Nm).

Spring Adjustment

Adjust the front and rear shock absorber springs by
rotating the adjustment cam either clockwise or counter­clockwise to increase or decrease spring tension.

Inside Mounting

Position

Rear Suspension Shown

Adjustment is similar for Front Suspension

Outside Mounting Position

Cam

65

MAINTENANCE

Tires

Operating your vehicle with worn tires, improperly inflated tires, non-standard tires or improperly
installed tires will affect vehicle handling and could cause an accident resulting in serious injury or
death. Always follow all tire maintenance procedures as outlined in this manual and on the labels on
the vehicle. Always use original equipment size and type when replacing tires.

Tire Tread Depth

Always replace tires when tread depth is
worn to 1/8" (3 mm) or less.

Axle and Wheel Nut Torque
Specifications

Inspect the following items occasionally for tightness, and if they've been loosened for main­tenance service.

Do not lubricate the stud or the lug nut.

Nut Type Location Nut Torque

Lug Nut
(Aluminum Wheels)

Front and Rear 120 ft. lbs. (163 Nm)

Lug Nut (Tapered) Front and Rear 60 ft. lbs. (81 Nm)

Spindle Nut Front 75 ft. lbs. (102 Nm)

Hub Retaining Nuts Rear 110 ft. lbs. (150 Nm)

WARNING

1/8" (3 mm)

66

MAINTENANCE

Tires

Wheel Removal

1. Position the vehicle on a level surface.

2. Place the transmission in PARK. Stop the engine.

3. Loosen the wheel nuts slightly.

4. Elevate the side of the vehicle by placing a suitable stand under the frame.

5. Remove the wheel nuts and washers. Remove the wheel.

Wheel Installation

1. Place the transmission in PARK.

2. Place the wheel in the correct position on the
wheel hub. Be sure the valve stem is toward
the outside and rotation arrows on the tire
point toward forward rotation.

WARNING! Improperly installed wheels can
adversely affect tire wear and vehicle handling, which
can result in serious injury or death. Always ensure
that all nuts are torqued to specification. Do not
service axle nuts that have a cotter pin installed. See
your POLARIS dealer.

3. Attach the wheel nuts and washers and fin­ger tighten.

4. Carefully lower the vehicle to the ground.

5. Torque the wheel nuts to specification. See page 65.

Power Steering Unit

If your model is equipped with power steering, fre­quently clean the areas around and on the power
steering unit to allow proper cooling. Clean these
areas thoroughly.

Clean Often

67

MAINTENANCE

Lights

Poor lighting can result in reduced visibility when driving. Headlight and taillight lenses
become dirty during normal operation. Clean lights frequently and replace burned out lamps
promptly. Always make sure lights are adjusted properly for best visibility.

When servicing a halogen lamp, don't touch the lamp with bare fingers. Oil from your skin
leaves a residue, causing a hot spot that will shorten the life of the lamp.

Headlight Lamp Replacement

Access a headlamp wiring harness through the front
wheel well.

CAUTION! Hot components can cause burns to skin.
Allow lamps to cool before servicing.

1. Unplug the headlamp from the wiring harness.
Be sure to pull on the connector, not on the wir­ing.

2. Turn the lamp counter-clockwise to remove it.

3. Install the new lamp.

Tip: Make sure the tab on the lamp locates properly in the

housing.

4. Reinstall the harness assembly into the headlight

assembly.

Brake Lights

When the brake pedal is depressed, the brake light comes on. Check the brake light before
each ride.

1. Turn the ignition switch to the ON position.

2. Depress the brake pedal. The brake light should come on after about 10 mm (0.4 in.) of

pedal travel.

Connector

68

MAINTENANCE

Lights

Headlight Beam Adjustment

1. Place the vehicle on a level surface with the headlight approximately 25 ft. (7.6 m) from
a wall.

2. Place the transmission in PARK.

3. Measure the distance from the floor to the center of the headlight and make a mark on

the wall at the same height.

4. Apply the brakes. Start the engine. Turn on the headlights.

5. Observe the headlight aim. The most intense part of the headlight beam should be aimed

8" (20 cm) below the mark placed on the wall. Include the weight of a rider on the seat
while performing this step.

6. If a headlight needs adjustment, locate the adjustment screw on the side of the headlight.

7. Loosen the screw. Adjust the headlight, then tighten the screw.

8. Repeat steps 5-7 until the lamp is properly adjusted.

25 ft.

(7.6 m)

8" (20 cm)

XX

69

MAINTENANCE

Fuses

If the engine stops or will not start, or if you experience other electrical failures, a fuse may
need replacement. Locate and correct any short circuits that may have caused the blown fuse,
then replace the fuse. Raise the passenger seat to access the fuses. Spare fuses are provided
in the fuse box. The power steering fuse (if equipped) is located on the power steering wiring
harness near the fuse box.

If you suspect that a fuse or relay may not be working properly, please see your POLARIS
dealer.

Fuse Feature Supported

10A Brake Lights

10A Fuel Pump

10A Drive System

20A Accessories, 12V Power Receptacle

20A Engine Control Module

20A Lights

30A Power Steering (if equipped)

Power Steering Fuse

(if equipped)

70

MAINTENANCE

Battery

Your vehicle has a sealed battery, which requires little maintenance. Always keep battery ter­minals and connections free of corrosion. If cleaning is necessary, remove the corrosion with
a stiff wire brush. Wash with a solution of one tablespoon baking soda and one cup water.
Rinse well with tap water and dry off with clean shop towels. Coat the terminals with dielec­tric grease or petroleum jelly.

Battery Removal

Improperly connecting or disconnecting battery cables can result in an explosion and cause serious
injury or death. When removing the battery, always disconnect the negative (black) cable first. When
reinstalling the battery, always connect the negative (black) cable last.

1. Remove the storage bin under the passenger seat to access the battery.

2. Disconnect the black (-) battery cable first. Disconnect the red (+) battery cable last.

3. Lift the battery out of the vehicle.

Battery Installation

Using a new battery that has not been fully charged can damage the battery and result in a
shorter life. It can also hinder vehicle performance. Follow the battery charging instructions
on page 71 before installing the battery.

1. Ensure that the battery is fully charged.

2. Place the fully charged battery in the battery holder. Make sure the positive terminal is

toward the driver’s side of the vehicle.

3. Coat the terminals with dielectric grease or petroleum jelly.

4. Connect and tighten the red (+) cable first. Connect and tighten the black (-) cable last.

5. Install the hold-down strap.

6. Reinstall the storage bin and seat.

Battery Storage

Whenever the vehicle is not used for a period of three months or more, remove the battery
from the vehicle, ensure that it's fully charged, and store it out of the sun in a cool, dry place.
Check battery voltage each month during storage and recharge as needed to maintain a full
charge. See page 71.

POLARIS recommends maintaining battery charge by using a POLARIS Battery Tender
charger or by charging about once a month to make up for normal self-discharge. Battery
Tender can be left connected during the storage period, and will automatically charge the bat­tery if the voltage drops below a pre-determined point. See page 78 for the part numbers of
POLARIS products.

WARNING

71

MAINTENANCE

Battery

Battery Charging

The following battery charging instructions apply only to the installation of a sealed battery.
Read all instructions before proceeding with the installation of this battery.

The sealed battery is already filled with electrolyte and has been sealed and fully charged at
the factory. Never pry the sealing strip off or add any other fluid to this battery.

The single most important thing about maintaining a sealed battery is to keep it fully
charged. Since the battery is sealed and the sealing strip cannot be removed, you must use a
voltmeter or multimeter to measure DC voltage.

WARNING! An overheated battery may explode, causing severe injury or death. Always watch
charging times carefully. Stop charging if the battery becomes very warm to the touch. Allow it to cool
before resuming charging.

For a refresh charge, follow all instructions carefully.

1. Check the battery voltage with a voltmeter or multimeter. A fully charged battery will
register 12.8 V or higher.

2. If the voltage is less than 12.8 volts, recharge the battery at 1.2 amps or less until battery

voltage is 12.8 or greater.

3. When using an automatic charger, refer to the charger manufacturer's instructions for

recharging. When using a constant current charger, use the guidelines below for recharg­ing.

Always verify battery condition before and 1-2 hours after the end of charging.

State of

Charge

Voltage Action

Charge Time

(Using constant current

charger @ standard amps

specified on top of battery)

100% 12.8-13.0 volts None, check at 3 mos. from date of

manufacture

None required

75%-100% 12.5-12.8 volts May need slight charge, if no charge

given, check in 3 months

3-6 hours

50%-75% 12.0-12.5 volts Needs charge 5-11 hours
25%-50% 11.5-12.0 volts Needs charge At least 13 hours,

verify state of charge

0%-25% 11.5 volts or less Needs charge with desulfating charger At least 20 hours

72

MAINTENANCE

Cleaning and Storage

Washing the Vehicle

Keeping your POLARIS vehicle clean will not only improve its appearance but it can also
extend the life of various components.

NOTICE: High water pressure may damage components. POLARIS recommends washing the vehicle

by hand or with a garden hose, using mild soap.

NOTICE: Certain products, including insect repellents and chemicals, will damage plastic surfaces.

Do not allow these types of products to contact the vehicle.

The best and safest way to clean your POLARIS vehicle is with a garden hose and a pail of
mild soap and water.

1. Use a professional-type washing cloth, cleaning the upper body first and the lower parts
last.

2. Rinse with clean water frequently.

3. Dry surfaces with a chamois to prevent water spots.

Washing Tips

• Avoid the use of harsh cleaners, which can scratch the finish.

• Do not use a power washer to clean the vehicle.

• Do not use medium to heavy duty compounds on the finish.

• Always use clean cloths and pads for cleaning and polishing. Old or reused cloths and

pads may contain dirt particles that will scratch the finish.

• Grease all zerk fittings immediately after washing. Allow the engine to run for a while to

evaporate any water that may have entered the engine or exhaust system.

If a high pressure water system is used for cleaning (not recommended), exercise extreme
caution. The water may damage components and could remove paint and labels. Avoid
directing the water stream at the following items:

If an informational or graphic label becomes illegible or comes off, contact your POLARIS
dealer to purchase a replacement. Replacement safety labels are provided by POLARIS at no
charge.

Polishing the Vehicle

POLARIS recommends the use of common household aerosol furniture polish for polishing
the finish on your POLARIS vehicle. Follow the instructions on the container.

• Avoid the use of automotive products, some of which can scratch the finish of your vehi-

cle.

• Always use clean cloths and pads for cleaning and polishing. Old or reused cloths and

pads may contain dirt particles that will scratch the finish.

• Wheel bearings • Brakes • Switches and controls

• Radiator • Cab and body panels • Electrical components and wiring

• Transmission seals • Labels and decals

73

MAINTENANCE

Cleaning and Storage

Storage Tips

NOTICE: Starting the engine during the storage period will disturb the protective film created by

fogging and damage could occur. Never start the engine during the storage period.

Clean the Exterior

Make any necessary repairs and clean the vehicle as recommended. See page 72.

Stabilize the Fuel

1. Fill the fuel tank.

2. Add POLARIS Carbon Clean Fuel Treatment or POLARIS Fuel Stabilizer. Follow the
instructions on the container for the recommended amount. Carbon Clean removes water
from fuel systems, stabilizes fuel and removes carbon deposits from pistons, rings,
valves and exhaust systems.

3. Allow the engine to run for 15-20 minutes to allow the stabilizer to disperse through the
entire fuel delivery system.

Oil and Filter

Change the oil and filter. See page 51.

Air Filter / Air Box

1. Replace the air filter. See page 60.

2. Clean the air box.

74

MAINTENANCE

Cleaning and Storage

Storage Tips

Inspect and Lubricate

Inspect all cables and lubricate all areas of the vehicle as recommended in the Periodic Main­tenance Chart beginning on page 47.

Battery Maintenance

See page 70 for storage and charging procedures.

Fluid Levels

Inspect the fluid levels. Add or change fluids as recommended in the Periodic Maintenance
Chart beginning on page 47.

• Front gearcase fluid

• Transmission fluid

• Brake fluid (change every two years and any time the fluid looks dark or contaminated)

• Coolant (test strength/fill)

Fog the Engine

1. Treat the fuel system with POLARIS Carbon Clean. Follow the instructions on the con­tainer. Start the engine. Allow it to idle for several minutes so the Carbon Clean reaches
the injectors. Stop the engine.

2. Remove the spark plugs and add 2-3 tablespoons of engine oil. To access the plug holes,

use a section of clear 1/4" hose and a small plastic squeeze bottle filled with the pre­measured amount of oil. Do this carefully! If you miss the plug holes, oil will drain from
the spark plug cavities into the hole at the front of the cylinder head, and appear to be an
oil leak.

3. Reinstall the spark plugs. Torque to specification. See page 55.

4. Turn the engine over several times. Oil will be forced in and around the piston rings and

ring lands, coating the cylinder with a protective film of fresh oil.

5. Apply dielectric grease to the inside of each spark plug cap and reinstall the caps onto

the plugs.

6. If POLARIS fuel system additive is not used, fuel tank, fuel lines and injectors should be

completely drained of gasoline.

Storage Area/Covers

Be sure the storage area is well ventilated. Cover the vehicle with a genuine POLARIS
cover. Do not use plastic or coated materials. They do not allow enough ventilation to pre­vent condensation, and may promote corrosion and oxidation.

75

MAINTENANCE

Removal from Storage

1. Charge the battery if necessary. Install it in the vehicle.

2. Make sure the spark plug is tight.

3. Fill the fuel tank with fuel.

4. Check all the points listed in the Daily Pre-Ride Inspection section on page 32. Tightness

of the bolts, nuts and other fasteners should be checked by an authorized POLARIS
dealer.

5. Lubricate at the intervals outlined in the Periodic Maintenance Chart beginning on page

47.

Transporting the RANGER

Follow these procedures when transporting the vehicle.

1. Place the transmission in PARK.

2. Stop the engine.

3. Secure the fuel cap, hood, seats and cargo box.

4. Always tie the frame of the RANGER to the transporting unit securely with suitable

straps or rope. Do not attach tie straps to the front A-arm bolt pockets.

5. Remove the key to prevent loss during transporting.

76

SPECIFICATIONS

RANGER XP 900

Maximum Weight Capacity 1500 lbs. (681 kg) (including operator, passenger, cargo, accessories)

1100 lbs. (499 kg) (Models sold in California)

Dry Weight 1360 lbs. (617 kg)

Fuel Capacity 10 gal. (37.8 l)

Engine Oil Capacity 2.5 qts. (3.4 l)

Coolant Capacity 5 qts. (4.75 l)

Towing Capacity 2000 lbs. (907 kg)

Hitch Tongue Capacity 150 lbs. (68 kg)

Max. Cargo Box Load* 1000 lbs. (454 kg)

600 lbs. (272 kg) (Models sold in California)

Overall Length 116 in. (295 cm)

Overall Width (box) 60 in. (152.4 cm)

Overall Width (tires) 58 in. (147.3 cm)

Overall Height 76 in. (193 cm)

Wheelbase 81 in. (205.7 cm)

Cargo Box Dimensions (Inside) 36.5 x 54 x 11.5 in. (93 x 137 x 29 cm)

Ground Clearance 12 in. (30.5 cm)

Min. Turning Radius 161 in. (409 cm)

Engine 4-Stroke DOHC Twin Cylinder

Displacement 875 cc

Bore x Stroke 93mm x 64.4mm

Alternator Output 575 W @ 3000 RPM

Compression Ratio 10.5:1

Starting System Electric

Fuel System Electronic fuel injection

Ignition System Electronic

Spark Plug / Gap RG4YCX / 0.7-0.8 mm

Front Suspension Dual A-arm w/10 in. (25.4 cm) of travel

Rear Suspension Independent w/10 in. (25.4 cm) of travel

Lubrication System Wet Sump

Engine Oil POLARIS 2W-50

77

SPECIFICATIONS

Clutching

See your POLARIS dealer for clutching specifications.

RANGER XP 900

Driving System Type PVT, 4-wheel independent shaft, lockable differential

Shift Type Single Lever (H/L/N/R/P)

Gear Reduction - Low 8.56:1

Gear Reduction - Reverse 7.67:1

Gear Reduction - High 3.48:1

Drive Ratio - Front: 3.818:1

Tire Size - Front 25 x 10 - 12 (26 x 9 - 12 for select models)

Tire Size - Rear 25 x 11 - 12 (26 x 11 - 12 for select models)

Tire Pressure - Front 10 psi (69 kPa)

Tire Pressure - Rear 12 psi (83 kPa)

Brakes, Front/Rear Foot Activated, 4 wheel hydraulic disc

Hood Headlight 2 single beam, 50W, quartz/halogen

Taillights 10 L.E.D. (.28W)

Brake Light 10 L.E.D. (3.1W)

78

POLARIS PRODUCTS

Part Number Description

Engine Lubricant

2870791 Fogging Oil (12 oz./355 ml Aerosol)

2876244 PS-4 PLUS Performance Synthetic 2W-50 4-Cycle Oil (qt./.95 l)

2876245 PS-4 PLUS Performance Synthetic 2W-50 4-Cycle Oil (gal./3.8 l)

Gearcase / Transmission Lubricants

2878068 AGL PLUS Transmission Fluid (qt./.95 l)

2878069 AGL PLUS Transmission Fluid (gal./3.8 l)

2877922 Demand Drive Plus Fluid (qt./.95 l)

2877923 Demand Drive Plus Fluid (gal./3.8 l)

2871653 Premium ATV Angle Drive Fluid (8 oz./237 ml)

2872276 Premium ATV Angle Drive Fluid (2.5 gal./9.5 l)

2870465 Pump for Gallon (3.8 l) Jug

Coolant

2871323 60/40 Coolant (gal./3.8 l)

2871534 60/40 Coolant (qt./.95 l)

Grease / Specialized Lubricants

2871312 Grease Gun Kit, Premium All Season

2871322 Premium All Season Grease (3 oz./89 ml cartridge)

2871423 Premium All Season Grease (14 oz./414 ml cartridge)

2871460 Starter Drive Grease

2871515 Premium U-Joint Lube (3 oz./89 ml cartridge)

2871551 Premium U-Joint Lube (14 oz./414 ml cartridge)

2871329 Dielectric Grease (Nyogel™)

2872073 Chain Lube, Aerosol (6.25 oz.)

2872348 Chain Lube, Aerosol (16 oz.)

Additives / Miscellaneous

2871326 Carbon Clean Plus

2872189 DOT 4 Brake Fluid

2871956 Loctite™ 565 Thread Sealant

2871076 POLARIS Battery Tender™ Charger

79

TROUBLESHOOTING

Drive Belt Wear/Burn

Possible Cause Solution

Driving onto a pickup or tall
trailer in high range

Use low range during loading.

Starting out going up a steep
incline

Use low range. See warnings on page 37.

Driving at low RPM or ground
speed (3-7 MPH)

Drive at a higher speed or use low range more frequently.

Insufficient warm-up at low
ambient temperatures

Warm the engine at least 5 minutes. With the transmission in neutral,
advance the throttle to about 1/8 throttle in short bursts, 5 to 7 times. The
belt will become more flexible and prevent belt burning.

Slow/easy clutch engagement Use the throttle quickly and effectively.

Towing/pushing at low RPM/low
ground speed

Use low range only.

Utility use/plowing Use low range only.

Stuck in mud or snow Shift the transmission to low range and carefully use fast, aggressive throt-

tle application to engage clutch.
WARNING: Excessive throttle may cause loss of control and vehicle over-

turn.

Climbing over large objects from
a stopped position

Shift the transmission to low range and carefully use fast, brief, aggressive
throttle application to engage clutch.

WARNING: Excessive throttle may cause loss of control and vehicle over­turn.

Belt slippage from water or snow
ingestion into the PVT system

Dry out the PVT. See page 59. Inspect clutch seals for damage if repeated
leaking occurs.

Clutch malfunction See your POLARIS dealer.

Poor engine performance Check for fouled plugs or foreign material in gas tank or fuel lines. See

your dealer.

Slippage from failure to warm up
belt

Always warm up the belt by operating below 30 MPH for one mile (5
miles or more when temperature is below freezing).

Wrong or missing belt Install the recommended belt.

Improper break-in Always break in a new belt and/or clutch. See pages 31 and 58.

80

TROUBLESHOOTING

Engine Doesn't Turn Over

Engine Turns Over, Fails to Start

Engine Backfires

Engine Pings or Knocks

Possible Cause Solution

Low battery voltage Recharge the battery to 12.8 VDC

Loose battery connections Check all connections and tighten

Loose solenoid connections Check all connections and tighten

Loose electronic control box connections Inspect, clean, reinstall connectors

Possible Cause Solution

Out of fuel Refuel

Water is present in fuel Drain the fuel system and refuel

Old or non-recommended fuel Replace with fresh recommended fuel

Fouled or defective spark plugs Inspect plugs and replace if necessary

No spark to spark plug Inspect plugs and replace if necessary

Water or fuel in crankcase Immediately see your POLARIS dealer

Low battery voltage Recharge the battery to 12.8 VDC

Mechanical failure See your dealer

Possible Cause Solution

Weak spark from spark plug Inspect, clean and/or replace spark plugs

Incorrect spark plug gap or heat range Set gap to specs or replace plugs

Old or non-recommended fuel Replace with fresh recommended fuel

Incorrectly installed spark plug wires See your dealer

Mechanical failure See your dealer

Loose ignition connections Check all connections and tighten

Water present in fuel Replace with fresh recommended fuel

Possible Cause Solution

Poor quality or low octane fuel Replace with recommended fuel

Incorrect spark plug gap or heat range Set gap to specs or replace plugs

81

TROUBLESHOOTING

Engine Runs Irregularly, Stalls or Misfires

Engine Stops or Loses Power

Possible Cause Solution

Fouled or defective spark plugs Inspect, clean and/or replace spark plugs

Worn or defective spark plug wires See your dealer

Incorrect spark plug gap or heat range Set gap to specs or replace plugs

Loose ignition connections Check all connections and tighten

Water present in fuel Replace with new fuel

Low battery voltage Recharge battery to 12.8 VDC

Incorrect fuel Replace with recommended fuel

Clogged air filter Inspect and clean or replace

Clogged intake screen Inspect and clean (with soapy water) or replace

Throttle release switch malfunction See your dealer

Other mechanical failure See your dealer

Possible Cause Solution

Out of fuel Refuel

Water is present in fuel Replace with new fuel

Fouled or defective spark plugs Inspect, clean and/or replace spark plug

Worn or defective spark plug wires See your dealer

Incorrect spark plug gap or heat range Set gap to specs or replace plug

Loose ignition connections Check all connections and tighten

Low battery voltage Recharge the battery to 12.8 VDC

Incorrect fuel Replace with fresh recommended fuel

Clogged air filter Inspect and clean or replace

Clogged intake screen Inspect and clean (with soapy water) or replace

Throttle release switch malfunction See your dealer

Other mechanical failure See your dealer

Overheated engine Clean radiator screen and core, clean engine exterior,

see your dealer

82

WARRANTY

LIMITED WARRANTY

POLARIS Sales Inc., 2100 Highway 55, Medina, MN 55340, gives a SIX MONTH LIMITED WARRANTY on
all components of the POLARIS RANGER against defects in material or workmanship. POLARIS also gives a
one year limited warranty on the final drive chain (if equipped) for failure due to defects. Waranty period will
vary by region. This warranty covers the parts and labor charges for repair or replacement of defective parts
which are covered by this warranty. This warranty begins on the date of purchase. This warranty is transferable to
another consumer during the warranty period through a POLARIS dealer.

REGISTRATION

At the time of sale, the Warranty Registration Form must be completed by your dealer and submitted to
POLARIS within ten days. Upon receipt of this registration, POLARIS will record the registration for warranty.
No verification of registration will be sent to the purchaser as the copy of the Warranty Registration Form will be
the warranty entitlement. If you have not signed the original registration and received the customer copy, please
contact your dealer immediately. NO WARRANTY COVERAGE WILL BE ALLOWED UNLESS YOUR
VEHICLE IS REGISTERED WITH POLARIS.

Initial dealer preparation and set-up of your vehicle is very important in ensuring 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, normal wear and tear, abuse or improper handling. This war­ranty also does not cover any vehicle that has been altered structurally, modified, neglected, improperly main­tained, used for racing, or used for purposes other than for which it was manufactured, or for any damages which
occur during trailer transit or as a result of unauthorized service or the use of unauthorized parts. In addition, this
warranty does not cover physical damage to paint or finish, stress cracks, tearing or puncturing of upholstery
material, corrosion, or defects in parts, components or the vehicle due to fire, explosions or any other cause
beyond POLARIS' control.

Warranty does not apply to parts exposed to friction surfaces, stresses, environmental conditions and/or contami­nation for which they were not designed or not intended, including but not limited to the following items:

Warranty applies to the product only and does not allow for coverage of personal loss. Some items are considered
“consumable,” meaning they are considered part of normal maintenance or part of completing an effective repair.
The following items are excluded from warranty coverage in the event of a warranty claim:

• Wheels and tires • Finished and unfinished surfaces

• Suspension components • Carburetor/Throttle body components

• Brake components • Engine components

• Seat components • Drive belts

• Clutches and components • Hydraulic components

• Steering components • Circuit breakers/Fuses

• Batteries • Electronic components

• Light bulbs/Sealed beam lamps

• Spark Plugs • Lubricants such as oil, grease, etc.

• Filters • Batteries (unless defective)

• Fuel • Cosmetic damage/repair

• Sealants • Coolants

• Hotel fees • Meals

• Towing charges • Shipping/ handling fees

• Mileage • Product pick-up/delivery

• Rentals/Loss of product use • Loss of vacation/personal time

83

WARRANTY

LIMITATIONS OF WARRANTIES AND REMEDIES

This warranty also excludes failures resulting from improper lubrication; improper engine timing; improper fuel;
surface imperfections caused by external stress, heat, cold or contamination; operator error or abuse; improper
component alignment, tension, adjustment or altitude compensation; failure due to snow, water, dirt or other for­eign substance ingestion/contamination; improper maintenance; modified components; use of aftermarket com­ponents resulting in failure; unauthorized repairs; repairs made after the warranty period expires or by an
unauthorized repair center; use of the product in competition or for commercial purposes. Warranty will not apply
to any product which has been damaged by abuse, accident, fire or any other casualty not determined a defect of
materials or workmanship.

This warranty does not cover the use of unauthorized lubricants, chemicals, or fuels that are not compatible with
the vehicle. The exclusive remedy for breach of this warranty shall be, at POLARIS' exclusive option, repair or
replacement of any defective materials, or components or products. THE REMEDIES SET FORTH IN THIS
WARRANTY ARE THE ONLY REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF THIS WAR­RANTY. POLARIS SHALL HAVE NO LIABILITY TO ANY PERSON FOR INCIDENTAL, CONSEQUEN­TIAL OR SPECIAL DAMAGES OF ANY DESCRIPTION, WHETHER ARISING OUT OF EXPRESS OR
IMPLIED WARRANTY OR ANY OTHER CONTRACT, NEGLIGENCE, OR OTHER TORT OR OTHER­WISE. THIS EXCLUSION OF CONSEQUENTIAL, INCIDENTAL, AND SPECIAL DAMAGES IS INDE­PENDENT FROM AND SHALL SURVIVE ANY FINDING THAT THE EXCLUSIVE REMEDY FAILED OF
ITS ESSENTIAL PURPOSE. Some states do not permit the exclusion or limitation of incidental or consequential
damages or implied warranties, so the above limitations or exclusions may not apply to you if inconsistent with
controlling state law.

California Residents

The model year 2013 RANGER XP 900 is available in 49-state and 50-state versions. Only the 50-state models
are certified for sale in California. The 50-state models available for sale in California are identified by the letter
“C” in the 10th digit of the model name (e.g., R13UH88A_C).

The 50-state RANGER XP 900 models are designed and built with a 600-pound (272-kg) cargo box capacity. Any
modifications to the factory-built suspension system, or any other means of altering the cargo box capacity, may
be a violation of the applicable California regulations and may void all warranty offered by the manufacturer.

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 WARRANTY PERIOD. POLARIS FURTHER DISCLAIMS ALL EXPRESS
WARRANTIES NOT STATED IN THIS WARRANTY. Some states do not allow limitations on how long an
implied warranty lasts, so the above limitation may not apply to you if inconsistent with controlling state law.

HOW TO OBTAIN WARRANTY SERVICE

If your vehicle requires warranty service, you must take it to a POLARIS Servicing Dealer. When requesting war­ranty service you must present your copy of the Warranty 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 POLARIS.

This warranty gives you specific legal rights, and you may also have other rights which vary from state to state.
If any of the above terms are void because of state or federal law, all other warranty terms will remain in effect.

Lubricants

1. Mixing oil brands or using non-recommended oil may cause engine damage. We recommend the use of
POLARIS engine oil.

2. Damage resulting from the use of non-recommended lubricants may not be covered by warranty.

84

WARRANTY

SPARK ARRESTER

POLARIS warrants that the spark arrester in this vehicle will meet the efficiency requirements of USFS standard
5100-1c for at least 1000 hours when subjected to normal use and when maintenance and installation are in accor­dance with POLARIS recommendations.

Exported Vehicles

EXCEPT WHERE SPECIFICALLY REQUIRED BY LAW, THERE IS NO WARRANTY OR SERVICE BUL­LETIN COVERAGE ON THIS VEHICLE IF IT IS SOLD OUTSIDE THE COUNTRY OF THE SELLING
DEALER'S AUTHORIZED LOCATION.

This policy does not apply to vehicles that have received authorization for export from POLARIS Industries.
Dealers may not give authorization for export. You should consult an authorized dealer to determine this vehicle's
warranty or service bulletin coverage if you have any questions.

This policy does not apply to vehicles registered to government officials or military personnel on assignment out­side the country of the selling dealer's authorized location.

This policy does not apply to Safety Bulletins.

How to Get Service

In the Country where your vehicle was purchased:

Warranty or Service Bulletin repairs must be done by an authorized POLARIS dealer. If you move or are travel­ing within the country where your vehicle was purchased, Warranty or Service Bulletin repairs may be requested
from any authorized POLARIS dealer who sells the same line as your vehicle.

Outside the Country where your vehicle was purchased:

If you are traveling temporarily outside the country where your vehicle was purchased, you should take your
vehicle to an authorized POLARIS dealer. You must show the dealer photo identification from the country of the
selling dealer's authorized location as proof of residence. Upon residence verification, the servicing dealer will be
authorized to perform the warranty repair.

If You Move:

If you move to another country, be sure to contact POLARIS Customer Assistance and the customs department of
the destination country before you move. Vehicles importation rules vary considerably from country to country.
You may be required to present documentation of your move to POLARIS Industries in order to continue your
warranty coverage. You may also be required to obtain documentation from POLARIS Industries in order to reg­ister your vehicle in your new country. You should warranty register your vehicle at a local POLARIS dealer in
your new country immediately after you move to continue your warranty coverage and to ensure that you receive
safety information and notices regarding your vehicle.

If Purchased From A Private Party:

If you purchase a POLARIS product from a private citizen, to be kept and used outside of the country in which
the vehicle was originally purchased, all warranty coverage will be denied. You must nonetheless warranty regis­ter your vehicle under your name and address with a local POLARIS dealer in your country to ensure that you
receive safety information and notices regarding your vehicle.

Notice

If your vehicle is registered outside of the country where it was purchased, and you have not followed the proce­dure set out above, your vehicle will no longer be eligible for warranty or service bulletin coverage of any kind,
other than safety bulletins. (Vehicles registered to Government officials or military personnel on assignment out­side of the country where the vehicle was purchased will continue to be covered by the basic warranty.)

For questions call POLARIS Customer Assistance:

United States: 1-888-704-5290
Canada: 1-204-925-7100

85

WARRANTY

U.S.A. EPA Emissions Limited Warranty

This emissions limited warranty is in addition to the POLARIS standard limited warranty for your vehicle.
POLARIS Industries Inc. warrants that at the time it is first purchased, this emissions-certified vehicle is
designed, built and equipped so it conforms with applicable U.S. Environmental Protection Agency emission reg­ulations. POLARIS warrants that the vehicle is free from defects in materials and workmanship that would cause
it to fail to meet these regulations.

The warranty period for this emissions-certified vehicle starts on the date the vehicle is first purchased and con­tinues for a period of 500 hours of engine operation, 5000 kilometers (3100 miles) of vehicle travel, or 30 calen­dar months from the date of purchase, whichever comes first.

This emissions limited warranty covers components whose failure increases the vehicle’s regulated emissions,
and it covers components of systems whose only purpose is to control emissions. Repairing or replacing other
components not covered by this warranty is the responsibility of the vehicle owner. This emissions limited war­ranty does not cover components whose failure does not increase the vehicle’s regulated emissions.

For exhaust emissions, emission-related components include any engine parts related to the following systems:

The following parts are also considered emission-related components for exhaust emissions:

The following parts are considered emission-related components for evaporative emissions:

*As related to the evaporative emission control system.
The exclusive remedy for breach of this limited warranty shall be, at the exclusive option of POLARIS, repair or

replacement of any defective materials, components or products. THE REMEDIES SET FORTH IN THIS LIM­ITED WARRANTY ARE THE ONLY REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF THIS
WARRANTY. POLARIS SHALL HAVE NO LIABILITY TO ANY PERSON FOR INCIDENTAL, CONSE­QUENTIAL OR SPECIAL DAMAGES OF ANY DESCRIPTION,WHETHER ARISING OUT OF EXPRESS
OR IMPLIED WARRANTY OR ANY OTHER CONTRACT, NEGLIGENCE OR OTHER TORT OR OTHER­WISE. THIS EXCLUSION OF CONSEQUENTIAL, INCIDENTAL, AND SPECIAL DAMAGES IS INDE­PENDENT FROM AND SHALL SURVIVE ANY FINDING THAT THE EXCLUSIVE REMEDY FAILED OF
ITS ESSENTIAL PURPOSE.

ALL IMPLIED WARRANTIES (INCLUDING BUT NOT LIMITED TO ANY IMPLIED WARRANTIES OF
MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE) ARE LIMITED IN DURATION TO
THE WARRANTY PERIOD DESCRIBED HEREIN. POLARIS DISCLAIMS ALL EXPRESS WARRANTIES
NOT STATED IN THIS WARRANTY. Some states do not allow limitations on how long an implied warranty
lasts, so the above limitation may not apply if it is inconsistent with the controlling state law.

• Air-induction system • Ignition system

• Fuel system • Exhaust gas recirculation systems

• Aftertreatment devices • Sensors

• Crankcase ventilation valves • Electronic control units

• Fuel Tank • Vacuum Control Diaphragms*

• Fuel Cap • Control Cables*

• Fuel Line • Control Linkages*

• Fuel Line Fittings • Purge Valves

• Clamps* • Vapor Hoses

• Pressure Relief Valves* • Liquid/Vapor Separator

• Control Valves* • Carbon Canister

• Control Solenoids* • Canister Mounting Brackets

• Electronic Controls* • Carburetor Purge Port Connector

86

WARRANTY

U.S.A. EPA Emissions Limited Warranty

This limited warranty excludes failures not caused by a defect in material or workmanship.This limited warranty
does not cover damage due to accidents, abuse or improper handling, maintenance or use. This limited warranty
also does not cover any engine that has been structurally altered, or when the vehicle has been used in racing
competition. This limited warranty also does not cover physical damage, corrosion or defects caused by fire,
explosions or other similar causes beyond the control of POLARIS.

Owners are responsible for performing the scheduled maintenance identified in the owner's manual. POLARIS
may deny warranty claims for failures that have been caused by the owner’s or operator’s improper maintenance
or use, by accidents for which POLARIS has no responsibility, or by acts of God.

Any qualified repair shop or person may maintain, replace, or repair the emission control devices or systems on
your vehicle. POLARIS recommends that you contact an authorized POLARIS dealer to perform any service that
may be necessary for your vehicle. POLARIS also recommends that you use only Pure POLARIS parts. It is a
potential violation of the Clean Air Act if a part supplied by an aftermarket parts manufacturer reduces the effec­tiveness of the vehicle's emission controls. Tampering with emission controls is prohibited by federal law.

If you have any questions regarding your warranty rights and responsibilities, please contact the POLARIS War­ranty Department at 1-888-704-5290.

87

MAINTENANCE LOG

Use the following chart to record periodic maintenance.

DATE MILES (KM)

OR HOURS

TECHNICIAN SERVICE PERFORMED / COMMENTS

88

INDEX

A

Accessory Outlets . . . . . . . . . . . . . . . . . . . . . . . . 19

Air Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

Air Filter Cleaning . . . . . . . . . . . . . . . . . . . . . . . . 60

All Wheel Drive . . . . . . . . . . . . . . . . . . . . . . . 44-45

Disengaging AWD . . . . . . . . . . . . . . . 44

Engaging AWD. . . . . . . . . . . . . . . . . . 44

Locking the Differential . . . . . . . . . . . 45

All Wheel Drive Switch. . . . . . . . . . . . . . . . . . . . 20

Arrester, Spark, Warning . . . . . . . . . . . . . . . . . . . 61

Auxiliary Outlets . . . . . . . . . . . . . . . . . . . . . . . . . 19

Axle Nut Inspection. . . . . . . . . . . . . . . . . . . . . . . 65

Axle Nut Torque . . . . . . . . . . . . . . . . . . . . . . . . . 65

B

Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-71

Charging . . . . . . . . . . . . . . . . . . . . . . . 71

Installation . . . . . . . . . . . . . . . . . . . . . 70

Removal . . . . . . . . . . . . . . . . . . . . . . . 70

Storage . . . . . . . . . . . . . . . . . . . . . . . . 70

Beam Adjustment, Headlight. . . . . . . . . . . . . . . . 68

Belt Burning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

Belt Life. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Belt Replacement. . . . . . . . . . . . . . . . . . . . . . . . . 58

Belt Wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

Boots . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Brake Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

Brake Inspection . . . . . . . . . . . . . . . . . . . . . . . . . 63

Brake Light Inspection . . . . . . . . . . . . . . . . . . . . 67

Brake Pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62-63

Braking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Break-In Period . . . . . . . . . . . . . . . . . . . . . . . . . . 31

C

Cab Frame, ROPS . . . . . . . . . . . . . . . . . . . . . . . . 24

Cab Nets. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Cargo . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Cargo Box, Dumping. . . . . . . . . . . . . . . . . . . . . . 43

Chart, Gearcase Specifications . . . . . . . . . . . . . . 53

Chart, Periodic Maintenance . . . . . . . . . . . . . . 47-49

Check Engine Indicator . . . . . . . . . . . . . . . . . . . . 30

Cleaning and Storage. . . . . . . . . . . . . . . . . . . . 72-74

Clothing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Clutching . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

Component Locations . . . . . . . . . . . . . . . . . . . . . 18

Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Coolant Level, Overflow Bottle (Coolant) . . . . . 57

Coolant Level, Radiator. . . . . . . . . . . . . . . . . . . . 57

Coolant, Adding or Changing . . . . . . . . . . . . . . . 56

Cooling Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

Cooling System . . . . . . . . . . . . . . . . . . . . . . . . 56-57

Crankcase Emission Control System. . . . . . . . . . 46

D

Differential Lock Switch . . . . . . . . . . . . . . . . . . . . 20

Differential Locking . . . . . . . . . . . . . . . . . . . . . . . 45

Disengaging AWD . . . . . . . . . . . . . . . . . . . . . . . . 44

Display Units, Standard/Metric . . . . . . . . . . . . . . . 28

Drive Belt Wear. . . . . . . . . . . . . . . . . . . . . . . . . . . 79

Drivetrain Break-In . . . . . . . . . . . . . . . . . . . . . . . . 31

Driving Downhill. . . . . . . . . . . . . . . . . . . . . . . . . . 37

Driving in Reverse. . . . . . . . . . . . . . . . . . . . . . . . . 39

Driving on a Sidehill . . . . . . . . . . . . . . . . . . . . . . . 37

Driving on Slippery Surfaces . . . . . . . . . . . . . . . . 36

Driving Over Obstacles . . . . . . . . . . . . . . . . . . . . . 35

Driving Procedure . . . . . . . . . . . . . . . . . . . . . . . . . 34

Driving Through Water . . . . . . . . . . . . . . . . . . . . . 38

Driving Uphill . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Driving with a Passenger . . . . . . . . . . . . . . . . . . . . 35

Driving, After Driving in Water . . . . . . . . . . . . . . 59

Drying the Transmission . . . . . . . . . . . . . . . . . . . . 59

Dumping the Cargo Box . . . . . . . . . . . . . . . . . . . . 43

E

Electromagnetic Interference. . . . . . . . . . . . . . . . . 46

Electronic Power Steering . . . . . . . . . . . . . . . . . . . 21

Emission Control, Crankcase . . . . . . . . . . . . . . . . 46

Emission Control, Exhaust . . . . . . . . . . . . . . . . . . 46

Emission Control, Noise . . . . . . . . . . . . . . . . . . . . 46

Emissions Limited Warranty. . . . . . . . . . . . . . 85-86

Engaging AWD . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

Engine Break-In. . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Engine Fogging . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-52

Engine Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Engine Stopping . . . . . . . . . . . . . . . . . . . . . . . . . . 33

EPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Equipment Modifications . . . . . . . . . . . . . . . . . . . 14

Error Codes, Engine . . . . . . . . . . . . . . . . . . . . . . . 30

Exhaust Emission Control System . . . . . . . . . . . . 46

Exhaust System Warning . . . . . . . . . . . . . . . . . . . 61

Eye Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

F

Fan, Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

Filter Cleaning, Air . . . . . . . . . . . . . . . . . . . . . . . . 60

Filter Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

Filter, Air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

Fluid, Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

Fluid Change

Engine Oil. . . . . . . . . . . . . . . . . . . . 51-52

Front Gearcase . . . . . . . . . . . . . . . . . . 54

Main Gearcase . . . . . . . . . . . . . . . . . . 53

Transmission. . . . . . . . . . . . . . . . . . . . 53

Fluid Level

Engine Oil. . . . . . . . . . . . . . . . . . . . . . 51

Front Gearcase . . . . . . . . . . . . . . . . . . 54

Main Gearcase . . . . . . . . . . . . . . . . . . 53

Transmission. . . . . . . . . . . . . . . . . . . . 53

89

INDEX

F

Fluid Levels During Storage. . . . . . . . . . . . . . . . . 74

Fluid Part Numbers. . . . . . . . . . . . . . . . . . . . . . . . 78

Fogging the Engine. . . . . . . . . . . . . . . . . . . . . . . . 74

Fouled Plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

Front Gearcase . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

Fuel Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Fuel Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Fuel Stabilizer. . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

Fuel Tank Filler Cap. . . . . . . . . . . . . . . . . . . . . . . 23

Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

G

Gap, Spark Plug . . . . . . . . . . . . . . . . . . . . . . . . . . 55

Gasoline Handling . . . . . . . . . . . . . . . . . . . . . . . . 14

Gear Selector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Gearcase Specification Chart . . . . . . . . . . . . . . . . 53

Gearcase, Front . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

Gearcases . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53-54

Gears, Shifting . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Gloves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

H

Hauling Cargo. . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Headlight Beam Adjustment. . . . . . . . . . . . . . . . . 68

Headlight Lamp Replacement . . . . . . . . . . . . . . . 67

Helmet. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Hitch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Hitch Weight. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Hood Latches . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

I

Ignition Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Indicator Lamps . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Inspection, Pre-Ride . . . . . . . . . . . . . . . . . . . . . . . 32

Instrument Cluster. . . . . . . . . . . . . . . . . . . . . . 26-30

Intake Screens. . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

Interference, Electromagnetic. . . . . . . . . . . . . . . . 46

K

Key, Periodic Maintenance Chart . . . . . . . . . . . . . 47

L

Lamp Replacement, Headlight . . . . . . . . . . . . . . . 67

Light Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67-68

Load Capacity. . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Lubrication Recommendations. . . . . . . . . . . . . . . 50

M

Maintenance Log . . . . . . . . . . . . . . . . . . . . . . . . . 87

Maintenance, Periodic . . . . . . . . . . . . . . . . . . 47-49

Metric Display . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Mode Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Modifications to Vehicle . . . . . . . . . . . . . . . . . . . 14

N

Noise Emission Control System . . . . . . . . . . . . . . 46

O

Obstacles. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Oil

Engine . . . . . . . . . . . . . . . . . . . . . . 50-52

Transmission . . . . . . . . . . . . . . . . . . . . 53

Oil and Filter Care During Storage. . . . . . . . . . . . 73

Oil Change

Engine . . . . . . . . . . . . . . . . . . . . . . 51-52

Front Gearcase . . . . . . . . . . . . . . . . . . . 54

Main Gearcase . . . . . . . . . . . . . . . . . . . 53

Transmission . . . . . . . . . . . . . . . . . . . . 53

Oil Level

Engine . . . . . . . . . . . . . . . . . . . . . . . . . 51

Front Gearcase . . . . . . . . . . . . . . . . . . . 54

Main Gearcase . . . . . . . . . . . . . . . . . . . 53

Transmission . . . . . . . . . . . . . . . . . . . . 53

Oil Recommendation, Engine. . . . . . . . . . . . . . . . 50

Operation on Public Lands . . . . . . . . . . . . . . . . . . 46

Operator Safety . . . . . . . . . . . . . . . . . . . . . . . . 12-17

Outlets, Auxiliary . . . . . . . . . . . . . . . . . . . . . . . . . 19

P

Parking on an Incline . . . . . . . . . . . . . . . . . . . . . . 40

Parking the Vehicle. . . . . . . . . . . . . . . . . . . . . . . . 40

Part Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

Periodic Maintenance Chart . . . . . . . . . . . . . . 47-49

Plug Gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

Plug Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

Plug, Accessory . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Plugs, Fouled . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

Plugs, Spark . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

Polaris Products . . . . . . . . . . . . . . . . . . . . . . . . . . 78

Polishing the Vehicle . . . . . . . . . . . . . . . . . . . . . . 72

Power Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Power Steering Unit (Cleaning) . . . . . . . . . . . . . . 66

Pre-Ride Inspection . . . . . . . . . . . . . . . . . . . . . . . 32

Product Part Numbers. . . . . . . . . . . . . . . . . . . . . . 78

Public Lands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

PVT Break-In . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

PVT Drying . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

PVT System . . . . . . . . . . . . . . . . . . . . . . . . . . 58-59

PVT Warning . . . . . . . . . . . . . . . . . . . . . . . . . 58-59

PVT, Cleaning Debris. . . . . . . . . . . . . . . . . . . . . . 58

R

Radiator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

Radiator Coolant Level. . . . . . . . . . . . . . . . . . . . . 57

Rear Suspension Adjustment . . . . . . . . . . . . . . . . 64

Receiver Hitch . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Removing the Vehicle from Storage . . . . . . . . . . 75

Reverse Operation . . . . . . . . . . . . . . . . . . . . . . . . 39

Rider Information Center . . . . . . . . . . . . . . . . 27-30

Riding Gear. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Rollover Protective Structure . . . . . . . . . . . . . . . . 24

ROPS Cab Frame . . . . . . . . . . . . . . . . . . . . . . . . . 24

90

INDEX

S

Safety Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-10

Safety Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Seat Belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Seat Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Severe Use Definition . . . . . . . . . . . . . . . . . . . . . 47

Shifter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Shifting Gears . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Shock Spring Adjustment . . . . . . . . . . . . . . . . . . 64

Signal Words . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Spark Arrester Warning. . . . . . . . . . . . . . . . . . . . 61

Spark Plug Gap . . . . . . . . . . . . . . . . . . . . . . . . . . 55

Spark Plug Inspection . . . . . . . . . . . . . . . . . . . . . 55

Spark Plug Recommendations. . . . . . . . . . . . . . . 55

Spark Plug Torque. . . . . . . . . . . . . . . . . . . . . . . . 55

Spark Plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

Spark Plugs, Fouled. . . . . . . . . . . . . . . . . . . . . . . 55

Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . 76-77

Specifications, Gearcase . . . . . . . . . . . . . . . . . . . 53

Speed, Towing . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Speedometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Spring, Shock, Adjustment . . . . . . . . . . . . . . . . . 64

Stabilizing the Fuel . . . . . . . . . . . . . . . . . . . . . . . 73

Starting the Engine . . . . . . . . . . . . . . . . . . . . . . . 33

Steering Wheel Inspection . . . . . . . . . . . . . . . . . . 63

Steering Wheel, Adjustment . . . . . . . . . . . . . . . . 21

Stopping the Engine. . . . . . . . . . . . . . . . . . . . . . . 33

Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72-74

Storage Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

Storage Compartment, Under-Seat . . . . . . . . . . . 22

Storage, Battery . . . . . . . . . . . . . . . . . . . . . . . . . . 70

Storage, Covers . . . . . . . . . . . . . . . . . . . . . . . . . . 74

Storage, Fluid Levels. . . . . . . . . . . . . . . . . . . . . . 74

Storage, Oil and Filter . . . . . . . . . . . . . . . . . . . . . 73

Storage, Removal. . . . . . . . . . . . . . . . . . . . . . . . . 75

Suspension Adjustment, Rear . . . . . . . . . . . . . . . 64

Switches

AWD Switch. . . . . . . . . . . . . . . . . . . . 20

Differential Lock Switch . . . . . . . . . . 20

Ignition . . . . . . . . . . . . . . . . . . . . . . . . 20

Light . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Mode Button . . . . . . . . . . . . . . . . . . . . 20

T

Tachometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Throttle Pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Tilt Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Tire Tread Depth . . . . . . . . . . . . . . . . . . . . . . . . . . 65

Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65-66

Torque, Axle Nuts . . . . . . . . . . . . . . . . . . . . . . . . . 65

Torque, Spark Plug . . . . . . . . . . . . . . . . . . . . . . . . 55

Torque, Wheel Nut . . . . . . . . . . . . . . . . . . . . . . . . 65

Towing Loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Towing Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Trailer Hitch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

Transmission Operation. . . . . . . . . . . . . . . . . . 58-59

Transmission System. . . . . . . . . . . . . . . . . . . . 58-59

Transmission Warning. . . . . . . . . . . . . . . . . . . 58-59

Transmission, Drying . . . . . . . . . . . . . . . . . . . . . . 59

Transporting the Vehicle . . . . . . . . . . . . . . . . . . . . 75

Tread Depth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

U

Under-Seat Storage . . . . . . . . . . . . . . . . . . . . . . . . 22

V

Vehicle Identification Numbers . . . . . . . . . . . . . . . 6

Vehicle Immersion . . . . . . . . . . . . . . . . . . . . . . . . 59

Vehicle Transport . . . . . . . . . . . . . . . . . . . . . . . . . 75

W

Warning Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Warning, Transmission Modification . . . . . . . 58-59

Washing the Vehicle . . . . . . . . . . . . . . . . . . . . . . . 72

Water, Immersion of Vehicle . . . . . . . . . . . . . . . . 59

Wheel Installation . . . . . . . . . . . . . . . . . . . . . . . . . 66

Wheel Nut Inspection . . . . . . . . . . . . . . . . . . . . . . 65

Wheel Nut Torque . . . . . . . . . . . . . . . . . . . . . . . . . 65

Wheel Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 66