Polaris Ranger 2005, 2005 Ranger 4x4, 2005 Ranger 6x6, 2005 Ranger TM Owner's Manual For Maintenance And Safety
The engine exhaust from this
product contains chemicals known
to cause cancer, birth defects or
other reproductive harm.
WARNING
2
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
3
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.
4
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):
1
31XX
3
2
5
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...................................
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7
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.
8
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.
9
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.
10
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.
11
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.
12
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.
13
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.
14
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.
15
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.
16
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.
17
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.
18
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.
19
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.
20
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
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
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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)
1
2
3
4
Remove flammable containers from box before refueling.
WARNING
WARNING
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)
22
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)
5
6
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.
23
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
7
7172675
8
24
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.
25
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
1
4
7
5
6
2
3
8
9
26
FEATURES AND CONTROLS
Component Locations
10. Headlights
11. Radiator (if equipped)
12. Front Bumper/Brush Guard
13. Hood Hold Down Strap
12
11
10
13
27
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
14
14
20
17
16
18
18
19
15
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