Polaris Ranger 2005, 2005 Ranger 4x4, 2005 Ranger 6x6, 2005 Ranger TM Owner's Manual For Maintenance And Safety

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WARNING

Copyright 2004 Polaris Sales Inc. All information contained within this publication is based on the latest product information at the time of publication. Due to constant improvements in the design and quality of production components, some minor discrepancies may result between the actual vehicle and the information presented in this publication. Depictions and/or procedures in this publication are intended for reference use only. No liability can be accepted for omissions or inaccuracies. Any reprinting or reuse of the depictions and/or procedures contained within, whether whole or in part, is expressly prohibited.

Printed in U.S.A.

RANGER 4X4/6X6/TM Owner’s Manual P /N 9919534

WELCOME

Thank you for purchasing a Polaris vehicle, and welcome to our world-wide family of Polaris owners. We proudly produce an exciting line of util ity and recreational products.

Polaris Recreational and Utility Vehicles

S Snowmobiles S All-terrain vehicles (ATVs) S Personal watercraft S Sport Boats S RANGER utility vehicles S Victory motorcycles

We believe Polaris sets a standard of excellence for all utility and recreational vehicles manufactured in the world today. Many years of experience have gone into the engineering, design, and development of your Polaris vehicle, making it the finest vehicle 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 inst ructions for minor maintenance, but information about major repairs i s outlined in the Polaris Service Manual and should be performed only by a Factory Certified Master Service D ealer (MSD) Technician.

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

We also take great pride in our Parts Apparel and Accessories (PAA) products, available through ou r online store at www.purepolaris.com. Have your accessories and clothing delivered right to your door!

POLARIS and POLARIS THE WAY OUT are registered trademarks of Polaris Industries Inc.

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. Your key can be duplicated only by mating a Polaris key blank with one of your existing keys, so if both keys are lost, the ignition switch must be replaced.

Vehicle Model Number: (behind left front wheel)

Frame VIN (1): (under hood)

Engine Serial Number (2): (right front side of engine crankcase)

Key Number (3):

31XX

TABLE OF CONTENTS

WELCOME 3.................................

VEHICLE IDENTIFICATION NUMBERS 4........

SAFETY 7...................................

FEATURES AND CONTROLS 25...............

OPERATION 34..............................

EMISSION CONTROL SYSTEMS 52............

MAINTENANCE AND LUBRICATION 54.........

POLARIS PRODUCTS 99......................

SPECIFICATIONS 100........................

TROUBLESHOOTING 106.....................

WARRANTY 109..............................

INDEX 117...................................

SAFETY

Operator Safety

WA R N I N G

Failure to follow the warnings contained in this manual can result in severe injury or death.

A Polaris RANGER is not a toy and can be hazardous to operate. This vehicle handles differently than other vehicles, such as motorcycles and cars. A collision or rollover can occur quickly, even during routine maneuvers like turning, or driving on hills or over obstacles, if you fail to take proper precautions.

Read and understand your owner’s manual and all warnings before operating the vehicle.

Age Restrictions

This vehicle is an ADULT VEHICLE ONLY. Operation is prohibited for anyone under 16 years of age. No person under the age of 5 may ride as a passenger i n this vehicle.

Know Your Vehicle

As the operator of the vehicle, you are responsible for your personal safety, the safety of others, and the protection of our environment. Read and understand your owner’s manual, which includes valuable information about all aspects of your vehicle, including safe operating procedures.

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

We strongly advise you t o strictly follow the recommended maintenance program outlined in your owner’s manual. This preventive maintenance program is designed to ensure that all critical components on your vehicle are thoroughly inspected at specific intervals.

SAFETY

Operator Safety

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

The safety alert symbol, on your vehicle or in this manual, alerts you to the potential for personal injury.

WA R N I N G

The safety alert warning indicates a potential hazard that may result in serious injury or death.

CAUTION

The safety alert caution indicates a potential hazard that may result in minor personal injury or damage to the vehicle.

CAUTION

A caution indicates a situation that may result in damage to the vehicle.

NOTE:

A note will alert you to important information or instructions.

SAFETY

Operator Safety

WA R N I N G

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.

S Read this manual and all l abels carefully. Follow the operating pro-

cedures described.

S Never allow anyone without a valid driver’s license to operate this

vehicle.

S Minimu m age recommendation for passengers is five years old. Pas-

sengers under five years of age require special restraints which are not available with this vehicle. Driver and passenger should wear their seat belts at all times.

S Never permit a guest to operate this vehicle unless the guest has read

this manual and all product labels.

S To reduce tipover risk, be especially careful when encountering ob-

stacles and slopes and when braking on hill s or during turns.

S This vehicle is for off road use only. Never operate on public roads.

Always avoid paved surfaces.

S Helmets are recommended whenever driving this vehicle in an

aggressive manner. Eye protection is recommended at all times.

S Never consume alcohol or drugs before or while operating this ve-

hicle.

S Never operate at excessive speeds. Always travel at a speed proper

for the terrain, visi bility and o perating conditions, and your experience.

S Never attempt wheelies, jumps or other stunts. S Always inspect your vehicle each time you us e it to make su re it’s in

safe operating condition. Always follow the inspection and maintenance procedures and schedules described in this manual.

S Always keep both hands on the steering wheel and both feet on the

floorboards of the vehicle d u ring operation.

S Always t ravel slowly and use extra caution when operating on unfa-

miliar terrain. Be alert to changing terrain.

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

SAFETY

Operator Safety

S Always follow proper procedures for turning as described in this

manual. Practice turning at slow speeds before attempting to turn at faster speeds. Never turn at excessive speeds.

S Always have this vehicle checked by an authorized Polaris dealer if

it has been involved in an accident.

S Never operate this vehicle on hills too steep for t he vehicle or for

your abilities. Practice on smaller hills b efore attempting larger hills.

S Always follow proper procedures for climbing hills as described in

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

S Always follow the proper procedures ou tlined in t his 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 t h e hill where possible.

S 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.

S Always be careful of ski dding or sliding. On slippery surfaces such

as ice, travel slowly and exercise caution to reduce the chance of skidding or sliding out of control.

S 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 ti mes to let friction dry out the pads.

S 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.

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

Always maintain proper tire pressure as specified on page 101.

SAFETY

Operator Safety

S Never modify this vehicle through improper installation or use of

accessories.

S Never exceed the stated load capacity for this vehicle. Cargo should

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

S Always wear the seat belts when operating this vehicle. Seat belts

reduce t he severity of injury in case of a sudden stop or collision.

S Always keep arms and legs inside the cab frame while the vehicle is

in motion.

S Always apply the parking brake before getting out of the vehicle.

See page 33.

S Always activate the foot pedal brake before releasing the park brake. S Always turn off the engine before refueling. Make sure the refueling

area is well ventilated and free of any source of flame or sparks. Gasoline is extremely flammable. See page 24 for refueling instructions.

S Always remove the i gnition key when the vehicle i s not in use to

prevent unauthorized use or accidental starting.

FOR MORE INFORMATION ABOUT SAFETY, call Polaris at 1-800-342-3764.

SAFETY

Operator Safety

WA R N I N G

Make sure your RANGER is in excellent operating condition at all times. We strongly recommend that the operator check all safety components before each ride.

Polaris RANGERs are designed to provide safe operation when used as directed. Failure of critical machine components may result from operation with any modifications, especially those that increase speed or power. The RANGER may become aerodynamically unstable at speeds higher than those for which it is designed. Loss of control may occur at higher speeds. Modifications may also create a safety hazard and lead to bodily injury.

Do not make any modifications to your RANGER.

Equipment Modifications

We are concerned for the safety of our customers and for the general public. Therefore, we strongly recommend that consumers do not install on a Polaris RANGER any equipment that may increase the speed or power of the vehicle, or make any other modifications to the vehicle for these purposes. Any modifications to the original equipment of the vehicle create a 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 i ncrease its speed or power.

NOTE: The addition of certain accessories, including (but not limited

to) mowers, blades, tires, sprayers, or large racks, may change the handling characteristics of the vehicle. Use only Polaris-approved accessories, and familiarize yourself with their function and effect on the vehicle.

SAFETY

Operator Safety

WA R N I N G

POTENTIAL HAZARD Stalling, rolling backwards while

climbing a hill WHAT CAN

HAPPEN Vehicle overturn HOW TO AVOID THE

HAZARD

Maintain a steady speed when climbing a hill.

If you lose all forward

speed: Apply the brakes. Lock the parking brake after when fully stopped. If you begin rolling

backwards: Never apply engine power. Apply the brake gradually. When fully stopped, lock parking brake. In the event of an accident, have a qualified service dealer check

the complete vehicle for possible damage, including (but not limited to) brakes, throttle and steering.

SAFETY

Operator Safety

WA R N I N G

POTENTIAL HAZARD Operating this vehicle on paved surfaces WHAT CAN

HAPPEN Loss of control HOW TO AVOID THE

HAZARD

This vehicle’s tires are designed for off-road use only, not for use on pavement. Paved surfaces may seriously affect handling and control of the vehicle, and may cause the vehicle to go out of control.

Avoid operating the vehicle on pavement. If you must operate on a paved surface, travel slowly and do not make sudden turns or stops.

WA R N I N G

POTENTIAL HAZARD Operating this vehicle without proper instruction WHAT CAN

HAPPEN Loss of control, accident HOW TO AVOID THE

HAZARD

The risk of an accident is greatly increased if the operator does not know how to operate the vehicle properly in different situations and on different types of terrain.

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

SAFETY

Operator Safety

WA R N I N G

POTENTIAL HAZARD Operating this vehicle on public streets, roads or highways WHAT CAN

HAPPEN Collision with another vehicle HOW TO AVOID THE

HAZARD

Never operate this vehicle on any public street, road or highway, including dirt or gravel.

In many states it’s illegal to operate vehicles of this type on public streets, roads and highways.

WA R N I N G

POTENTIAL HAZARD Operating this vehicle after consuming alcohol or drugs WHAT CAN

HAPPEN Could seriously affect your judgment. Could cause you to react more slowly. Could affect your balance and perception. Could result in an accident. HOW TO AVOID THE

HAZARD

Driving a RANGER requires your full attention. DO NOT drink alcohol or use drugs or medications before or while driving. They will reduce your alertness and slow your reaction time. In most states and provinces, it’s prohibited by law to drive while intoxicated or under the influence of drugs.

SAFETY

Operator Safety

WA R N I N G

POTENTIAL HAZARD Operating this vehicle at excessive speeds WHAT CAN

HAPPEN Loss of control, accident HOW TO AVOID THE

HAZARD

Always travel at a speed proper for the terrain, visibility and operating conditions, and your experience.

WA R N I N G

POTENTIAL HAZARD Attempting jumps and other stunts WHAT CAN

HAPPEN Loss of control, accident and/or vehicle overturn HOW TO AVOID THE

HAZARD

Never attempt jumps and other stunts. Avoid exhibition driving.

WA R N I N G

POTENTIAL HAZARD Operating on frozen bodies of water. WHAT CAN

HAPPEN Severe injury or death can result if the vehicle and/or the operator

fall through the ice. HOW TO AVOID THE

HAZARD

Never operate the RANGER on a frozen body of water.

SAFETY

Operator Safety

WA R N I N G

POTENTIAL HAZARD Failure to inspect the vehicle before operating Failure to properly maintain the vehicle WHAT CAN

HAPPEN Accident, equipment damage HOW TO AVOID THE

HAZARD

Always inspect your RANGER before each use to make sure it’s in safe operating condition.

Always follow the inspection and maintenance procedures and schedules described in the Owner’s Manual.

WA R N I N G

POTENTIAL HAZARD Failure to use extra caution when operating this vehicle on

unfamiliar terrain WHAT CAN

HAPPEN Loss of control, vehicle overturn HOW TO AVOID THE

HAZARD

Travel slowly and use extra caution when operating on unfamiliar terrain.

Always be alert to changing terrain conditions when operating the vehicle. You may come upon hidden rocks, bumps, or holes suddenly, without enough time to react.

SAFETY

Operator Safety

WA R N I N G

POTENTIAL HAZARD Failure to follow the minimum age recommendations for this

vehicle WHAT CAN

HAPPEN Serious injury or death (the child or others) HOW TO AVOID THE

HAZARD

Only persons with a valid driver’s license should operate a Polaris RANGER.

Even though a child may be within the age group for which some vehicles are recommended, he or she may not have the skills, abilities, or judgment needed to operate the vehicle safely and may be involved in a serious accident.

WA R N I N G

POTENTIAL HAZARD Operating this vehicle with improper tires or with improper or

uneven tire pressure WHAT CAN

HAPPEN Loss of control, accident and/or overturn HOW TO AVOID THE

HAZARD

Always use the size and type of tires specified in the Owner’s Manual for this vehicle. See page 101.

Always maintain proper tire pressure as described on the decal and in the Owner’s Manual. See page 101.

SAFETY

Operator Safety

WA R N I N G

Leaving the keys in the ignition can lead to unauthorized use of the vehicle resulting in serious injury or death. Always remove the ignition key when the vehicle is not in use.

WA R N I N G

After any overturn or accident, have a qualified service dealer inspect the entire vehicle for possible damage, including (but not limited to) brakes, throttle and st eering systems.

CAUTION

Always keep combustible materials away from the exhaust system. Exposure to the hot components could result in a fire.

SAFETY

Safety Decals and Locations

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

If any decal becomes illegible or comes off, contact y our Polaris dealer to purchase a replacement. Replacement safety decals are provided by Polaris at no charge. The part number is printed on the decal.

S VEHICLE ROLLOVER could cause severe injury or death. This cab frame is not designed or intended to provide rollover protection.

S ALWAYS WEAR YOUR SEAT BELT for maximum protection.

IMPROPER TIRE PRESSURE OR OVERLOADING can cause loss of control resulting in SEVERE INJURY OR DEATH.

TIRE PRESSURE (PSI): FRONT ___ REAR ___

MAXIMUM WEIGHT CAPACITY (Gross Vehicle Weight)

INCLUDING MACHINE, DRIVER AND CARGO IS _______ LBS.

Reduce s peed 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 c areful if load extends over the side of the box.

Read Owner’s Manual for more detailed loading information.

7172676

Location 1

Location 2

Location 3

WARNING

S Moving parts hazard under belt-clutch guard. To

prevent serious injury, do not operate vehicle with guard removed.

S Do not modify engine or clutch. Doing so can

cause part failure, possible imbalance, and excessive engine RPM, which can result in serious injury or death.

NO STEP

7172563

WARNING

SAFETY

Safety Decals and Locations

Fuel / Passenger Warning Decal Text

Remove flammable containers from box before refueling.

S Passengers can b e thrown off. This can cause serious i n j u ry or death. S Never carry passengers in cargo box.

Maximum 2X4 (TM) Box Load 750 lbs. (340 kg) Maximum 4X4 Box Load 1000 lbs. (454 kg) Maximum 6X6 Box Load 1250 lbs. (567 kg)

Remove flammable containers from box before refueling.

WARNING

Maximum Box Load is ___ lbs.

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

Never carry passengers in cargo box.

Location 4 (inside front of box)

SAFETY

Safety Decals and Locations

MANUFACTURED BY: POLARIS IND INC.

DATE:

VIN:

THIS VEHICLE IS A GENERAL PURPOSE OFF-ROAD UTILITY VEHICLE AND IS NOT INTENDED FOR USE ON PUBLIC ROADS.

7078472

CE VÉHICULE USAGE GENERAL VEHICULE UTILITAIRE POUR SERVICE HORS ROUTE QUI NEST PAS DESTINE A ETRE UTILISE SUR LES CHEMINS PUBLICS.

Location 5 (under hood)

ATTENTION

S Operation of this vehicle without the

filter element will severely damage the engine.

S Clean air filter often, more frequent

cleaning required in dusty conditions

S Operation of this vehicle without en-

gine breather filter(s) can cause engine damage. Consult owner’s manual for details.

S Specific carburetor jetting and adjust-

ments are required depending on temperature and altitude. See your Owner’s Manual.

Factory setting:

40_ to 80_ F. at 0-3000 feet

(5_ to 27_ C. at 0-900 meters).

7079902

Location 6

Location 7

7172674

CAUTION

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

SAFETY

Safety Decals and Locations

Discretionary Warning Decal

Improper vehicle use can result in SEVERE INJURY or DEATH.

NEVER:

S Operate on public roads. A collision can occur with another vehicle. S Carry more than two passengers, or passengers under age five. S Use ALCOHOL or DRUGS before or while operating this vehicle. S Operate at speeds too fast for yo ur skills or the conditions. S Operate thi s vehicle on HILLS steeper than 15 degrees. To prevent

flipover on hilly terrain, use throttle and brakes gradually.

ALWAYS:

S Avoid paved surfaces, which may adversely affect handling and

control.

S Use proper RIDING TECHNIQUES to avoid vehicle overturns on

hills and rough terrain and in tu rns.

S Wear eye protection. REVERSE o p eration can be dangerous, even at low speeds. Steering

becomes difficult. To prevent flipover, avoid sharp turns. The park/emergency brake lever will supply in creased braking, but

should be us ed as an emergency or parking brake only.

READ OWNER’S MANUAL. FOLLOW ALL INSTRUC TIONS

AND WARNINGS. IF OWNER’S MANUAL IS MISSING,

CONTACT A POLARIS DEALER FOR A REPLACEMENT.

THIS GENERAL PUR POSE OFF-ROAD UTILITY VEHICLE DOES

NOT MEET FEDERAL MOTOR VEHICLE SAFETY STANDARDS

FOR ON-ROAD VEHICLES.

Location 8

WARNING

7172675

SAFETY

Fuel Safety

WA R N I N G

Gasoline is highly flammable and is explosive under certain conditions. Always exercise extreme caution whenever handling gasoline.

Always stop the engine when refueling. Always refuel outdoors or in a well ventilated area. Do not smoke or allow open flames or sparks in or near the

refueling area or where gasoline is stored. Do not over fill the tank. Do not fill the tank neck. If gasoline spills on your skin or clothing, immediately wash it off

with soap and water and change clothing. Never start the engine or let it run in an enclosed area. Gasoline

powered engine exhaust fumes are poisonous and can cause loss of consciousness and death in a short time.

FEATURES AND CONTROLS

Some Polaris vehicles are equipped with special features such as the cab frame. Not all models come with all features. Refer to the specifications section beginning on page 100.

Component Locations

1. Cab Frame (if equipped)

2. Hip Bar

3. Console

4. Steering Wheel

5. Seat

6. Cargo Box

7. Seat Belts

8. Fuel Tank Cap / Fuel Gauge

9. Battery

FEATURES AND CONTROLS

Component Locations

10. Headlights

11. Radiator (if equipped)

12. Front Bumper/Brush Guard

13. Hood Hold Down Strap

FEATURES AND CONTROLS

Component Locations

14. Taillights

15. Tailgate

16. Tailgate Latch Release

17. Muffler (Spark Arrester)

18. CV Boot/Rear Caliper

19. Air Box

20. Receiver Hitch

FEATURES AND CONTROLS

Indicator Lights

The indicator lights on the console display:

1. High Gear

2. Low Gear (if equipped)

3. Neutral Gear

4. Reverse Gear

5. High Temperature

6. Brakes

Trailer Hitch Bracket

This vehicle is equipped with a receiver hitch bracket for a trailer hitch. Trailer towing equipment is not supp lied with this vehicle.

To avoid injury and property damage, always heed the warnings and towing capacities outlined on page 49.

Auxiliary Outlet (1)

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

Fuel Cap/Fuel Gauge (2)

The fuel tank filler cap is located on the right-hand side of the vehicle near the passenger seat. It has a built-in fuel gauge that indicates the amount of fuel remaining in the tank.

When the indicator needle nears the E (empty) mark, refuel at the earliest opportunity.

When refueling, always use either leaded or unleaded gasoline with a minimum pum p octane number of 87 R+ M/2 octane.

FEATURES AND CONTROLS

Seat Removal

Pull up on th e front of the seat and slide it toward the front of the vehicle.

Install the seat by sli ding the tabs into the rear of the seat base. Push down firmly on the front of the seat until the pins are fully seated into the grommets.

Seat Belts

The RANGER is equipped with lap-style seat belts for the operator and passenger.

WA R N I N G

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

Passengers under five years of age require special restraints, which are not available with this vehicle. No person under the age of five years may ride in the RANGER.

To wear the seat belt properly, follow this procedure:

1. Place the belt across your lap as low on your hips as possible, taking care that th e belt is not twisted.

2. Push the latch plate into the buckle until it clicks.

3. Release the strap, it will self ti ghten.

NOTE: The center belt must be tightened manually by pulling on the

strap.

To unfasten, press t h e square red button in the buckle’s center.

FEATURES AND CONTROLS

Console

1. Cup Holder

2. Indicator Lights

3. Shift Lever

4. Light S witch

5. AWD/Differential Switch (if equipped)

6. Hour Meter

7. Glove Box with Lid

8. 12V Accessory Plug

9. Storage Tray

10. Choke Knob

11. Ignition Switch

12. Differential Lock Lever (TM)

13. Storage Box

FEATURES AND CONTROLS

Gear Selector (1)

RANGER 4 X4, 6X6

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

RANGER TM

H: High Gear N: Neutral R: Reverse

NOTE: Low is the primary driving range for the

RANGER 4X4 and 6X6. High is intended for use on hard-packed surfaces with light loads.

To change gears, stop the vehicle and with the engine idling, move the lever to the desired gear. Do not attempt to shift gears with engine speed above idle or while the vehicle is moving.

Always place the transmission in gear with the parking brake locked whenever the vehicle is left un attended.

Maintaining shift linkage adjustment is important to assure proper transmission function. See your dealer if you experience any shifting problems.

CAUTION

Do not attempt to shift the transmission while the vehicle is moving or damage to the transmission could result. Always shift when the vehicle is stationary and the engine is at idle.

Always place the transmission in gear with the parking brake applied and turn the vehicle off whenever the vehicle is left unattended.

FEATURES AND CONTROLS

Switches

Ignition Switch (1)

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

OFF Engine off. All electrical circuits

are off except Acc. 12V.

ON Electrical circuits are on.

Electrical equipment can be used.

START Electric starter is engaged by

holding ignition switch key in this position. Upon release, the key will return to the ON position.

WA R N I N G

Leaving the keys in the ignition can lead to unauthorized use of the vehicle resulting in serious injury or death. Always remove the ignition key when the vehicle is not in use.

Light Switch (2)

The ignition switch key must be in the ON position to operate the headlights. The switch has three positions:

A: High Beam B: Low Beam C: Off

AWD/Differential Lock Switch (3)

The AWD/Differential Switch has three pos itions: D: AWD

E: Differential Lock F: Off

See page 33 for differential switch operating instructions.

Vehicles equipped with AWD can be operated in either 2WD or AWD. Press the AWD switch to engage the AWD. Press the bottom of the rocker switch to return to 2WD.

NOTE: Under some conditions, it’s possible for the AWD to remain

engaged. See page 51 for manual disengagement instructions.

AWD

FEATURES AND CONTROLS

Brake Pedal (1)

Depress the brake pedal to slow or stop th e vehicle.

Throttle Pedal (2)

Push the pedal down to increase engine speed. Spring pressure returns the pedal to the rest position when released. Always check t hat the throttle pedal returns normally before starting the engine. Make sure there’s adequate throttle pedal freeplay. See page 82 for throttle pedal adjustment procedures.

Parking Brake Lever (3)

Engage the parking brake when parking the vehicle to help prevent the vehicle from rolling. To apply the parking brake, push down on the pedal with your foot.

Parking Brake Release (4)

To release the parking brake, pull the release handle Spring pressure helps return the lever to the released position. Make sure the parking brake lever is functioning properly before each operation.

Differential Lock Lever (5) and Switch (6)

The rear axle is equipp ed with a lockable differential that allows the operator to choose between an open differential or a closed differential. It’s beneficial to lock the differential in low traction situatio ns.

To lock the differential on the TM, push the lock lever up.

To lock the differential on the 4X4, move the AWD/Differential Switch to the center position.

CAUTION

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

OPERATION

Vehicle Break-In Period

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

CAUTION

Excessive heat build-up during the first three hours of operation will damage close-fitted engine parts. Do not operate at full throttle or high speeds for extended periods during the first three hours of use.

Use of any oils other than those recommended by Polaris may cause serious engine damage. We recommend the use of Polaris Premium 4 Synthetic Oil for your 4-cycle engine.

1. Fill the fuel tank with gasoline. Heed the gasoline warnings on page 24.

2. Check the oil level on the dips tick. See page 61. Add Polaris Premium 4 Synthetic Oi l if necessary to maintain the oil level i n 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 35.

6. Pull onl y light loads.

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

OPERATION

Pre-Ride Inspection

WA R N I N G

If a proper inspection is not done before each use, severe injury or death could result. Always inspect the vehicle before each use to ensure it’s in proper operating condition.

Pre-Ride Checklist

Item Remarks See

Page

Brake system / lever travel Ensure proper opera tion 84 Brake fluid Ensure proper level 84 Front suspension Inspect, lubricate if necessary 58 Rear suspension Inspect, lubricate if necessary 58 Steering Ensure free operation -Tires Inspect condition and pressure 88,103 Wheels / fasteners Inspect, ensure faste ner tightness 88 Frame nuts, bolts, fasteners Inspect, en sure tightness -Fuel and oil Ensure proper levels 61, 64 Coolant level (4X4, 6X6) Ensure proper level 72 Coolant hoses (4X4, 6X 6) Inspect for leaks -Throttle Ensure proper opera tion 33, 83 Indicator lights / switches Ensure operation 28, 32 Air filter, pre-filter Inspect, clean 77, 79 Air box sediment tube Drain deposits whenever visible -Headlam p Check operation, apply Polaris dielec-

tric grease when lamp is replaced

Brake light / tail lamp Check operation, apply Polaris dielec-

tric grease when lamp is replaced

OPERATION

Starting the Engine

WA R N I N G

Engine exhaust contains poisonous carbon monoxide and can cause loss of consciousness resulting in severe injury or death. Never run an engine in an enclosed area.

CAUTION

Operating the vehicle immediately after starting could cause engine damage. Allow the engine to warm up for several minutes before operating the vehicle.

Starting a Cold Engine

1. Place the transmission in neutral.

2. Lock the parking brake.

3. Sit i n the driver’s seat and fasten the seat belt.

NOTE: Do not use the choke before

attempting to start the TM model. If the engine does not start on the first attempt without choking, proceed to step 4.

4. Pull the choke knob (1) all the way out (2).

NOTE: Do not press the throttle pedal while

starting the engine.

CAUTION

Do not operate the starter continuously for more than five seconds or the starter will overheat and the battery power will drop temporarily. Wait at least five seconds between each operation of the starter to allow it to cool and to allow battery power recovery.

Do not turn the ignition switch key to the START position while the engine is running. Damage to the starter can result.

5. Turn the ignition key to START.

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.

7. After the engine starts, push the choke knob in half way (3).

8. Vary the engine RPM slightly with the throttle to aid in warm up until the engine idles smoothly.

9. Push the choke completely i n (4).

OPERATION

Starting the Engine

Starting a Warm Engine

Warm engines do not normally require the use of the choke. Overuse of the choke can cause the spark plug to become wet fouled.

1. Place the transmission in neutral and move the vehicle to a level surface.

2. Lock the parking brake.

3. Sit i n the driver’s seat and fasten the seat belt.

4. Turn the ignition key to START.

5. If the engine has cooled and does not readily start, intermittent use of the choke knob (pulled half way out) may be necessary.

6. If the engine is over-choked when warm, depress the throttle lever fully while cranking to aid in st arting.

7. Release the throttle lever immediately after the engine starts.

NOTE: If the engine does not start and all conditions are favorable,

change the spark plug.

Stopping the Engine

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

2. Put the gear shift lever into neutral.

3. Apply the parking brake.

WA R N I N G

A rolling vehicle can cause property damage and serious injury. Always apply the parking brake after stopping the engine.

OPERATION

Braking

1. Release t he throttle pedal completely.

2. Press on the brake pedal evenly and firmly.

NOTE: Practice starting and stopping (using the brakes) until you’re

familiar with the controls.

NOTE: When the throttle pedal is released completely and the

engine speed drops near an idle, the vehicle has no engine braking.

WA R N I N G

Failure to allow for increased braking distance when hauling cargo or towing a trailer may result in accident and injury. Always slow down and allow additional braking distance when towing or hauling cargo.

Suspension Adjustment (4X4)

The rear suspension of th e RANGER 4X4 may be adjusted to provide a stiffer suspension if necessary. The shocks are mounted to the inside mounting holes (A) at the factory, but they may be relocated to the outside mounting holes (B).

1. Remove the shock m o u n t i n g bolts.

2. Reposition the shocks to the outs ide mounting holes.

3. Reinstall the s h o ck mounting bolts. Torque to 30 ft. lbs. (40 Nm).

OPERATION

Driving Safely

Driving Procedures

1. Sit i n the driver’s seat and fasten the seat belt.

2. After starting the engine and allowing it to warm up, shift the transmission into gear.

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

4. Release the parking brake.

5. Keeping both hands on the steering wheel, slowly depress the throttle with your right foot and begin driving. Vehicle speed is controlled by the amount of throttle opening and Po laris Variable Transmission (PVT) shifting is automatic.

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

NOTE: Low is the primary gear for operating the RANGER 4X4 and

6X6. High gear is intended for use on hard-packed surfaces with light loads.

OPERATION

Driving Safely

Driving On Slippery Surfaces

When driving on slippery surfaces such as wet trails, loose gravel, or ice, be alert for the possibi lity of skidding and sliding. Under these conditions, follow these precautions:

1. Slow down when entering slippery areas.

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

3. Correct a skid by turning the steering wheel in the di rection of the skid.

4. Drive with AWD engaged (if equipped) to assist in controlling the vehicle.

CAUTION

Severe damage to the drive train may occur if the AWD is engaged while the wheels are spinning. Always allow the wheels to stop spinning before engaging AWD.

WA R N I N G

Failure to exercise care when operating on slippery surfaces can result in loss of tire traction and cause loss of control, accident, and serious injury or death.

Never apply the brakes during a skid. Do not operate on excessively slippery surf aces. Always reduce speed and use additional caution when operating

on slippery surfaces.

OPERATION

Driving Safely

Driving Uphill

Whenever traveling uphill, follow these precautions:

1. Always travel straight uphill.

2. Avoid steep hills (15_ maximum).

3. Keep both feet on the floor.

4. Proceed at a steady rate of speed and throttle o pening.

WA R N I N G

Climbing hills improperly can cause loss of control or vehicle overturn. Always check the terrain carefully before climbing a hill.

Braking and handling are greatly affected when operating in hilly terrain. Improper procedure could cause loss of control or overturn and result in serious injury or death.

Avoid climbing steep hills (15_ maximum). Use extreme caution when operating on hills, and follow proper

operating procedures outlined in the owner’s manual. Never climb hills with excessively slippery or loose surfaces. Never open the throttle suddenly. Never go over the crest of a hill at high speed. An obstacle, a

sharp drop, or another vehicle or person could be on the other side of the hill.

15_ Maximum

OPERATION

Driving Safely

Sidehilling

WA R N I N G

Crossing hillsides or turning on hills can result in loss of control or vehicle overturn, resulting in severe injury or death. Avoid crossing the side of a hill when possible. When unavoidable, exercise extreme caution. Avoid operating on steep hills (15_ maximum).

Driving Downhill

Whenever descending a hill, follow these precautions:

1. Proceed directly downhill.

2. Slow down.

3. Apply the brakes slightly to aid in slowing.

WA R N I N G

Traveling downhill improperly could cause loss of control or vehicle overturn. Always check the terrain carefully before descending a hill.

Never descend a hill at high speed. Excessive speed may result in loss of vehicle control and lead to serious injury or death. Always operate slowly when traveling downhill.

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

OPERATION

Driving Safely

Driving Through Water

WA R N I N G

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

Your Polaris RANGER can operate through water up to a maximum recommended depth equal to the floorboards (1). Follow these procedures when operating through water:

1. Always determine water depths and current before entering.

2. Choose a crossing where both banks have gradual inclines.

3. Proceed slowly, avoiding rocks and obstacles.

4. After leaving water, always dry the brakes by applying l i g h t pressure to the lever repeatedly until braking action is n ormal.

NOTE: After running your vehicle in water, it’s critical that you

perform the services outlined in the Periodic Maintenance Chart beginning on page 54. Give special attention to engine oil, transmission oil, front and rear gearcases, and all grease fittings.

CAUTION

Immersion can result in major damage if the vehicle isn’t serviced correctly and promptly. After immersion, always take the vehicle to your dealer service. Do not start the engine!

If it’s impossible to bring the vehicle to your dealer before starting the engine, perform the service outlined on page 76, and take the vehicle to your dealer at the first opportunity.

OPERATION

Driving Safely

Driving Over Obstacles

Be alert! Look ahead and learn to read the terrain you’re traveling on. Watch for hazards such as logs, rocks and low hanging branches.

WA R N I N G

Severe injury or death can result if your vehicle suddenly comes in contact with a hidden obstacle. Not all obstacles are immediately visible. Reduce speed and travel with caution in unfamiliar terrain.

OPERATION

Driving Safely

Driving in Reverse

Follow these guidelines when operating in reverse:

1. Back slowly.

2. Apply the b rakes lightly for s t o p p i n g .

3. Avoid turning at sharp angles.

4. Always avoid backing downhill.

5. Never o pen the throttle suddenly while backing.

6. Always inspect left and right fields of vision before backing.

WA R N I N G

Failure to use caution when operating in reverse can result in serious injury or death. Before shifting into reverse, always check for obstacles or people behind the vehicle and follow the reverse operation procedures outlined in this manual. Always back slowly.

OPERATION

Driving Safely

Parking on an Incline

Avoid parking on an incline i f possible. If it’s unavoidable, follow these precautions:

1. Place the transmission in gear.

2. Set the parking brake.

3. Block the rear wheels on the downhill side.

WA R N I N G

A rolling vehicle can cause property damage and serious injury. Always apply the parking brake after stopping the engine. Always block the downhill side of the wheels if leaving the vehicle on a hill, or park the vehicle in a sidehill position instead.

Operating the vehicle while the parking brake is engaged could cause loss of control and result in serious injury or death. Always disengage the parking brake before operating the vehicle.

OPERATION

Hauling Cargo

WA R N I N G

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

Always load the cargo box with the load as far forward as possible.

Always operate the vehicle with extreme care when hauling or towing loads.

Slow down and drive in the lowest gear available.

The RANGER has been designed to carry or tow specific capacities. Always read and understand the load distribution warnings listed on the warning labels. Never exceed the following capacities.

Maximum Capacities

(Level Ground)

Cargo Box

RANGER 4X4 1500 lbs. (681 kg) 1000 lbs. (454 kg) RANGER 6X6 1750 lbs. (794 kg) 1250 lbs. (567 kg)

RANGER TM 1250 lbs. (681 kg) 750 lbs. (340 kg)

WA R N I N G

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.

OPERATION

Hauling Cargo

Dumping the Cargo Box

WA R N I N G

Operating the vehicle while the cargo box is raised could result in severe injury. The box could close unexpectedly and cause injury to the driver or passenger. The rear tires will also catch the rear of a raised box, damaging the vehicle and creating hazardous driving conditions.

Never operate this vehicle with the cargo box in t he raised position.

1. Select a level site to dump the cargo box. Do not attempt to dump or unload the vehicle while parked on an incline.

2. Set the parking brake.

3. Dismount the vehicle.

4. Ensure that the cargo is positioned evenly or toward the front of the cargo box.

5. Release the tailgate by pulling up on the tailgate latch.

6. Stand clear and pull up on the cargo box release lever (1).

7. Lift the front of the cargo box to dump the cargo.

8. Lower the cargo box and pu s h down securely to latch.

WA R N I N G

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.

OPERATION

Hauling Cargo

Towing Loads

WA R N I N G

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

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

Do not operate the vehicle faster than 10 mph (16 km/h) when towing. Towing a trailer increases braking distance.

Do not tow more than the recommended weight for the vehicle. See the towing capacity chart below and the specifications charts beginning on page 100.

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

Never tow a trailer on a grade steeper than 15!.

Maximum Towing Capacities (Level Ground)

Total Towed

Load Weight

(level ground)

Total Towed

Load Weight

(15! grade)

Total Hitch

Vertical

Weight

Maximum

Towing

Speed

RANGER

4X4

1500 lbs.

(681 kg)

850 lbs.

(386 kg)

150 lbs.

(68.1 kg)

10 mph

(16 kph)

RANGER

6X6

1750 lbs.

(794 kg)

1000 lbs.

(454 kg)

150 lbs.

(68.1 kg)

10 mph

(16 kph)

RANGER

1000 lbs.

(454 kg)

600 lbs.

(272 kg)

100 lbs.

45.4 kg)

10 mph

(16 kph)

Belt Life

To extend belt l ife, use the lowest gear p ossible when hauling or towing heavy cargo.

OPERATION

Driving Safely

Parking the RANGER

WA R N I N G

A rolling vehicle can cause property damage and serious injury. Always apply the parking brake after stopping the engine.

1. Stop the vehicle on a level surface.

2. When the engine has stopped, apply the parking brake.

3. Remove the igniti on switch key to prevent unauthorized use.

WA R N I N G

Gasoline is extremely flammable and can be explosive under certain conditions. When parking inside a garage or other structure, be sure that the structure is well ventilated and that the vehicle is not close to any source of flame or sparks, including any appliance with pilot lights.

OPERATION

All Wheel Drive (AWD)

Your Polaris RANGER (4X4 and 6X6) is equipped with an exclusive P olaris All Wheel Drive (AWD) s ystem that can be activated by a switch on th e console (1). When the swi t ch is off, the RANGER is in two-wheel drive at all times. When the switch is on, the RANGER is in AWD, and the front wheels will automatically engage anytime the rear wheels lose traction. When the rear wheels regain traction, the front wheels will automatically disengage.

The AWD switch position indicates whether the vehicle is in AWD. There is no limit to the length of time the vehicle may remain in AWD.

The AWD switch may be turned on or off while the vehicle i s moving. If the switch is turned off while the front hubs are driving, they will not release until the rear wheels regain traction.

CAUTION

Switching to AWD while t he 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

Under certain conditions, it may be possible for one or both hubs to remain engaged unnecessarily. This condition causes increased steering effort and some vehicle speed restriction.

Take th e following steps to disengage the AWD system:

1. Stop the vehicle.

2. Shift to reverse and back up a minimum of 10 feet.

3. Stop completely.

4. Shift into forward and drive. If the hubs remain engaged after following these instructions, return the

vehicle to your dealer for service.

WA R N I N G

Operating with only one front hub engaged could result in loss of control, accident, and severe injury or death.

When hub engagement symptoms are present, use the disengaging procedure before proceeding.

EMISSION CONTROL SYSTEMS

Crankcase Emission Control System

This engine is equipped with a closed crankcase system. Blow-by gases are forced back to the combustion chamber by the intake system. The system does not allow the blow-by gases to enter the atmosphere.

Exhaust Emission Control System

The emissions from the exhaust of this vehicle are controlled by engine design, including factory-set fuel delivery and ignition. The engine and related components must be maintained at Polaris specifications to achieve optimal performance.

Adjustment to engine idle is the only adjustment Polaris recommends that the operator perform. Any other adjustments should be performed by an authorized Polaris dealer.

The RANGER TM emissions label (1) is located on the front of the engine. Remove the service panel (2) to view the label. The label on the RANGER 4X4 and 6X6 (3) is l o cated on the recoil cover. Remove the seat and look through the gap in the aluminum exhaust shield to view the label.

WA R N I N G

The installation of devices that effectively increase exhaust emissions beyond their legal limits will void all manufacturer warranties and may violate laws governing the registration and operation of this vehicle.

EMISSION CONTROL SYSTEMS

Noise Emission Control System

Do not modify the engine, in t ake or exhaust components, as doing so may affect compliance with state and local no ise level requirements.

Spark Arrestor

Your Polaris vehicle has a spark arrestor that was tested and approved in accordance with the USDA Forest Service Standard 5100-1C. Federal law requires that this spark arrestor be installed and functional when the vehicle is operated on public lands.

Electromagnetic Interference

This spark ignition system complies with Canadian ICES-002 and European 89/336/EEC.

MAINTENANCE AND LUBRICATION

Periodic Maintenance Chart

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

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

NOTE: Service and adjustments are critical. If you’re not familiar

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

Maintenance in tervals in the following chart are based upon average riding conditions and an average vehicle speed of approximately 10 miles per hour. Vehicles subjected to severe use must be inspected and serviced more frequently.

Severe Use Definition

S Frequent immersion in mud, water or sand S Racing or race-style high RPM use S Prolonged low speed, heavy load operation S Extended idle S Short trip cold weather operation

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

Maintenance Chart Key

" Perform these procedures more frequently for vehicles subjected to

severe use.

E Emission Control System Service (California)

J Have an authorized Polaris dealer perform these services.

WA R N I N G

Improperly performing the procedures marked with a J could result in component failure and lead to serious injury or death. Have an authorized Polaris dealer perform these services.

MAINTENANCE AND LUBRICATION

Periodic Maintenance Chart

Perform all services at whichever maintenance interval is reached first.

Item Maintenance Interval

(whichever comes first)

Remarks

Hours Calendar Miles

(Km)

Steering -- Pre-Ride --

Make adjustments as need-

Front suspension -- Pre-Ride --

ed. See Pre-Ride Checklist on page 35.

Rear suspension -- Pre-Ride --

onpage3

Tires -- Pre-Ride --

Brake fluid level -- Pre-Ride --

Brake lever travel -- Pre-Ride -Brake systems -- Pre-Ride -Wheels/fasteners -- Pre-Ride -Frame fasteners -- Pre-Ride --

Engine oil level -- Pre-Ride --

Air filter, pre-filter -- Daily -- Inspect; clean often

Air box sediment tube

-- Daily -- Drain deposits when visible

Coolant (if applicable)

-- Daily -- Check level daily, change coolant every 2 years

Headlamp/tail lamp

-- Daily -- Check operation; apply dielectric grease if replacing

Air filter, main element

-- Weekly -- Inspect; replace as needed

Recoil housing -- Weekly -- Drain water as needed,

check often if operating in wet conditions

" J

Brake pad wear 10 H Monthly -- Inspect periodically

Battery 20 H Monthly -- Check terminals; clean; test

Front gearcase oil (if equipped)

25 H Monthly -- Inspect level; change yearly

Middle gearcase oil (if equipped)

25 H Monthly -- Inspect level; change yearly

Rear gearcase oil (if equipped)

25 H Monthly -- Inspect level; change yearly

Transmission oil 25 H Monthly -- Inspect level; change yearly

" Perform these procedures more often for vehicle s subjected to severe use.

E Emission Control System Service (California)

J Have an authorized Polaris dealer perform these services.

MAINTENANCE AND LUBRICATION

Periodic Maintenance Chart

Item Maintenance Interval

(whichever comes first)

Remarks

Hours Calendar Miles

(Km)

Engine breather filter (if equipped)

25 H Monthly -- Inspect; replace if necessary

Engine oil change (break-in)

25 H 1M -- Perform a break-in oil

change at one month

General lubrication

50 H 3M -- Lubricate all fittings, pivots,

cables, etc.

Shift Linkage 50 H 6M -- Inspect, lubricate, adjust

Steering 50 H 6M -- Lubricate

Front suspension 50 H 6M -- Lubricate

Rear suspension 50 H 6M -- Lubricate Carburetor float

bowl

50 H 6M -- Drain bowl periodically and

prior to storage

Throttle Cable/ ETC Switch

50 H 6M -- Inspect; adjust; lubricate;

replace if necessary

Choke cable 50 H 6M -- Inspect; adjust; lubricate;

replace if necessary

Carburetor air intake ducts/ flange

50 H 6M -- Inspect ducts for proper

sealing/air leaks

Drive belt 50 H 6M -- Inspect; adjust; replace as

needed

Cooling system (if applicable)

50 H 6M -- Inspect coolant strength

seasonally; pressure test system yearly

Engine oil change 100 H 6M -- Perform a break-in oil

change at 25 hours/one month

Oil filter change 100 H 6M -- Replace with oil c hange

Oil tank vent hose 100 H 12 M -- Inspect routing, condition

Valve clearance 100 H 12 M -- Ins pect; adjust

" Perform these procedures more often for vehicle s subjected to severe use.

E Emission Control System Service (California)

J Have an authorized Polaris dealer perform these services.

MAINTENANCE AND LUBRICATION

Periodic Maintenance Chart

Item Maintenance Interval

(whichever comes first)

Remarks

Hours Calendar Miles

(Km)

Fuel system 100 H 12 M -- Check for leaks at tank cap,

lines, fuel valve, filter, pump, carburetor; replace lines every two years

Fuel filter 100 H 12 M -- Replace yearly

Radiator (if applicable)

100 H 12 M -- Inspect; clean external

surfaces

Cooling hoses (if applicable)

100 H 12 M -- Inspect for leaks

Engine mounts 100 H 12 M -- Inspect Exhaust muffler/

pipe

100 H 12 M -- Inspect

Spark plug 100 H 12 M -- Inspect; replace as needed

Ignition Timing 100 H 12 M -- Inspect

Wiring 100 H 12 M -- Inspect for wear, routing,

security; apply dielectric grease to connectors subjected to water, mud, etc.

Clutches (drive and driven)

100 H 12 M -- Inspect; clean; replace worn

parts

Front wheel bearings

100 H 12 M -- Inspect; replace as needed

Brake fluid 200 H 24 M -- Change every two years Spark arrestor 300 H 36 M -- Clean out

Idle speed -- Adjust as needed

Toe adjustment -- Inspect periodically; adjust

when parts are replaced

" J

Auxiliary brake (if equipped)

-- Inspect daily; adjust as needed

Headlight aim -- Adjust as needed

" Perform these procedures more often for vehicle s subjected to severe use.

E Emission Control System Service (California)

J Have an authorized Polaris dealer perform these services.

MAINTENANCE AND LUBRICATION

Lubrication Recommendations

Check and lubricate all components at the intervals o utlined in the Periodic Maintenance Chart beginning on page 54. Items not listed in the chart should be lubricated at the General Lubrication in terval.

Lubrication Chart Key

" More often under severe use, such as wet or dusty conditions

L Polaris P remium all Season Grease or grease conforming to NLGI

No. 2, such as Conoco Superlube M or Mobilegrease Special

F Use Polaris Premium U-Joint Lu be every 500 miles, before long

periods of storage, or after pressure washing or submerging.

Item Lube Method

Engine Oil Polaris Premium 4

Synthetic 0W40

Add to proper level on dipstick.

Brake Fluid DOT 3 or DOT 4 Maintain level between fill lines. See

page 84.

Main Gearcase Oil (Transmission)

Premium AGL Synthetic Gearcase Lube

Maintain as recommended on page 67.

Front Gearcase Oil Premium Demand

Drive Hub Fluid

Maintain as recommended on page 68.

Middle Gearcase Oil (6X6 only)

Premium ATV Angle Drive Fluid

Maintain as recommended on page 69.

Rear Gearcase Oil Premium ATV Angle

Drive Fluid

Maintain as recommended on page 70.

(1) Prop Shaft U-joints FGrease Locate fittings and grease Front Prop Shaft Yoke FGrease Locate fittings and grease

(3 pumps maximum)

Ball Joint

"LGrease

Locate fitting (back side of struts), grease with grease gun.

(2) Sw ing Arm Bushings

LGrease

Locate fittings on swing arm and grease with grease gun.

MAINTENANCE AND LUBRICATION

Lubrication Recommendations

(1)

(2)

TM 6X6

4X4 6X6

6X6

TM 6X6

MAINTENANCE AND LUBRICATION

Engine Oil

Always check and change the engine oil at the in tervals outlined in the Periodic Maintenance Chart beginning on page 54. Always change the oil filter whenever changing oil.

Premium 4 Synthetic Oil

Polaris Premium 4 All Season Synthetic engine oil has been specially formulated for use in Polaris 4-cycle engines. It’s a fully sy nthetic, high performance, multi-viscosity oil designed to provide the ultimate in lubrication performance and protection. See page 99 for the part numbers of Polaris products.

Premium 4 possesses unsurpassed film strength over the widest possible temperature range. It resists vis cosity and frictional breakdown in ambient temperatures from -40! F. to 120! F. Its exceptional frictional properties result in more efficient operation, more power output and lower fuel consumption.

Although P olaris Premium 4 is the only oil recommended for us e in this engine, use of any API certified “SH” oil is allowable as long as it’s 0W-40. Oil may need to be changed more frequently if Polaris Premium 4 is not used. Follow the manufacturer’s recommendations for ambient temperature operation.

CAUTION

Mixing brands or using a non-recommended oil may cause serious engine damage. We recommend the use of Polaris Premium 4 All Season synthetic oil or API certified “SH” oil, 0W-40. Never substitute or mix oil brands. Use only 0W-40.

WA R N I N G

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.

MAINTENANCE AND LUBRICATION

Engine Oil

Always check and change the oil at the intervals outl ined in the Periodic Maintenance Chart beginning on page 54. We recommend the use of Polaris Premium 4 All Season Synthetic engine oil.

Oil Check (RANGER 4X4, 6X6)

The oil tank is located under the seat.

1. Position the vehicle on a level surface.

2. Start the engine and let it idle for 20-30 seconds.

3. Stop the engine and remove the seat (see page 29).

4. Remove the dipst ick (1) and wipe it dry with a clean cloth.

5. Reinstall the dipstick and screw it in completely.

NOTE: The dipstick must be

screwed in completely to keep the angle and depth of the stick consistent.

6. Remove the dipsti ck and check to see that the oil level is between the full and add marks (2). Add oil if necessary. Do not overfill.

NOTE: A rising oil level between checks in cool weather driving can

indicate moisture collecting in the oil reservoir. If the oil level is above the full mark, change the oil.

ADD 8 OZ. NORMAL FULL

MAINTENANCE AND LUBRICATION

Engine Oil

Oil and Filter Change (RANGER 4X4, 6X6)

CAUTION

Hot oil can cause serious burns. Do not allow hot oil to come into contact with skin.

1. Run the engine two to th ree mi n u t es until warm. Stop the engine.

2. Clean the area around the drain plug (B) at the bottom of the oil tank.

3. Place a drain pan beneath the oil tank and remove the drain plug. Allow the o il to drain completely.

4. Replace the sealing washer (A) on the drain plug.

NOTE: The sealing surfaces on the drain plug and oil tank should be

clean and f ree of burrs, nicks or scrat ches.

5. Reinstall the drain plug and torque to 14 ft. lbs. (19 Nm).

6. Loosen the clamp (D) and remove the oil hose from the screen fitting (C) on the bottom of the oil tank.

7. Remove the screen fitting and clean the screen thorough ly.

8. Apply Loctitet 565 Thread Sealant to the clean and oil-free threads of the fitting.

9. Reinstall the screen fitting and tighten to 14 ft. lbs. (19 Nm).

10. Reinstall the oil hose on the fittin g and reinstall the clamp.

11. Place shop towels beneath the oil filter (1). Using an oil filter wrench, turn the filter counterclockwise to remove.

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

13. Check to make sure the o-ring is in good condition. Lubricate the o-ring on the new filter wit h a film of engine oil.

MAINTENANCE AND LUBRICATION

Engine Oil

Oil and Filter Change (RANGER 4X4, 6X6)

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

15. Approximately one cup of engine oil will remain in the crankcase. To drain, remove the drain plug on the lower right side of the crankcase.

NOTE: The sealing surfaces on the drain plug and crankcase should

be clean and free of burrs, nicks or scratches.

16. Reinstall the drain plug and torque to 14 ft. lbs. (19 Nm).

17. Remove the dipstick and fill the tank with two quarts (1.9 l) of Polaris Premium 4 Synthetic Oil.

18. Place the gear selector in neutral and set the parking brake.

19. Prime the oil pump using the procedure below. Then stop the engine and inspect for leaks.

20. Re-check the oil level on the dipstick and add oil as necessary to bring the level to the upper mark on the dips t i ck.

21. Dispose of used filter and oil properly.

Oil Pump Priming (RANGER 4X4, 6X6)

This priming procedure must be performed whenever the oil hose connection between the oil tank and pump inl et has been disconnected.

1. Clamp or pinch off the vent line (1) approximately 2I from the oil tank (2), between the end of the oil tank vent fitting and the vent line’s pressure relief slit (3).

2. Run the engine for 15-20 seconds.

3. Remove the vent line clamp. The oil pump will now b e properly primed and ready for operation.

MAINTENANCE AND LUBRICATION

Engine Oil

Oil Check (RANGER TM)

1. Position the vehicle on a level surface.

2. Start the engine and let it idle for 20-30 seconds.

3. Stop the engine and remove the seat as described on page 29. Remove the service panel (1) by pulling upward.

4. Remove the dipst ick (2) and wipe it dry with a clean cloth.

5. Replace the dipstick and seat it completely.

6. Remove the dipstick and check to see that the oi l level is between the FULL (3) and ADD (4) marks. Add oil through the oil filler hol e (5) as n eeded. Do not overfill.

NOTE: A rising oil level between checks

in cool weather driving can indicate moisture collecting in the oil reservoir. If the oil level is over the full mark, change the oil.

Oil and Filter Change (RANGER TM)

1. Position the vehicle on a level surface.

2. Run the engine two to three mi nutes until warm, then stop the engine.

3. Clean the area around the drain plug (6) at t h e bottom of the engine. The plug i s accessible through the access hole in the bottom of the skid plate.

CAUTION

Hot oil can cause serious burns. Do not allow hot oil to come into contact with skin.

4. Place a drain pan beneath the engine and remove the drain plug. Allow the o il to drain completely.

MAINTENANCE AND LUBRICATION

Engine Oil

Oil and Filter Change (RANGER TM)

5. Replace th e sealing washer on the drain plug.

NOTE: The sealing surfaces on the drain plug and crankcase should

be clean and free of burrs, nicks or scratches.

6. Reinstall the drain plug and torque to 14 ft. lbs. (19 Nm).

7. Place shop towels beneath the oil filter (1). Using an oil filter wrench (2), turn the filter counterclockwise to remove.

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

9. Check to m ake sure the o-ring (3) is in good condition. Lubricate the o-ring on the new filter wit h a film of engine oil.

10. Install the new filter and turn by hand until the filter gasket contacts the sealing surface, then turn an additional 3/4 turn.

NOTE: The sealing surfaces on the

drain plug and crankcase should be clean and free of burrs, nicks or scratches.

11. Add 1.64 quarts (1550 ml) of the recommended oil.

12. Start the engine and allow it to run for two to three minutes.

13. Place the gear selector in neutral and set the parking brake.

14. Stop the engine and check the oil level on the dipstick. Add oil to the FULL mark if necessary.

15. Dispose of used filter and oil properly.

MAINTENANCE AND LUBRICATION

Gearcases

Gearcase Specification Chart

Gearcase Lubricant Capacity Fill Plug

Torque

Drain Plug

Torque

Main Gearcase (Transmission)

(4X4, 6X6)

Premium AGL

Synthetic Gearcase

Lube

15.2 oz. (450 ml)

14 ft. lbs.

(19.4 Nm)

14 ft. lbs.

(19.4 Nm)

Main Gearcase (Transmission)

(TM)

Premium AGL

Synthetic Gearcase

Lube

18.2 oz. (540 ml)

14 ft. lbs.

(19.4 Nm)

14 ft. lbs.

(19.4 Nm)

Front Gearcase

(4X4, 6X6)

Premium Demand

Drive Hub Fluid

5 oz .

(150 ml)

8-10 ft. lbs.

(11-13.6 Nm)

11 ft. lbs.

(15 Nm)

Middle Gearcase

(6X6)

Premium ATV Angle

Drive Fluid

6.75 oz. (200 ml)

14 ft. lbs.

(19.4 Nm)

14 ft. lbs.

(19.4 Nm)

Rear Gearcase

(4X4)

Premium ATV Angle

Drive Fluid

18 oz.

(532 ml)

40-50 ft. lbs.

(54-68 Nm)

30-45 in. lbs.

(3-5 Nm)

Rear Gearcase

(6X6, TM)

Premium ATV Angle

Drive Fluid

10 oz.

(300 ml)

14 ft. lbs.

(19.4 Nm)

14 ft. lbs.

(19.4 Nm)

MAINTENANCE AND LUBRICATION

Gearcases

Transmission (Main Gearcase)

Always check and change the transmission oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 54. Maintain the oil level even with the bottom of the fill plug hole. We recommend the use of Premium AGL Synthetic Gearcase Lubricant. See page 99 for the part numbers of Polaris products.

Oil Check

1. Position the vehicle on a level surface.

2. Remove the fill plug (1), which is located on the rear of the vehicle.

3. Check the oil level and add as needed.

4. Reinstall the fill plug . Torque to specification. See page 66.

Oil Change

The drain plug (2) is located on the bottom of the transmission. Access t he drain plug through the drain hole in the skid plate.

1. Remove the fill plug.

2. Remove the drain plug and drain the oil into a drain pan. Dispose of used oil properly.

3. Wipe the magnetic end of the drain plug clean to remove accumulated metallic filings.

4. After the oil has drained completely, install a new sealing washer and reinstall the drain plug. Torque to specification. See page 66.

NOTE: Refer to the Gearcase Specifications Chart on page 66.

5. Add the recommended oil as needed. Do not overfill.

6. Reinstall the fill plug . Torque to specification.

7. Check for leaks.

MAINTENANCE AND LUBRICATION

Gearcases

Front Gearcase (RANGER 4X4, 6X6)

Always check and change the front gearcase oil at the intervals outlined in the Periodic M aint enance Chart beginning on page 54. Maintain the oil level even with the bottom thread of the fill plu g hole. We recommend the use of Polaris Premium Demand Drive Hub Fluid. See page 99 for the part numbers of Polaris products.

The front gearcase fill plug (1) is located on the right side of the front gearcase.

Oil Check

1. Position the vehicle on a level surface.

2. Remove the fill plug and check the oil level.

3. Add the recommended hub fluid as needed.

4. Reinstall the fill plug . Torque to specification. See page 66.

Oil Change

1. Support the vehicle securely with a jackstand.

2. Remove the front tire on the driver’s side.

3. Remove the fill plug.

4. Remove the gearcase drain plug (2) located on the bottom right-hand side and drain the oil into a drain pan. Discard used oil properly.

5. Clean and reinstall the drain plug . Torque to specification. See page 66.

6. Add 5 oz. (150 ml) of the recommended hub fluid. Refer t o the Gearcase Specifications Chart on page 66.

7. Reinstall the fill plug . Torque to specification. See page 66.

8. Check for leaks.

MAINTENANCE AND LUBRICATION

Gearcases

Middle Gearcase (RANGER 6X6)

Always check and change the middle gearcase oil at the intervals outlined in the Periodic M aint enance Chart beginning on page 54. Maintain the oil level even with the bottom thread of the fill plu g hole. We recommend the use of Polaris ATV Angle Drive Fluid. See page 99 for the part numbers of Polaris products.

The middle gearcase fill plug (1) is located on the driver’s side of the gearcase.

Oil Check

1. Position the vehicle on a level surface.

2. Remove the fill plug and check the oil level.

3. Add the recommended fluid as needed.

4. Reinstall the fill plug . Torque to specification. See page 66.

Oil Change

1. Remove the fill plug.

2. Remove the drain plug (2) from the bottom of the gearcase and drain the oil into a drain pan. Discard used oil properly.

3. Clean and reinstall the drain plug . Torque to specification. See page 66.

4. Add the recommended fluid. Refer to the Gearcase Specifications Chart on page 66.

5. Reinstall the fill plug . Torque to specification. See page 66.

6. Check for leaks.

TM 6X6

4X4

MAINTENANCE AND LUBRICATION

Gearcases

Rear Gearcase

Always check and change the rear gearcase oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 54. Maintain the oil level even with the bottom thread of the fill plug ho le. We recommend the use of Polaris ATV Angle Drive Fluid. See page 99 for the part numb ers of Polaris products.

The rear gearcase fill plug (1) is on the driver’s side of the rear gearcase.

Oil Check

1. Position the vehicle on a level surface.

2. Remove the fill plug and check the oil level.

3. Add the recommended fluid as needed.

4. Reinstall the fill plug . Torque to specification. See page 66.

Oil Change

1. Remove the fill plug.

2. Remove the drain plug (2) from the bottom of the gearcase and drain the oil into a drain pan. Discard used oil properly.

3. Clean and reinstall the drain plug. Torque to specification. See page 66.

4. Add the recommended fluid. Refer to the Gearcase Specifications Chart on page

66.

5. Reinstall the fill plug . Torque to specification. See page 66.

6. Check for leaks.

MAINTENANCE AND LUBRICATION

Cooling System (RANGER 4X4, 6X6)

Operation

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

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

NOTE: Some coolant level drop on new vehicles is normal as the

system is purging itself of trapped air. Observe coolant levels and maintain as recommended by adding coolant to the overflow bottle.

Adding or Changing Coolant

To ensure that the coolant maintains its ability to protect the engine, we recommend that the system be completely drained every two years and a fresh mixture of antifreeze and water added. Polaris recommends the use of Polaris Premium 60/40 anti-freeze/coolant or a 50/50 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 99 for the part numbers of Polaris products.

NOTE: Always follow the manufacturer’s mixing recommendations

for the freeze protection required in your area.

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

MAINTENANCE AND LUBRICATION

Cooling System (RANGER 4X4, 6X6)

Radiator and Cooling Fan

Always check and clean the screen and radiator fins at the intervals outlined in the Periodic M aint enance Chart beginning on page 54. Do not obstruct or deflect air flow through t he radiator by installing unauthorized accessories in front of the radiator or behind the cooling fan. Interference with the radiator air flow can lead to overheating and consequent engine damage.

CAUTION

Washing the vehicle with a high-pressure hose could damage the radiator fins and impair the radiator’s effectiveness. Exercise caution if a high-pressure system is used for washing the vehicle.

Coolant Level

Always check and change the coolant at the intervals outlined in the Periodic Maintenance Chart beginning on page 54. Maintain the coolant level between the minimum and maximum marks on the bottle (when the fluid is cool). The overflow bottle (1) is located in front of the right front wheel.

1. Position the vehicle on level ground.

2. View the coolant level in the overflow bottle.

3. If the coolant level is below the safe operating range, lift the hood and locate the overflow bottle lid. Remove the lid and use a funnel to add coolant through the filler opening. Reinstall the cap.

NOTE: 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.

MAINTENANCE AND LUBRICATION

Cooling System (RANGER 4X4, 6X6)

Radiator Coolant Level

Always check and change the coolant at t he intervals outlined in the Periodic Maintenance Chart beginning on page 54.

WA R N I N G

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

1. Lift the hood and slowly remove the radiator cap (1).

2. View the coolant level th rough the opening.

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

NOTE: This procedure is

required only if the cooling system has been drained for maintenance and/or repair. But if the overflow bottle has run dry, the level in the radiator should also be inspected.

NOTE: Use of a non-standard pressure cap will not allow the

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

MAINTENANCE AND LUBRICATION

Spark Plugs

CAUTION

Using non-recommended spark plugs can result in serious engine damage. Always use Polaris-recommended spark plugs. Refer to the specifications section beginning on page 100.

Spark Plug Gap/Torque

Model Electrode Gap New Plug Torque Used Plug Torque

RANGER

4X4, 6X6

.025" (.06 cm)

9-11 ft. lbs.

(12-15 Nm)

9-11 ft. lbs.

(12-15 Nm)

RANGER TM

.025" (.06 cm)

8.7-10.8 ft. lbs. (11.8-14.6 Nm)

16.6-19.5 ft. lbs. (22.5-26.4 Nm)

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

WA R N I N G

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

1. Normal

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

NOTE: The tip should not be white. A white insulator tip indicates

overheating, caused by use of an improper spark plug or incorrect carburetion adjustments.

2. Wet Fouled

The wet fouled insulator tip is black. A damp oil film covers the firing end. There m ay be a carbon layer over the entire nose. Generally, the electrodes are not worn. General causes of fouling are excessive oil, use of non-recommended injection oi l, improper us e of the choke, or incorrect carburetion adjustments.

Spark Plug Removal and Replacement

1. Remove the seat to access the engine compartment.

2. Remove the spark plug cap. Using the spark plug wrench provided in the t ool kit, remove the plug by rotating it counterclockwise.

3. Reverse the procedure for spark plug installation. Torque to specification.

MAINTENANCE AND LUBRICATION

Polaris Variable Transmission (PVT) System

WA R N I N G

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

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

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

Always follow all recommended maintenance procedures. See your dealer as outlined in the owner’s manual.

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

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

PVT Drying

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

1. Shift the transmission i nto neutral and apply full throttle for no longer than 10 seconds and repeat as necessary. This will expel the moisture and air dry the belt and clutches.

2. Allow the engi ne RPM to settle to idle speed, then shift the transmission to the lowest available range.

3. Test for belt s lippage. If the belt s lips, repeat the process.

4. Take th e vehicle to your dealer for service as soon as possible.

MAINTENANCE AND LUBRICATION

Vehicle Immersion

CAUTION

If your vehicle becomes immersed, major engine damage can result if the vehicle is not thoroughly inspected. Take the vehicle to your dealer before starting the engine.

If it’s impossible to take your RANGER to a dealer before starting it, follow the steps outlined b elow.

1. Move the vehicle to dry land, or at the very least, to a water level below the floor.

2. Disconnect the fuel pump wires.

3. Remove the spark plug.

4. Place a clean container under the engine and loosen the carburetor drain screw (1) two t urns.

RANGER 4X4, 6X6 RANGER TM

5. Turn the engine over several times with electric start. Inspect the drained fuel for water or sediment.

6. Dry the spark plug and reinstall, or install a new plug.

7. Tighten the carburetor drain screw.

8. Reconnect the fuel pump wires.

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

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

NOTE: If water has been ingested into the PVT follow the procedure

on page 75 for drying.

MAINTENANCE AND LUBRICATION

Filter Systems (RANGER 4X4, 6X6)

Air Filter

Always change the air filter at the intervals outlined in the Periodic Maintenance Chart beginning on page 54.

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

2. Remove the air box cover and inspect the gasket. It should adhere tightly to the cover and seal all the way around.

3. Remove the air filter (1).

4. Do not attempt t o clean the main element. Install a new air filter.

NOTE: Apply a small amount of

general purpose grease to the sealing edges of the filter before installing.

5. Inspect the air box for oil or water deposits. If present, drain them into a s uitable container.

NOTE: Service the air filter more frequently if t he vehicle is operated

in wet conditions or at high throttle openings for extended periods.

MAINTENANCE AND LUBRICATION

Filter Systems (RANGER 4X4, 6X6)

Breather Filter and Hoses

1. Lift the cargo box and locate the air box.

2. Follow the right-hand breather line (1) out the side of the air box and locate the filter (2).

3. Remove and inspect the filter for debris. Blow gently through the filter in the direction of the arrow to check for clogging. Replace as needed.

4. Check hoses for cracks, deterioration, abrasion, or leaks. Replace as needed.

5. Reinstall the filter with the arrow poi n t i n g toward the engine and secure the clamps.

CAUTION

Operation of the vehicle without a breather filter can cause engine damage. Always reinstall the breather filter after removing it for service.

Fuel Filter

Your Polaris vehicle is equipped with an in-line fuel filter. Have your dealer replace it after every 100 ho u rs of operation. Do n o t attempt to clean the fuel filter.

MAINTENANCE AND LUBRICATION

Filter Systems (RANGER TM)

Air Filter

Always check and change the air filter at the intervals out lined in the Periodic Maintenance Chart beginning on page 54.

1. Remove the seat to access the air cleaner.

2. Remove the breather hose (1) from the cylinder.

3. Remove the wing nut (2) and remove the air cleaner cover (3).

4. Remove the primary filter (4) and the secondary filter (5).

NOTE: Do not attempt to clean the

primary filter. Install new.

5. Wash the secondary (foam) filter with hot soapy water. Rinse and dry thoroughly.

6. Inspect the filter for t ears or damage. Replace with a new filter if needed.

7. Apply foam filter oil or clean engine oil and squeeze the filter until excess oil is removed.

8. Reassemble all components.

Fuel Filter

Your Polaris vehicle is equipped with an in-line fuel filter. Have your dealer replace it after every 100 ho u rs of operation. Do n o t attempt to clean the fuel filter.

MAINTENANCE AND LUBRICATION

Spark Arrestor

WA R N I N G

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

Do not perform service on the spark arrestor while the system is hot. Exhaust system temperatures can reach 1000! F. Allow components to cool sufficiently before proceeding.

Remove any combustible materials from the area. Wear eye protection and gloves. Do not stand behind or in front of the vehicle while purging. Never run the engine in an enclosed area. Exhaust contains

poisonous carbon monoxide gas that can cause loss of consciousness or death in a very short time.

Never go under the vehicle while it’s inclined.

MAINTENANCE AND LUBRICATION

Spark Arrestor

Use the following procedure to periodically purge accumulated carbon from the exhaust pipe.

1. Remove the arrestor clean-out plugs (1) located on the bottom of the muffler.

2. Place the transmission in neutral and start the engine.

3. Purge accumulated carbon from the system by momentarily revving the engine several times.

4. If carbon is expelled, cover or plug the exhaust outlet (2) and rap on the pipe around the clean-out plugs while revving the engine several more times.

5. If particles are still suspected to be in the muffler, elevate t he rear of the vehicle one foot higher than the front. Set the parking brake and block the wheels. Make sure the vehicle is in neutral and repeat steps 2 and 4.

6. If particles are still suspected to be in the muffler, drive the vehicle onto the incline so the front of the vehicle is one foot higher t h an the rear. Set the parking brake and block the wheels. Make sure the vehicle is in neutral and repeat steps 3 and 4 until no more particles are expelled when the engine is revved.

7. Stop the engine and allow the arrestor to cool.

8. Reinstall the arrestor plugs and remove the outlet cover or plug.

MAINTENANCE AND LUBRICATION

Throttle System

WA R N I N G

Failure to check or maintain proper operation of the throttle system can result in an accident and lead to serious injury or death if the throttle pedal sticks during operation.

Never start or operate this vehicle if it has a sticking or improperly operating throttle pedal.

Immediately contact your dealer for service if throttle problems arise.

Always check the pedal for free movement and return before starting the engine and occasionally during operation.

Throttle Freepl ay

If the throttle pedal (1) has excessive play due to cable stretch or misadjustment, it will cause a delay in throttle response, especially at low engine speed. The throttle may also not open fully. If the throttle pedal has no freeplay, the throttle may be hard to control, and the idle speed may be erratic.

Check the throttle pedal freeplay at t he intervals outlined in the Periodic Maintenance Chart beginning on page 54. Adjust the freeplay if necessary.

Throttle Freeplay Inspection

1. Apply the parking brake (2) and shift the transmission to neutral.

2. Start the engine and warm it up thoroughly.

3. Measure t h e distance the throttle pedal moves before the engine begins to pick up speed. Freeplay should be 1/16 to 1/8 inches.

Throttle Freepl ay Adjustment

1. Slide the boots (1) off the inline cable adjuster sleeve (2). Loosen the adjuster locknut (3).

2. Turn the adjuster until 1/ 16 to 1/8 inch freeplay is achieved.

NOTE: While adjusting, flip the throttle lever back and forth.

3. Tighten the locknut and slide the boots over the cable adjuster until they touch at the midp oint of adjuster.

MAINTENANCE AND LUBRICATION

Throttle System

Throttle Cable Adjustment (RANGER TM)

If the proper freeplay cannot be obtained with the throttle block adjuster, adjust the cable at the carburetor using the following procedure.

1. Remove the seat and loosen the clamp screw (1) and the throttle cable adjustment screw (2).

2. Adjust the cable as needed.

3. Tighten both screws and reinstall the seat.

4. Check for proper throttle operation and correct freeplay in all steering wheel posi tions.

Carburetor/Engine Idle RPM Adjustment

The idle speed adjustment should be performed as outlined in the Periodic Maintenance Chart, or whenever the idle speed is changed. Recommended engine idle RPM for the RANGER 4X4 and 6X6 is 1200 +/- 200. Recommended engine idle RP M for the RANGER TM is 1000 +/- 100.

If the engine idle speed is not satisfactory, and all other conditions are favorable, the carburetor can be adjusted with the following procedure.

1. Engage the parking brake and place the gear shift lever in the neutral position.

2. Warm up the engine by running the vehicle approximately five minutes.

3. Remove the the seat and locate the idle adjust s crew (1).

4. Place the transmission in gear (with park brake engaged).

5. Turn the carburetor idle adjust screw in or o ut until the desired idle RPM is reached. Turn the screw in (clockwise) to raise RPM. Turn the screw out (counterclockwise) to l o w er RPM.

4X4 6X6

MAINTENANCE AND LUBRICATION

Brakes

The front and rear brakes are hydraulic disc type b rakes and are activated by the brake pedal. See page 33.

Brake Fluid

Routine inspections are recommended to keep the brake system in good operating condition. Inspect the level of the brake fluid before each operation.

Change the brake fluid at the intervals outlined in th e Periodic Maintenance Chart beginning on page 54. The brake fluid should also be changed if it becomes contaminated, if the fluid level is below the minimum, or if th e type and brand of the fluid in the reservoir are unknown.

1. Position the vehicle on a level surface.

2. View the brake fluid level at the reservoir (1) under the hood. The level should be between the upp er (MAX) and lower (MIN) level lines.

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

4. Apply the b rake forcefully for a few seconds and check for fluid leakage around the fittings.

WA R N I N G

After opening a bottle of brake fluid, always discard any unused portion. Never st ore 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.

MAINTENANCE AND LUBRICATION

Brakes

Brake Inspection

5. Check the brake system for fluid leaks.

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

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

8. Inspect the brake disc s pline and pad wear surface for excessive wear.

9. Change pads when worn to 3/64" (.1 cm).

Parking Brake Inspection

1. Slowly push the parking brake down with y o u r foot.

2. After 8 to 12 clicks of lever travel, check the vehicle for movement. The vehicle should not roll while parked. If the vehicle moves, adjustm ent is necessary

Parking Brake Adjustment

1. Position the vehicle on a level surface.

2. Place the transmission in neutral.

3. Loosen or tighten the nuts on each end of the parking brake cable as needed.

3/64" (.1 cm)

MAINTENANCE AND LUBRICATION

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 54.

1. Position the vehicle on level ground.

2. Lightly turn the steering wheel left and right.

3. There should be 0.8 - 1.0 in (20 - 25 mm) of free play.

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

Cylinder Head/Cylinder Base Fastener Torque

Have your dealer check the RANGER cylinder head and cylinder base fasteners for p roper torque at the first service or after 25 hours.

Rear Spring Adjustment

The rear shock absorber springs are adjusted by rotating the adjustment cam (1) either clockwise or counterclockwise to increase or decrease spring tension.

MAINTENANCE AND LUBRICATION

Seat Belts

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

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

2. Push the red button in t h e middle of the buckle to make sure it releases freely.

3. Check the belt webbing for wear, cuts or damage. If any irregularities are found, have the seat belt system checked and/or replaced by an authorized Polaris dealer.

The RANGER seat belt is adjustable and should be adjusted for both the operator and passenger before driving. Although having the belt at 30! is typical for many people, it will not accommodate all body sizes and shapes. Make sure the seat belt

is adjusted to the lowest possible lap position before riding.

1. To adjust, loosen the bolts (1).

2. Reposition both the buckle and retractor. Tighten the bolts.

NOTE: The center belt does not self

adjust. Before riding, pull on the strap to secure the belt on the lap of the center passenger.

WA R N I N G

Failure to follow the age recommendations for this vehicle could result in serious injury or death. No one under t he age of 16 may operate this vehicle. No one under the age of 5 may ride as a passenger in this vehicle.

MAINTENANCE AND LUBRICATION

Tires

WA R N I N G

Operating your vehicle with worn tires will increase the possibility of skidding, loss of control and an accident, which could result in serious injury or death. Always replace t ires when the tread depth measures 1/8" (.3 cm) or less.

Improper tire inflation or the use of non-standard size or type of tires may adversely affect vehicle handling, which could result in vehicle damage or personal injury. Always maintain proper tire pressure. When replacing tires, always use original equipment size and type.

Tire Tread Depth

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

Axle and Wheel Nut Torque Specifications

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

Location Specification

Front Wheel Nuts 35 ft. lbs. (47 Nm)

Rear Wheel Nuts 35 ft. lbs. (47 Nm)

Front Spindle Nut 70 ft. lbs. (95 Nm)

Center and Rear Hub

Retaining Nuts

110 ft. lbs. (150 Nm)

1/8I (.3 cm)

MAINTENANCE AND LUBRICATION

Tires

WA R N I N G

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

Wheel Removal

1. Stop the engine, place the transmission in gear and lo ck the parking brake.

2. Loosen the wheel nuts sli ghtly.

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

4. Remove the wheel nuts and washers. Remove the wheel.

Wheel Installation

1. With the transmission in gear and th e parking brake locked, place the wheel in the correct position on the wheel hub. Be sure the valve stem is toward the outside and rotation arrows on the tire point toward forward rotation.

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

3. Carefully lower the vehicle to the ground.

4. Torque the wheel nuts according to the specifications on page 88.

MAINTENANCE AND LUBRICATION

Lights

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

WA R N I N G

Poor lighting while driving can result in severe injury or death. Headlight and taillight lenses become dirty during normal operation. Wash the headlights frequently to maintain lighting quality.

Hot components can cause serious burns to skin. Do not service the headlamps until t hey’ve cooled sufficiently.

Headligh t Lamp Replacement

1. Open the hood.

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

3. Turn the lamp counterclockwise to remove it.

4. Install the new lamp.

NOTE: Make sure the tab on the

lamp locates properly in the housing.

5. Reinstall the harness assembly into the headlight assembly.

MAINTENANCE AND LUBRICATION

Lights

Headligh t Beam Adjustment

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

2. Measure the distance from the floor to the center of the headlight and make a mark on the wall at the same height.

3. Start the engine and switch on the headlight.

4. Observe the headlight aim. The most intense part of the headlight beam should be aimed 8" (20.3 cm) b elow the mark placed on the wall in step 2.

NOTE: Include the weight of a rider on

the seat while performing this step.

5. Adjust the beam to the desired position by turning the adjust ment screw (1).

Brake Lights

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

1. Turn the ignition switch to t he ON position.

2. Depress the brake pedal. The brake light should come on after about 10mm (0.4 i n .) of pedal travel. If the light doesn’t come on, check the bulb.

MAINTENANCE AND LUBRICATION

Lights

Indicator Lamp Replacement

1. Lift the hood.

2. Reach in behind the console panel and lift the release (1) to unplug the ligh t from the harness.

3. Using a flathead screwdriver, press on the tab (2) on the top of the light to remove the indicator light assembly from the console panel.

4. Using a screwdriver, turn the light that needs to be replaced 1/4 turn counterclockwise.

5. Grip the light with a needle nose plier and remove the li ght from the assembly.

6. Install the new light and use a small flat head screwdriver to seat it into place, 1/4 turn clockwise.

7. Snap the assembly back into the console panel and reconnect the harness.

8. Close the hood.

Tool Kit

To help you perform routine maintenance, a too l kit is provided with your vehicle. Items included in the kit are:

S A screwdriver S An open-end wrench (8-10 mm) S An open-end wrench (12-14 mm) S A tire pressure gauge S A spark plug wrench and handle S A spanner wrench (for shock adjustment)

NOTE: Additional tools will be necessary to perform routine

maintenance.

MAINTENANCE AND LUBRICATION

Cleaning Your RANGER

Keeping your vehicle clean will not only improve its appearance but it can also extend the life of various components. With a few precautions, your vehicle can be cleaned much like an automobile.

The best and safest way to clean your vehicle is with a garden hose and a pail of mild soap and water. Use a professional type washing mitten, cleaning the upper body first and the lower p arts last. Rinse with water frequently and dry with a chamois to prevent water s pots.

NOTE: If warning labels are damaged, contact your Polaris dealer

for free replacement.

If a high pressure type car wash sys tem is used, extreme care must be taken to avoid water damage to the wheel bearings, transmission seals, body panels, brakes, headlights and warning labels. Many expensive repair bills can result from using high pressure detergent systems.

NOTE: If a high pressure car wash is used, grease all zerk fittings

immediately after washing. Also run the vehicle to evaporate any water that may have entered the engine or exhaust system.

MAINTENANCE AND LUBRICATION

Storage

If your vehicle is to be placed in extended or off season storage, the following steps should be taken to preserve its condition.

1. Perform all necessary repairs and thorough ly clean the vehicle.

2. Remove the spark plug and pour approximately one oun ce of Premium 4 oil into the cylinder. Operate the starter for a few seconds and reinstall the spark plug.

3. Remove the battery. Store it in a cool, dry place out of the sun.

4. Lubricate suspension pivot points, lower steering post and rear axle fittings.

5. Drain the engine side cover (RANGER 4X4, 6X6).

6. Block the vehicle so all tires are suspended off the ground.

7. Spray oil on all unpainted metal surfaces to prevent rusting. Avoid getting oil on rubber parts or in the brakes.

8. Lubricate all cables.

9. Tie a plastic bag over the exhaust pipe and air cleaner inlet to prevent moisture or small animals from entering.

10. Cover the vehicle with a canvas cover. Do not use plastic or coated materials since they d o not allow ventilation for the vehicle.

MAINTENANCE AND LUBRICATION

Removal from Storage

1. Check the battery electrolyte level and charge the battery if necessary. Install it in the vehicle. Make sure th e battery vent hose is routed properly and that it’s not pinched or restricted in any way.

2. Make sure the spark plug is tight.

3. Fill the fuel tank with fuel.

4. Check all th e points listed in the Daily Pre-Ride Inspection section on page 35.

NOTE: 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 54.

WA R N I N G

Engine exhaust contains poisonous carbon monoxide and can cause loss of consciousness or death. Never run an engine in an enclosed area.

MAINTENANCE AND LUBRICATION

Battery

Keep the battery terminals and connections free of corrosion. If cleaning is necessary, remove the corrosion with a stiff wire brush. Wash with a solution of one tablespoon baking soda and one cup water. Rinse well with tap water and dry off with clean shop towels. Coat the terminals with dielectric grease or petroleum jelly.

Be careful not t o allow cleaning solution or tap water into the battery.

WA R N I N G

Battery electrolyte is poisonous. It contains sulfuric acid. Serious burns can result from contact with skin, eyes or clothing.

Antidote External: Flush with water. Internal: Drink large quantities of water or milk. Follow with milk

of magnesia, beaten egg, or vegetable oil. Call physician immediately.

Eyes: Flush with water for 15 minutes and get prompt medical attention.

Batteries produce explosive gases. Keep sparks, flame, cigarettes, etc. away. Ventilate when charging or using in an enclosed space. Always shield eyes when working near batteries. KEEP OUT OF REACH OF CHILDREN.

MAINTENANCE AND LUBRICATION

Battery

Replenishing Battery Fluid (Conventiona l Battery)

A poorly maintained battery will deteriorate rapidly. Check the battery fluid level often. The fluid level should be kept between the upper and lower level marks (1).

To refill use only di stilled water. Tap water contains minerals that are harmful to a battery.

WA R N I N G

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

Battery Removal

1. Open the hood.

2. Remove the battery vent tube from the battery.

3. Disconnect the black (negative) battery cable first.

4. Disconnect the red (positiv e) battery cable next.

5. Lift the battery out of the vehicle, being careful not to tip it sideways and spill any electrolyte.

CAUTION

If electrolyte spills, immediately wash it off with a solution of one tablespoon baking soda and one cup water to prevent damage to the vehicle.

Polaris Ranger 2005, 2005 Ranger 4x4, 2005 Ranger 6x6, 2005 Ranger TM Owner's Manual For Maintenance And Safety

Specifications and Main Features

Frequently Asked Questions

User Manual