Polaris RANGER (2019) Owner's Manual

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2019

RANGER

Diesel

EPS EU

Owner's Manual

for Maintenance and Safety

Page 2

WARNING

Read, understand, and follow all of the instructions and safety

precautions in this manual and on all product labels.

Failure to follow the safety precautions

could result in serious injury or death.

WARNING

Operating, servicing, and maintaining a passenger vehicle or off-road

vehicle can expose you to chemicals including engine exhaust, carbon

monoxide, phthalates, and lead, which are known to the State of California

to cause cancer and birth defects or other reproductive harm. To minimize

exposure, avoid breathing exhaust, do not idle the engine except as

necessary, service your vehicle in a well-ventilated area and wear gloves

or wash your hands frequently when servicing your vehicle.

For more information go to www.P65Warnings.ca.gov/passenger-vehicle.

For videos and more information

about a safe riding experience with

your Polaris vehicle, scan this QR

code with your smartphone.

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2019 Owner’s Manual

RANGER® Diesel EPS EU

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POLARIS®, RANGER®, and POLARIS GENERAL™ are trademarks of POLARIS Industries Inc.

Copyright 2019 Polaris Industries Inc. All information contained within this publication is based on the latest product information at the time of publication. Due to constant improvements in the design and quality of production components, some minor discrepancies may result between the actual vehicle and the information presented in this publication. Depictions and/or procedures in this publication are intended for reference use only. No liability can be accepted for omissions or inaccuracies. Any reprinting or reuse of the depictions and/or procedures contained within, whether whole or in part, is expressly prohibited.

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

Printed in Czech Republic

2019 RANGER® Owner’s Manual 9929238 Rev 01

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WELCOME

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

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

• Snowmobiles

• All-terrain vehicles (ATVs)

• Low emission vehicles (LEVs)

• RANGER® utility vehicles

• BRUTUS® work vehicles

• SLINGSHOT® three wheel motorcycles

Always follow the instructions and recommendations in this manual. The manual contains instructions for minor maintenance, but information about major repairs is outlined in the POLARIS Service Manual and should be performed only by a factory-certified Master Service Dealer® (MSD) technician. Please see your dealer for all of your service needs during (and after) the warranty period.

• RZR® sport vehicles

• GEM® vehicles

• INDIAN® motorcycles

• POLARIS POWER® generators

• POLARIS DEFENSE® combat vehicles

• Timbersled® Snow Bikes

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WELCOME

Page 7

Introduction . . . . . . . . . . . . . . . . . . . . 7

Safety . . . . . . . . . . . . . . . . . . . . . . 11

Features and Controls . . . . . . . . . . . . . . 29

Operation . . . . . . . . . . . . . . . . . . . . 59

Winch Guide. . . . . . . . . . . . . . . . . . . 85

Emission Control Systems . . . . . . . . . . . . . 95

Maintenance . . . . . . . . . . . . . . . . . . 97

Specifications . . . . . . . . . . . . . . . . . . 155

POLARIS Products . . . . . . . . . . . . . . . . 159

Troubleshooting . . . . . . . . . . . . . . . . . 161

Warranty . . . . . . . . . . . . . . . . . . . . 165

Maintenance Log . . . . . . . . . . . . . . . . 171

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INTRODUCTION

WARNING

Failure to follow the warnings contained in this manual can result in severe

injury or death.

This vehicle is not a toy and can be hazardous to operate. This vehicle handles

differently than other vehicles. A collision or rollover can occur quickly, even

during routine maneuvers, if you fail to take proper precautions.

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

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

• No person under the age of 12 may ride as a passenger in this vehicle.

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

• Always keep hands, feet, and all other body parts inside the vehicle at all times.

• Always wear the proper clothing when operating or riding in this vehicle. All riders should wear substantial footwear, long pants, and a close-fitting shirt. A hard hat or helmet and approved eye protection are recommended when appropriate for riding or working conditions.

• Never use this vehicle with drugs or alcohol, as these conditions impair judgment and reduce operator reaction time.

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INTRODUCTION

SAFETY SYMBOLS AND SIGNAL WORDS

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

DANGER

DANGER indicates a hazardous situation which, if not avoided, WILL result in

death or serious injury.

WARNING

SAFETY ALERT WARNING indicates a hazardous situation which, if not

avoided, COULD result in serious injury or death.

CAUTION

SAFETY ALERT CAUTION indicates a hazardous situation which, if not

avoided, COULD result in minor to moderate injury.

CAUTION

CAUTION indicates special precautions that must be taken to avoid vehicle

damage or property damage.

IMPORTANT

IMPORTANT provides key reminders during disassembly, assembly, and

inspection of components.

NOTICE

NOTICE provides key information by clarifying instructions.

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

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

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DECLARATION OF CONFORMITY

Polaris Sales Europe Sàrl Place de l’Industrie 2 1180 Rolle, Switzerland Telephone +41213–218–700

DECLARATION OF CONFORMITY

January 21, 2019 Polaris Sales Europe Sàrl declares that the vehicle(s) listed below conform to the essential requirements to all terrain vehicles.

INTRODUCTION

APPLICABLE EUROPEAN

DIRECTIVES

2006/42/EC as amended

(Machinery Directive)

2014/30/EU as amended

(EMC Directive)

MODEL COMMERCIAL NAME VEHICLE SERIAL

R_ _RR_D1_ _

(All combinations)

RANGER Diesel (See Product

TEST / EVALUATION METHODS:

EN ISO 12100:2010 Hazard Analysis

EN 15997:2011/AC:2012 Driver

Perceived Noise Level & Vibration

UNECE R10

NUMBER

Identification Label)

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INTRODUCTION

VEHICLE IDENTIFICATION NUMBERS

Record your vehicle's identification numbers in the spaces provided. The engine serial number is located on the side of the engine, below the injection pump.

All keys have the number 4083. Remove the spare key and store it in a safe place. Additional pre-cut keys for your vehicle can be ordered.

Vehicle Model Number

Vehicle Identification Number (VIN)

Engine Serial Number

Key Number 4083

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SAFETY

SAFETY TRAINING

Safety training is a top priority for POLARIS. POLARIS strongly encourages you and any family members who will be riding this vehicle to take a training course.

For more information about safety, contact an authorized POLARIS dealer or visit the POLARIS web site at www.polaris.com.

Your POLARIS vehicle is designed for off-road operation. Familiarize yourself with all laws and regulations concerning the operation of this vehicle in your area.

We strongly advise you to strictly follow the recommended maintenance program outlined in your owner's manual. This preventive maintenance program is designed to ensure that all critical components on your vehicle are thoroughly inspected at specific intervals.

SAFE RIDING GEAR

Always wear helmet, eye protection, gloves, long-sleeve shirt, long pants, overthe-ankle boots and seat belt at all times. Protective gear reduces the chance of injury.

RIDER COMFORT

Under certain operating conditions, heat generated by the engine and exhaust system can elevate temperatures in the rider cab area.

The condition occurs most frequently when a vehicle is being operated in high ambient temperatures at low speeds and/or high load conditions for an extended period of time. The use of certain windshield, roof and/or cab systems may contribute to this condition by restricting airflow. Any discomfort due to heat buildup in this area can be minimized by wearing proper riding apparel and by varying speeds to increase airflow.

Helmet

Eye Protection

Long Sleeves

Gloves

Long Pants

Over-the-Ankle Boots

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SAFETY

HELMET

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

Approved helmets in Europe, Asia and Oceania bear the ECE

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

EYE PROTECTION

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

GLOVES

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

BOOTS

Wear sturdy over-the-ankle boots for support and protection. Never ride a POLARIS vehicle with bare feet or sandals.

CLOTHING

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

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SAFETY

SAFETY LABELS AND LOCATIONS

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

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

GENERAL ALERT

Read your owner’s manual. Never allow anyone under 16 years of age to operate this vehicle. Never use alcohol or drugs before or while driving or riding. Do not allow operation on public roads (unless designated for off-highway vehicle access). Wear approved helmet, goggles, and protective clothing, always wear seat belts. Always use the cab nets or doors. Never exceed seating capacity.

SHIFT ALERT

CAUTION

To avoid transmission damage, shift only when vehicle is stationary and at idle. APPLY BRAKE TO START. When this vehicle is not in operation, or unattended, place shift in the park position.

General Alert

Shift Alert

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SAFETY

LOAD/PASSENGER/TIRE PRESSURE ALERT

Never carry passengers in cargo box. Passengers can be thrown off. This can cause serious injury or death. Read owner's manual. NEVER carry fuel or other flammable liquids on this vehicle. Failure to follow this instruction could lead to serious burn injuries or death.

RANGER EU/ZUG

MAXIMUM CARGO BOX LOAD

TIRE PRESSURE IN kPa (bar)

TIRE PRESSURE WITH FULL LOAD (MAX CARGO + PASSENGER) IN kPa (bar)

MAXIMUM WEIGHT CAPACITY

INCLUDES WEIGHT OF OPERATOR, PASSENGER, CARGO AND ACCESSORIES

Read Operation and Maintenance Manual for more detailed loading information.

FRONT 69 (0,69)

412 kg

(908 lbs.)

REAR 97 (0,97)

REAR 210 (2,1)

696 kg

(1534 lbs.)

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JACKING POINTS ALERT

Jacking positions are located beneath the vehicle’s center points. Read the owner’s manual.

GREASING POINTS ALERT

Lubricate as recommended. Read owner’s manual.

SAFETY

Load/Passenger/Tire Pressure

Alert

Jacking Points Alert

Greasing Points Alert

CLUTCH COVER ALERT

Read your owner’s manual. Keep body parts away from belt.

Clutch Cover Alert

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SAFETY

SAFETY WARNINGS

PROPER OPERATION

WARNING

Failure to operate the RANGER

properly can result in a collision, loss

of control, accident or rollover, which

may result in serious injury or death.

Heed all safety warnings outlined in

this section of the owner’s manual.

See the OPERATION section of the

owner’s manual for proper operating

procedures.

OPERATOR SAFETY

WARNING

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

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

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

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

• All riders must be able to sit with backs against the seat, both feet flat on the floor and both hands on the steering wheel (if driving) or on a passenger hand hold.

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

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

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

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

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

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

• This vehicle is approved for on-road operation.

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SAFETY

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

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

• Never attempt jumps or other stunts.

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

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

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

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

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

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

• Always follow proper procedures for climbing hills as described in this manual. Check the terrain carefully before attempting to climb a hill. Never climb hills with excessively slippery or loose surfaces. Never apply throttle suddenly. Never make sudden gear changes. Never go over the top of a hill at high speed.

• Always follow the proper procedures outlined in this manual for traveling downhill and for braking on hills. Check the terrain carefully before descending a hill. Never travel downhill at high speed. Avoid going downhill at an angle, which would cause the vehicle to lean sharply to one side. Travel straight down the hill where possible.

• Always check for obstacles before operating in a new area. Never attempt to operate over large obstacles such as large rocks or fallen trees. Always follow the proper procedures outlined in this manual when operating over obstacles.

• Always be careful of skidding or sliding. On slippery surfaces such as ice, travel slowly and exercise caution to reduce the chance of skidding or sliding out of control.

• Never operate your vehicle in fast-flowing water or in water deeper than that specified in this manual. Wet brakes may have reduced stopping ability. Test your brakes after leaving water. If necessary, apply them lightly several times to let friction dry out the pads.

• Always be sure there are no obstacles or people behind your vehicle when operating in reverse. When it’s safe to proceed in reverse, move slowly. Avoid turning at sharp angles in reverse.

• Always use the proper size and type of tires specified in this manual. Always maintain proper tire pressure as specified on safety labels.

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

• Always reinstall plastics and heat shields after vehicle is serviced.

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SAFETY

• 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.

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

• Always engage the park brake when leaving the vehicle unattended.

• Always stop the engine before refueling. Remove flammable material containers from the box before filling them with fuel. Make sure the refueling area is well ventilated and free of any source of flame or sparks. Gasoline is extremely flammable.

• Always remove the ignition key when the vehicle is not in use to prevent unauthorized use by someone under the age of 16 or without a driver’s license and proper training, or accidental starting.

OPERATING WITHOUT INSTRUCTION

Operating this vehicle without proper instruction increases the risk of an accident. The operator must understand how to operate the vehicle properly in different situations and on different types of terrain. All operators must read and understand the Owner's Manual and all warning and instruction labels before operating the vehicle.

AGE RESTRICTIONS

This vehicle is an ADULT VEHICLE ONLY. Operation is prohibited for anyone under 16 years of age or anyone without a valid driver’s license.

The operator must be tall enough to sit with back against the seat, both feet flat on the floor and both hands on the steering wheel (if equipped) or handlebars.

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SAFETY

USING ALCOHOL OR DRUGS

WARNING

Never consume alcohol or drugs before or while

operating this vehicle.

Operating this vehicle after consuming alcohol or

drugs could adversely affect operator judgment,

reaction time, balance and perception.

FAILURE TO INSPECT BEFORE OPERATING

WARNING

Failure to inspect and verify that the vehicle is in safe operating condition

before operating increases the risk of an accident. Always perform the Pre-

Ride Inspection outlined in the Operation chapter before each use of your

vehicle to make sure it's in safe operating condition. Always follow the

inspection and maintenance procedures and schedules described in this

owner’s manual. See the Periodic Maintenance section of the Maintenance

chapter.

PROTECTIVE APPAREL

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

Operator and/or all passengers must always wear an approved helmet that fits properly, gloves, long-sleeve shirt, long pants, over-the-ankle boots, and eye protection (goggles or face shield).

DUST EXPOSURE

Exposure to dust created by the movement of the vehicle in dry weather may lead to respiratory distress. Be aware of operating environments and take precautions to avoid dust ingestion. Wear proper clothing, helmet, and eye protection.

SEAT BELTS

WARNING

Riding in this vehicle without wearing the seat belt increases the risk of serious

injury in the event of rollover, loss of control, other accident or sudden stop.

Seat belts may reduce the severity of injury in these circumstances. The

operator MUST wear the seat belt at all times.

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SAFETY

CAB NETS

Riding in this vehicle without using the cab nets increases the risk of serious injury or death in the event of an accident or rollover.

Cab nets must be used by both operator and passenger at all times. Make sure all latches are secure before operating the vehicle.

Always inspect cab nets for tightness, wear and damage before each use of the vehicle. Use the strap adjusters to tighten any loose straps. Promptly replace worn or damaged cab nets or latches with new cab nets and latches. Your POLARIS dealer can assist.

CARRYING PASSENGERS

A passenger must always be seated in a passenger seat with seat belt secured. Never carry more than two passengers in a 3-seat vehicle.

OPERATING WITH A LOAD ON THE VEHICLE

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

• Do not exceed vehicle weight capacities. The vehicle’s maximum weight

capacity is listed in the specifications section of this manual and on a label on the vehicle. When determining the weight you are adding to the vehicle, include the weight of the operator, accessories, loads in the rack or box and the load on the trailer tongue. The combined weight of these items must not exceed the maximum weight capacity.

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

Always follow these guidelines:

UNDER ANY OF THESE CONDITIONS: DO ALL OF THESE STEPS:

Operator and/or cargo exceeds half the maximum weight capacity

Operating in rough terrain

Operating over obstacles

Climbing an incline

1. Slow down.

2. Verify tire pressure.

3. Use extra caution when operating.

Towing

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SAFETY

IMPROPER TIRE MAINTENANCE

WARNING

Operating this vehicle with improper tires or with improper or uneven tire

pressure could cause loss of control or accident. Always use the size and type

of tires specified for your vehicle. Always maintain proper tire pressure as

described in the owner's manual and on safety labels.

OPERATING ON PAVEMENT

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

OPERATING ON PUBLIC ROADS

WARNING

Operating this vehicle on public streets, roads or highways could result in a

collision with another vehicle. Never operate this vehicle on any public street,

road or highway, including dirt and gravel roads (unless designated for off-

highway use).

OPERATING AT EXCESSIVE SPEEDS

CAUTION

Operating this vehicle at excessive speeds increases the operator's risk of

losing control. Always operate at a speed that's appropriate for the terrain, the

visibility and operating conditions and your skills and experience.

JUMPS AND STUNTS

CAUTION

Exhibition driving increases the risk of an accident or rollover. DO NOT do

power slides, “donuts”, jumps or other driving stunts. Avoid exhibition driving.

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SAFETY

TURNING IMPROPERLY

CAUTION

Turning improperly could cause loss of traction, loss of control, accident or

rollover. Always follow proper procedures for turning as described in this

owner’s manual.

Avoid sharp turns. Never turn while applying heavy throttle. Never make abrupt steering maneuvers. Practice turning at slow speeds before attempting to turn at faster speeds.

IMPROPER HILL CLIMBING

CAUTION

Improper hill climbing could cause loss of control or rollover. Use extreme

caution when operating on hills. Always follow proper procedures for hill

climbing as described in this owner's manual.

DESCENDING HILLS IMPROPERLY

CAUTION

Improperly descending a hill could cause loss of control or rollover. Always

follow proper procedures for traveling down hills as described in this owner’s

manual.

CROSSING HILLSIDES

CAUTION

Driving on a sidehill is not recommended. Improper procedure could cause

loss of control or rollover. Avoid crossing the side of any hill unless absolutely

necessary. If crossing a hillside is unavoidable, always follow proper

procedures as described in this owner's manual.

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SAFETY

STALLING WHILE CLIMBING A HILL

CAUTION

Stalling or rolling backwards while climbing a hill could cause a rollover.

Maintain a steady speed when climbing a hill.

If you lose all forward speed:

Apply the brakes gradually until the vehicle is fully stopped. Place the transmission in reverse and slowly allow the vehicle to roll straight downhill while applying light brake pressure to control speed.

If you begin rolling downhill:

Never apply engine power. Apply the brakes gradually until the vehicle is fully stopped. Place the transmission in reverse and slowly allow the vehicle to roll straight downhill while applying light brake pressure to control speed.

OPERATING IN UNFAMILIAR TERRAIN

CAUTION

Failure to use extra caution when operating on unfamiliar terrain could result in

an accident or rollover.

CAUTION

Unfamiliar terrain may contain hidden rocks, bumps, or holes that could cause

loss of control or rollover.

Travel slowly and use extra caution when operating on unfamiliar terrain. Always be alert to changing terrain conditions.

OPERATING IMPROPERLY IN REVERSE

CAUTION

Improperly operating in reverse could result in a collision with an obstacle or

person. Always follow proper operating procedures as outlined in this manual.

Before shifting into reverse gear, always check for obstacles or people behind the vehicle. When it's safe to proceed, back slowly.

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SAFETY

SKIDDING OR SLIDING

CAUTION

Failure to use extra caution when operating on excessively rough, slippery or

loose terrain could cause loss of traction, loss of control, accident or rollover. Do not operate on excessively slippery surfaces. Always slow down and use

additional caution when operating on slippery surfaces.

CAUTION

Skidding or sliding due to loss of traction can cause loss of control or rollover (if

tires regain traction unexpectedly). Always follow proper procedures for

operating on slippery surfaces as described in this owner's manual.

OPERATING OVER OBSTACLES

CAUTION

Improperly operating over obstacles could cause loss of control or rollover.

Before operating in a new area, check for obstacles. Avoid operating over

large obstacles such as large rocks and fallen trees. Always follow the proper

procedures outlined in this manual when operating over obstacles.

Page 27

SAFETY

OPERATING THROUGH WATER

CAUTION

Operating through deep or fast-flowing water can cause loss of traction, loss of

control, rollover or accident. Never operate in fast-flowing water or in water that

exceeds the floor level of the vehicle.

Always follow proper procedures for operating in water as described in this owner’s manual.

Wet brakes will have reduced stopping ability. After leaving water, test the brakes. Apply them lightly several times while driving slowly. The friction will help dry out the pads.

OPERATING ON FROZEN BODIES OF WATER

WARNING

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

the ice. Never operate the vehicle on a frozen body of water unless you have

first verified that the ice is sufficiently thick to support the weight and moving

force of the vehicle, you and your cargo, together with any other vehicles in

your party.

Always check with local authorities and residents to confirm ice conditions and thickness over your entire route. Vehicle operators assume all risk associated with ice conditions on frozen bodies of water.

OPERATING A DAMAGED VEHICLE

CAUTION

Operating a damaged vehicle can result in an accident. After any rollover or

other accident, have a qualified service dealer inspect the entire machine for

possible damage, including (but not limited to) seat belts, rollover protection

devices, brakes, throttle and steering systems.

IMPROPER CARGO LOADING

Overloading the vehicle or carrying cargo improperly may cause changes in stability and handling, which could cause loss of control or an accident.

• Always follow the instructions in this owner’s manual for carrying cargo.

• Never exceed the stated load capacity for this vehicle.

• Cargo should be properly distributed and securely attached.

• Reduce speed when carrying cargo or pulling a trailer. Allow a greater distance for braking.

Page 28

SAFETY

POOR VISIBILITY

CAUTION

Operating this vehicle in darkness or inclement weather could result in a

collision or accident, especially if operating on a road or street. This vehicle is

not equipped with highway-approved lights. Operate this vehicle off-road only.

Use caution and drive at reduced speeds in conditions of reduced visibility

such as fog, rain and darkness. Clean headlights frequently and replace

burned out headlamps promptly.

HOT EXHAUST SYSTEMS

WARNING

Exhaust system components are very hot during and after use of the vehicle.

Hot components can cause burns and fire. Do not touch hot exhaust system

components. Always keep combustible materials away from the exhaust

system. Use caution when traveling through tall grass, especially dry grass.

Always inspect the underside of the vehicle and areas near the exhaust

system after driving through tall grass, weeds, brush, and other tall ground

cover. Promptly remove any grass or debris clinging to the vehicle.

EXPOSURE TO EXHAUST

CAUTION

Engine exhaust fumes are poisonous and can cause loss of consciousness or

death in a short time. Never start the engine or let it run in an enclosed area.

Operate this vehicle only outdoors or in well-ventilated areas.

Page 29

SAFETY

REFUELING

Diesel fuel is highly flammable and explosive under certain conditions.

• Always exercise extreme caution whenever handling diesel fuel.

• Always turn off the engine when refueling.

• Always refuel outdoors or in a well ventilated area free of any source of flame or sparks.

• NEVER carry fuel or other flammable liquids on this vehicle. Failure to follow this instruction could lead to serious burn injuries or death.

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

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

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

UNAUTHORIZED USE OF THE VEHICLE

Leaving the keys in the ignition can lead to unauthorized use of the vehicle by someone under the age of 16, without a drivers license, or without proper training. This could result in an accident or rollover. Always remove the ignition key when the vehicle is not in use.

EQUIPMENT MODIFICATIONS

Your POLARIS vehicle is designed to provide safe operation when used as directed. Modifications to your vehicle may negatively impact vehicle stability. Failure of critical machine components may result from operation with any modifications, especially those that increase speed or power. This vehicle may become less stable at speeds higher than those for which it is designed. Loss of control may occur at higher speeds.

Do not install any non-POLARIS-approved accessory or modify the vehicle for the purpose of increasing speed or power. Any modifications or installation of non-POLARIS-approved accessories could create a substantial safety hazard and increase the risk of bodily injury.

The POLARIS limited warranty on your POLARIS vehicle will be terminated if any non-POLARIS-approved equipment and/or modifications have been added to the vehicle that increase speed or power.

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

For more information about safety, contact an authorized POLARIS

dealer or visit the POLARIS web site at www.polaris.com.

Page 30

Page 31

FEATURES AND CONTROLS

COMPONENT LOCATIONS

Console

Headlights

Radiator

Bumper / Brush Guard

Taillights

Tailgate

CV Boot / Rear Caliper

Receiver Hitch

ROPS Cab Frame

Hip Bar

Cargo Box

Fuel Cap

Page 32

FEATURES AND CONTROLS

CONSOLE

Turn Signal Lever

Hazard Switch

Instrument Cluster

Steering Wheel Adjustment

Lever

Ignition Switch

Gear Selector (Shifter)

Park Brake Lever

Glow Plug/Park Brake Indicator

ADC Switch

AWD Switch

12V Auxiliary Outlets

Storage Compartment

ADJUSTABLE STEERING WHEEL

The steering wheel can be tilted upward or downward for rider preference. Lift and hold the adjustment lever you while moving the steering wheel upward or downward. Release the lever when the steering wheel is at the desired position. Always make sure the steering wheel position does not impede proper operation of the brake pedal, throttle pedal, and all other controls.

toward

Page 33

FEATURES AND CONTROLS

GEAR SELECTOR

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

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

Low gear is the primary driving range for the RANGER. High gear is intended for use on hard-packed surfaces with light loads. Whenever the vehicle is left unattended, always place the transmission in PARK.

TIP

Maintaining shift linkage adjustment is important to assure proper transmission

function. Your POLARIS dealer can assist in resolving any shifting problems.

NOTICE

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.

SWITCHES

IGNITION SWITCH / LIGHT SWITCH

Use the ignition switch to start the engine and to turn the lights on or off. The key can be removed from the switch when it is in the OFF position.

OFF

Turn the key to the OFF position to stop the engine. Electrical circuits are off.

LIGHTS ON

POSITION LIGHTS ON

START

All lights are on. Electrical circuits are on. Electrical equipment can be used.

The headlights are off. Position lights are on. Electrical equipment can be used.

Turn the key to the START position to engage the electric starter. See the Starting the Engine section for details.

Page 34

FEATURES AND CONTROLS

TURN SIGNAL LEVER

Before turning, activate a turn signal to alert others of your intentions. Check turn signal lamps before each ride.

TIP

The key must be in the ON position to activate the turn signals.

Move the turn signal lever downward to signal a left turn. The left turn signal lamps in the taillight and below the front headlight will flash. The turn signal indicator in the gauge will also flash.

Move the lever upward right turn. The right signal lamps and indicator will flash.

Return the lever to the center position to end the signal.

to signal a

AWD SWITCH

The AWD switch has three positions: All Wheel Drive (AWD), Differential Lock/Two Wheel Drive (2WD) and Off (1WD/Turf Mode).

Press the top of the switch to engage All Wheel Drive (AWD).

Move the switch to the center position to lock the differential and operate in two wheel drive (2WD).

Press the bottom of the switch to unlock the differential and allow the rear drive wheels to operate independently (1WD). This mode of operation is well suited to turf driving or when active traction is not needed.

Page 35

FEATURES AND CONTROLS

HAZARD SWITCH

Push the hazard warning switch to cause all turn signal lights to flash simultaneously. Both turn signal indicators on the console will also flash. Use this feature to alert others of an emergency or other situation requiring caution.

ADC SWITCH

The ADC switch has two positions, ON/OFF. ADC will activate when all of the following conditions are met:

• AWD mode is engaged.

• No throttle applied.

• Vehicle speed is between 1-12.5 MPH.

• ADC switch is in ON position.

PARK BRAKE/GLOW PLUG INDICATOR

The park brake indicator illuminates when the park brake is engaged. The glow plug indicator illuminates when the glow plugs are active. The indicator turns off when the engine is ready to start.

Page 36

FEATURES AND CONTROLS

AUXILIARY OUTLET

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

BRAKE PEDAL

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

THROTTLE PEDAL

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

TIP

If the throttle pedal and brake pedal are applied simultaneously, engine power

may be limited.

Page 37

FEATURES AND CONTROLS

PARK BRAKE LEVER

Always apply the service brakes before engaging or releasing the park brake. To help prevent the vehicle from rolling, set the park brake when parking the vehicle.

TIP

This feature will not operate properly if the park brake connector or switch

(under the hood) malfunctions or becomes disconnected, or if the switch has

moved. See your dealer or other qualified service person promptly if this

feature fails to operate properly. If the switch is disconnected, the park brake

light will be on and a signal will sound if the engine revs above a certain

threshold while the vehicle is not in park.

1. To set the park brake, apply the brakes. Pull the park brake lever towards yourself as far as possible.

2. To release the park brake, apply the brakes. Turn the park brake lever counterclockwise and push it in as far as possible.

SEAT

SEAT REMOVAL

To remove the driver’s seat, lift up on the rear of the seat and rotate the seat base up and forward.

To put the passenger seat into the upright position, lift up on the front of the seat and raise it to the upright position.

Page 38

FEATURES AND CONTROLS

SEAT BELTS

This vehicle is equipped with three-point lap and diagonal seat belts for the operator and passengers. Always make sure the seat belts are secured for all riders before operating.

WARNING

Falling from a moving vehicle could result in serious injury or death. Always

fasten your seat belt securely before operating or riding in the vehicle.

To wear the seat belt properly, follow this procedure:

1. For 3-point belts, pull the seat belt latch toward the buckle at the inner edge of the seat. The belt should fit snugly across your hips and diagonally across your chest. Make sure the belt is not twisted.

2. Push the latch plate

3. Release the strap, it will self tighten.

4. To release the seat belt, press the square red button in the buckle’s center.

into the buckle w until it clicks.

downward and across your chest

Page 39

FEATURES AND CONTROLS

SEAT BELT INSPECTION

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

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

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

3. Pull each seat belt completely out and inspect the full length for any damage, including cuts, wear, fraying or stiffness. If any damage is found, or if the seat belt does not operate properly, have the seat belt system checked and/or replaced by an authorized dealer.

4. To clean dirt or debris from the seat belts, sponge the straps with mild soap and water. Do not use bleach, dye or household detergents. Rinse the entire length of the belt webbing. Use a garden hose to flush out the retractor and latch housings regularly.

SEAT AND STORAGE COMPARTMENTS

The electrical compartment is located under the center seat. Never use this area for storage. A storage bin is located under the passenger seat. To access this storage area, lift up on the front of the passenger seat and raise it to the upright position. Remove the storage bin to access the battery.

Always make sure all seats are properly installed before operating. Push down firmly on the rear of each seat until the latch pins are fully seated into the grommets.

Page 40

FEATURES AND CONTROLS

SEAT ADJUSTMENTS

The driver’s seat is equipped with an adjustment lever and adjustment knob for optimal spacing.

• Pull the adjustment lever to the left to move the seat forward or rearward. Once released, the lever will lock into place.

• Rotate the adjustment knob to move the seat forward and upward or rearward and downward.

Driver’s Seat

Up Position

To adjust the front passenger seat, loosen (do not remove) the four screws located on the seat bottom. Slide the seat forward or rearward to the desired position. Tighten the screws to 5.4 Nm. (4 ft. lbs.) Do not overtighten.

Driver’s Seat

Down Position

ELECTRONIC POWER STEERING (EPS)

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

To conserve battery power, the EPS will shut down 5 minutes after the engine is stopped if the key remains in the ON position. The EPS warning indicator will illuminate to indicate the EPS has shut down. Turn the key off and on to reset the unit. If the light remains on after starting the engine, the EPS system is inoperative. Your POLARIS dealer can assist..

Page 41

FEATURES AND CONTROLS

FUEL CAP

The fuel tank filler cap q is located on the left-hand side of the vehicle near the driver’s seat. When refueling, always use one of the compatible diesel fuels for this vehicle: B7, B10, or B20. Always ensure that the fuel tank filler cap is fully tightened and secure before operating or transporting the vehicle. Tighten the cap until you hear two clicks.

CAB NETS

Riding in this vehicle without using the cab nets increases the risk of serious injury or death in the event of an accident or rollover.

Cab nets must be used by both operator and passenger at all times. Make sure all latches are secure before operating the vehicle.

SECURING THE NET

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

2. Connect the latch at the top edge of the net to the receiver latch mounted on the front frame.

OPENING THE NET

1. To exit the vehicle, release the top front latch.

2. Rotate the net rearward and slide the lower net rod out of the mount to remove it.

3. Allow the net to hang freely outside the vehicle while dismounting.

Page 42

FEATURES AND CONTROLS

ROLLOVER PROTECTIVE STRUCTURE (ROPS)

The Rollover Protective Structure (ROPS) on this vehicle meets OECD Code 4 rollover performance requirements. Always have your authorized dealer thoroughly inspect the ROPS if it ever becomes damaged in any way.

No device can assure occupant protection in the event of a rollover. Always follow all safe operating practices outlined in this manual to avoid vehicle rollover.

WARNING

Vehicle rollover could cause severe injury or death. Always avoid operating in

a manner that could result in vehicle rollover.

HOOD LATCHES

To remove the hood, rotate the hood latches away from the vehicle.

1/4-turn and lift the hood

TRAILER HITCH BRACKET

This vehicle is equipped with a receiver hitch bracket for a trailer hitch. To avoid injury and property damage, always heed the warnings and towing capacities outlined in the Towing Loads section.

Page 43

FEATURES AND CONTROLS

HITCHES

WARNING

Whenever the vehicle is towing, always stay clear of the area between the

vehicle and the towed object.

REAR HITCH

Use the rear hitch for towing a trailer.

REAR HITCH SPECIFICATIONS

Material S355J2+N

Fasteners Metal pin with security cotter pin

Weld Length and Positions 7 mm fillet, all around

Maximum Vertical Load 100 kg applied on coupling point

Maximum Towable Mass 1000 kg

Approval # E9-55R-01.6126

REAR HITCH CERTIFICATION LABEL

The hitch certification label is located near the hitch on models equipped with a factory-installed rear hitch.

Page 44

FEATURES AND CONTROLS

HITCH REMOVAL / INSTALLATION

1. To remove the hitch, remove the cotter pin q and hitch pin w. Remove the hitch, then reinstall the hitch pin

and secure the cotter pin q.

2. To install the hitch, remove the cotter pin the hitch pin

3. Install the hitch to the receiver.

4. Reinstall the hitch pin (from the left side of the hitch) through the bore of both the receiver and the hitch.

5. Reinstall the cotter pin. Make sure the hitch assembly is secure at that the cotter pin is properly engaged over the hitch pin.

from the hitch pin and remove

Page 45

FEATURES AND CONTROLS

7-WAY TRAILER CONNECTOR

The 7-way trailer connector q installed on your vehicle meets the requirements of European standard ISO 1724.

This connector uses all 7 pins on newer model trailers. An older model trailer may not be compatible with this connector.

Improper electrical wiring changes can result in damage to both vehicle and trailer components. When in doubt about your trailer connection, please contact a qualified towbar specialist for assistance.

Page 46

FEATURES AND CONTROLS

INSTRUMENT CLUSTER

OVERVIEW

NOTICE

The use of a high pressure washer may damage the instrument cluster. Wash

the vehicle by hand or with a garden hose using mild soap. Do not use alcohol

to clean the instrument cluster. Do not allow insect sprays to contact the lens.

Immediately clean off any gasoline that splashes on the instrument cluster.

H = High Gear L = Low Gear

Gear Indicator

Display Area 2

Display Area 1

Fuel Gauge

N = Neutral R = Reverse Gear P = Park – = Gear Signal Error (or shifter between gears)

This area displays odometer, trip meter, trip meter 2, voltage, engine temperature, engine hour meter, programmable service hour interval, ground speed, or engine RPM.

This area displays engine RPM, ground speed, or coolant temperature.

The segments of the fuel gauge show the level of fuel in the fuel tank. When the last segment clears, a low fuel warning is activated. All segments including the fuel icon will flash. Refuel immediately.

Service Indicator

Clock

AWD Indicator

A flashing wrench symbol alerts the operator that the preset service interval has been reached. Your POLARIS dealer can provide scheduled maintenance. See page 54 for more information.

The clock displays time in a 12-hour or 24-hour format.

Segments of the indicator illuminate based on drive mode engaged.

Page 47

INDICATOR LAMPS

Check Engine

EPS Warning

FEATURES AND CONTROLS

This lamp illuminates when the ECM detects a Diagnostic Trouble Code in the engine management system. Do not operate the vehicle if this warning appears. Serious engine damage could result. Your authorized POLARIS dealer can assist.

This lamp illuminates to indicate that EPS has shut down. EPS shuts down automatically 5 minutes after the engine is turned off if the key remains in the ON position. Turn the key off and on to reset the unit. If the light remains on after starting the engine, the EPS system is inoperative. Your POLARIS dealer can assist.

Engine Hot

Neutral

Helmet/Seat Belt

High Beam

Brake Failure

Trailer Indicator

This lamp illuminates to indicate an overheated engine. If the indicator flashes, a severe overheating condition exists.

This lamp illuminates when the transmission is in neutral and the ignition key is in the ON position.

This lamp flashes for several seconds when the key is turned to the ON position. The lamp is a reminder to wear a helmet and your seat belt.

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

This lamp illuminates when the brake system detects low pressure in the brake hydraulic system.

This lamp illuminates when the trailer turn signals are active.

Page 48

FEATURES AND CONTROLS

DISPLAY AREA 1

Pressing the MODE button will change the information displayed in Area 1 q.

Speed

RPM

Engine

Temperature

Ambient

Temperature

(Optional)

Page 49

DISPLAY AREA 2

FEATURES AND CONTROLS

Toggle the Up/Down buttons to change the information displayed in Area 2 w.

Odometer

Trip 1

Trip 2

Engine

Temperature

Ambient

Temperature

(Optional)

RPM

Voltage

Engine Hours

Speed

Service Hours

Page 50

FEATURES AND CONTROLS

OPTIONS MENU

Press and hold the MODE button to enter the Options Menu.

OPTIONS MENU NOTES

Diagnostic Codes Only displays if fault codes are

present or stored

Units - Distance Select MPH or KPH

Units - Temp Select between °F and °C

Clock Select between 12H or 24H, and set

time

Backlight Color Select between Blue or Red

Backlight Level Set backlight brightness level

Service Hours View/Set Service hours

Exit Menu Exit

Page 51

FEATURES AND CONTROLS

UNIT SELECTION DISTANCE

1. Press and hold the MODE button to enter the Options Menu.

NOTICE

“OPTIONS” will display on the screen for 3 seconds before showing first menu

item.

2. Select “Units-Distance” from the Options Menu by pressing the MODE button.

Reference the image shown above:

Press the MODE button.

Toggle the Up/Down Buttons to change the units (MPH or KPH)

With the correct unit displayed, Press the mode button which will set

the unit and return to the Options Menu.

3. To exit the Options Menu the user can select Exit Menu function from Options Menu, can hold Mode Button and exit out of Options Menu, or not press any button for 10 seconds, which will exit out of the Options Menu.

Page 52

FEATURES AND CONTROLS

UNIT SELECTION TEMPERATURE

1. Press and hold the MODE button to enter the Options Menu.

NOTICE

“OPTIONS” will display on the screen for 3 seconds before showing first menu

item.

2. Select “Units - Temp” from the Options Menu by pressing the MODE button.

Reference the image shown above:

Press the MODE button.

Toggle the Up/Down Buttons to change the units (°F or °C)

With the correct unit displayed, Press the mode button which will set

the unit and return to the Options Menu.

Page 53

FEATURES AND CONTROLS

CLOCK

1. Press and hold the MODE button to enter the Options Menu.

NOTICE

“OPTIONS” will display on the screen for 3 seconds before showing first menu

item.

2. Select “Clock” from the Options Menu by pressing the MODE button.

Reference the image shown above:

Press the MODE button.

Toggle the Up/Down Buttons to change the units (12H or 24H)

With the correct unit displayed, Press the mode button which will set

the unit.

Toggle the Up/Down Buttons to change the units (Cycles Hours)

With the correct unit displayed, Press the mode button which will set

the unit.

Toggle the Up/Down Buttons to change the units (Cycles 10s of

Minutes)

With the correct unit displayed, Press the mode button which will set

the unit.

Toggle the Up/Down Buttons to change the units (Cycles 1s of

Minutes)

With the correct unit displayed, Press the mode button which will set

the unit and return to the Options Menu.

Page 54

FEATURES AND CONTROLS

BACK LIGHT COLOR

1. Press and hold the MODE button to enter the Options Menu.

NOTICE

“OPTIONS” will display on the screen for 3 seconds before showing first menu

item.

2. Select “Backlight Color” from the Options Menu by pressing the MODE button.

Reference the image shown above:

Press the MODE button.

Toggle the Up/Down Buttons to change the units (Blue or Red)

With the correct unit displayed, Press the mode button which will set

the unit and return to the Options Menu.

Page 55

FEATURES AND CONTROLS

BACK LIGHT LEVEL

1. Press and hold the MODE button to enter the Options Menu.

NOTICE

“OPTIONS” will display on the screen for 3 seconds before showing first menu

item.

2. Select “Backlight Level” from the Options Menu by pressing the MODE button.

Reference the image shown above:

Press the MODE button.

Toggle the Up/Down Buttons to change the units (Increase or De-

crease Level)

With the correct unit displayed, Press the mode button which will set

the unit and return to the Options Menu.

Page 56

FEATURES AND CONTROLS

SERVICE HOURS

1. Press and hold the MODE button to enter the Options Menu.

NOTICE

“OPTIONS” will display on the screen for 3 seconds before showing first menu

item.

2. Select “Service Hours” from the Options Menu by pressing the MODE button.

Reference the image shown above:

Press the MODE button.

Toggle the Up/Down Buttons to change the units (0, 5, 10 - 95, 100)

With the correct unit displayed, press the MODE button, which will set

the unit and return you to the Options Menu.

NOTICE

To reset service hours after they have counted down to "0.0", reselect the

existing setpoint or select a new service hour value.

Page 57

FEATURES AND CONTROLS

DIAGNOSTIC CODE

NOTICE

Diagnostic Code Screen will show available MIL that has come on during that

ignition cycle.

1. Press and hold the MODE button to enter the Options Menu.

NOTICE

“OPTIONS” will display on the screen for 3 seconds before showing first menu

item.

2. Select “Diagnostic Codes” from the Options Menu by pressing the MODE button.

Toggle the Up/Down Buttons to cycle through Code(s).

NOTICE

This option will only be available if a fault code was set or is active during the

current ignition key 'on' cycle. Turning off the ignition will clear any save fault

codes from the gauge.

Reference the image shown above:

Area A will Display FMI (XX)

Area B will Display SPN (XXXXXX)

Clock Area will Display Count (XXX)

Page 58

FEATURES AND CONTROLS

DIAGNOSTIC DISPLAY CODE DEFINITIONS

DIAGNOSTIC CODES

COMPONENT CONDITION SPN FMI

Low oil pressure switch fault

Engine Temperature Sensor

System Power (Battery Potential/ Power Input)

CAN message 65390 Timeout error

Current below normal or open circuit

Voltage above normal, or shorted to high source

Data valid but below normal operational range - most severe level

Voltage above normal, or shorted to high source

Voltage below normal, or shorted to low source

100 11

100 5

110 3

110 4

168 1

168 3

168 4

Gear Sensor Signal Voltage below normal,

or shorted to low source

Rear Differential Output

Fan Relay Driver Ckt. Voltage above normal,

Voltage above normal, or shorted to high source

Voltage below normal, or shorted to low source

Current below normal or open circuit

or shorted to high source

Voltage below normal, or shorted to low source

Current below normal or open circuit

523 4

746 3

746 4

746 5

1071 3

1071 4

1071 5

Page 59

FEATURES AND CONTROLS

DIAGNOSTIC CODES

COMPONENT CONDITION SPN FMI

Fuel Pump Driver Ckt. Voltage above normal,

or shorted to high source

Voltage below normal, or shorted to low source

1347 3

1347 4

ECU Output Supply Voltage 1

ECU Output Supply Voltage 3

All Wheel Drive Control Circuit

Current below normal or open circuit

Voltage above normal, or shorted to high source

Voltage below normal, or shorted to low source

Voltage above normal, or shorted to high source

Voltage below normal, or shorted to low source

Voltage above normal, or shorted to high source

Voltage below normal, or shorted to low source

1347 5

3597 3

3597 4

3598 3

3598 4

520207 3

520207 4

Brake failure lamp faults

Glow Plug Relay Driver Circuit

Current below normal or open circuit

Voltage above normal, or shorted to high source

Voltage below normal, or shorted to low source

Current below normal or open circuit

Voltage above normal, or shorted to high source

Voltage below normal, or shorted to low source

520207 5

520214 3

520214 4

520214 5

520272 3

520272 4

Page 60

FEATURES AND CONTROLS

DIAGNOSTIC CODES

COMPONENT CONDITION SPN FMI

Brake switch (1 or 2 indeterminable)

Engine Oil Pressure Sensor

Current below normal or open circuit

Data erratic, intermittent or incorrect

Data valid but below normal operating range - least severe level

520272 5

520285 2

524076 17

Page 61

OPERATION

WARNING

Failure to operate the vehicle properly can result in a collision, loss of control,

accident or rollover, which may result in serious injury or death. Read and

understand all safety warnings outlined in the safety section of this owner’s

manual.

VEHICLE BREAK-IN PERIOD

The break-in period for your new vehicle is the first 50 hours of operation. No single action on your part is as important as a proper break-in period. Careful treatment of a new engine will result in more efficient performance and longer life for the engine. Perform the following procedures carefully.

NOTICE

Excessive heat build-up during the first 3 hours of operation will damage close-

fitted engine parts and drive components. Do not operate at full throttle or high

speeds during the first 3 hours of use.

BRAKE SYSTEM BREAK-IN

Apply only moderate braking force for the first 50 stops. Aggressive or overly forceful braking when the brake system is new could damage brake pads and rotors.

ENGINE AND DRIVETRAIN BREAK-IN

1. Fill the fuel tank with clean, fresh fuel.

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

3. Complete the New Operator Driving Procedures.

4. Avoid aggressive use of the brakes.

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

6. Pull only light loads.

7. Perform regular checks on fluid levels, controls and areas outlined on the daily pre-ride inspection checklist.

8. During the break-in period, change both the oil and the filter at 50 hours or one month.

9. Check fluid levels of transmission and all gearcases after the first 50 hours of operation and every 100 hours thereafter.

Page 62

OPERATION

PVT BREAK-IN (CLUTCHES/BELT)

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

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

KNOW YOUR RIDING AREA/TREAD LIGHTLY

Familiarize yourself with all laws and regulations concerning the operation of this vehicle in your area. Respect the environment in which you ride your vehicle. Find out where the designated riding areas are by contacting your POLARIS dealer, a local riding club, or local officials.

Help keep our trails open for recreational vehicle use. As an off-road enthusiast, you represent the sport and can set a good example (or a poor example) for others to follow. Tread lightly. Operate with respect for the terrain, avoid littering, and always stay on the designated trails.

TRAIL ETIQUETTE

Always practice good etiquette when riding. Allow a safe distance between your vehicle and other vehicles operating in the same area. Communicate to oncoming operators by signaling the number of vehicles in your group. When stopping, move your vehicle to the edge of the trail as far as possible to allow others to pass safely.

Page 63

OPERATION

SAFE OPERATION PRACTICES

1. Do not allow anyone under 16 years of age or without a valid driver’s license to operate this vehicle.

2. Engine exhaust fumes are poisonous. Never start the engine or let it run in an enclosed area.

3. Never operate with accessories not approved by POLARIS for use on this vehicle.

4. Use caution and drive at reduced speeds in conditions of reduced visibility such as fog, rain and darkness. Clean headlights frequently and replace burned out headlamps promptly.

5. Always operate at a speed that's appropriate for the terrain, the visibility and operating conditions and your skills and experience. Never operate at excessive speeds. Never attempt wheelies, jumps, or other stunts. Keep both hands on the steering wheel or handlebars during operation.

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

7. Always use the size and type of tires specified for your vehicle. Always maintain proper tire pressure.

8. Never operate a damaged vehicle. After any rollover or accident, have a qualified service dealer inspect the entire machine for possible damage.

9. Never operate the vehicle on a frozen body of water unless you have first verified that the ice is sufficiently thick to support the weight and moving force of the vehicle, you and your cargo, together with any other vehicles in your party.

10. Do not touch hot exhaust system components. Always keep combustible materials away from the exhaust system.

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

Page 64

OPERATION

PRE-RIDE INSPECTION

WARNING

Failure to inspect and verify that the vehicle is in safe operating condition

before operating increases the risk of an accident. Always inspect the vehicle

before each use to make sure it's in safe operating condition.

ITEM REMARKS PAGE

Brake system/pedal travel Ensure proper operation page 132

Brake fluid Ensure proper level page 132

Front suspension Inspect, lubricate if necessary page 101

Rear suspension Inspect, lubricate if necessary page 101

Steering Ensure free operation -

Tires Inspect condition and pressure page 135

Wheels/fasteners Inspect, ensure fastener tightness page 135

Frame nuts, bolts, fasteners Inspect, ensure tightness -

Drive belt Inspect, ensure installed correctly -

Fuel and oil Ensure proper levels, check underneath vehicle

for leaks

Coolant level Ensure proper level page 111

Coolant hoses Inspect for leaks -

Throttle Ensure proper operation page 34

Indicator lights/switches Ensure proper operation of switches

Ensure proper operation of glow plug indicator and glow plugs

Air filter Inspect and clean without removing from the

vehicle; remove air filter only when replacing it

page 101

page 45 page 31

page 122

Headlamps Check operation, apply POLARIS dielectric

grease when lamp is replaced

Brake light/tail lamps Check operation -

Seat latch Push down on the seat back to ensure the latch

is secure

Seat belts Check length of belts for damage, check latches

for proper operation

page 136

page 36

Page 65

OPERATION

ITEM REMARKS PAGE

Cab nets Check nets and latches for wear or damage -

Grass and leaves Remove grass, leaves, and other flammable

material or debris

Park brake Ensure proper operation page 35

Engine check Start engine and listen for unusual engine noise,

check color of exhaust fumes

FUEL RECOMMENDATIONS

NOTICE

For the best engine performance, to prevent engine damage and to comply

with EPA/CARB warranty requirements, use ONLY the recommended diesel

fuels. Use only CLEAN diesel fuel.

POLARIS recommends the following diesel fuels for use in this vehicle:

• Ultra Low Sulfur #2

• #1 Diesel Fuel containing no more than 20% bio-diesel

For more information about recommended diesel fuels and the consequences of using bio-diesel fuel exceeding 20% bio- diesel, see Additional Technical Fuel Requirements below.

Diesel fuel should comply with the following world-wide specifications.

DIESEL FUEL SPECIFICATION LOCATION

ASTM D975

USA No. 1D S15, S500 No. 2D S15, S500

EN590:96 European Union

ISO 8217 DMX International

BS 2869-A1 or A2 United Kingdom

JIS K2204 Grade No. 2 Japan

KSM-2610 Korea

GB252 China

Page 66

OPERATION

ADDITIONAL TECHNICAL FUEL REQUIREMENTS

• The fuel cetane number should be equal to 45 or higher.

• The sulfur content must not exceed 0.5% by volume. Less than 0.5% is preferred. Especially in the U.S.A. and Canada, Ultra Low Sulfur fuel should be used.

• Bio-Diesel fuels.

• NEVER mix kerosene, used engine oil or residual fuels with diesel fuel.

• Water and sediment in the fuel should not exceed 0.05% by volume.

• Keep the fuel tank and fuel-handling equipment clean at all times.

• Poor quality fuel can reduce engine performance and/or cause engine damage.

• Fuel additives are not recommended. Some fuel additives may cause poor engine performance.

• Ash content must not exceed 0.01% by volume.

• Carbon residue content must not exceed 0.35% by volume. Less than 0.1% is preferred.

• Total aromatics content should not exceed 35% by volume. Less than 30% is preferred.

• PAH (polycyclic aromatic hydrocarbons) content should be below 10% by volume.

• Metal content of Na, Mg, Si and Al should be equal to or lower than 1 mass ppm (test analysis method JPI-5S-44-95).

• Lubricity: Wear mark of WS1.4 should be Max. 460μm (0.018 in.) at HFRR test.

BIO-DIESEL FUELS

In Europe and in the United States, as well as some other countries, non-mineral oil based fuel resources such as RME (Rapeseed Methyl Ester) and SOME (Soybean Methyl Ester), collectively known as FAME (Fatty Acid Methyl Esters), are being used as extenders for mineral oil derived diesel fuels.

These B20 diesel fuels must meet certain requirements:

1. The bio-fuels must meet the minimum specifications for the country in which

they are used.

• In Europe, bio-diesel fuels must comply with the European Standard EN14214.

• In the United States, bio-diesel fuels must comply with the American Standard ASTMD-6751.2.

2. Bio-fuels should be purchased only from recognized and authorized diesel fuel suppliers.

Precautions and concerns regarding the use of bio-fuels:

Page 67

OPERATION

1. Free methanol in FAME may result in corrosion of aluminum and zinc FIE components.

2. Free water in FAME may result in plugging of fuel filters and increased bacterial growth.

3. High viscosity at low temperatures may result in fuel delivery problems, injection pump seizures and poor injection nozzle spray atomization.

4. FAME may have adverse effects on some elastomers (seal materials) and may result in fuel leakage and dilution of the engine lubricating oil.

5. Even bio-diesel fuels that comply with a suitable standard as delivered will require additional care and attention to maintain the quality of the fuel in the equipment or other fuel tanks. It is important to maintain a supply of clean, fresh fuel. Regular flushing of the fuel system and/or fuel storage containers may be necessary.

6. The use of bio-diesel fuels that do not comply with the standards as agreed to by the diesel engine manufacturers and the diesel fuel injection equipment manufacturers, or bio-diesel fuels that have degraded as per the precautions and concerns above, may affect the warranty coverage of your engine.

B21 To B100 Bio-diesel Fuel Blend Usage

B21 to B100 bio-diesel is not approved for this POLARIS application.

Approved Engines

Only the Kubota engine series listed below may operate with bio-diesel fuel concentrations up to B20 for POLARIS applications.

NOTICE

Do not exceed bio-diesel fuel blend B20 for this POLARIS application.

• Kubota D902

Approved Fuel

NOTICE

Raw pressed vegetable oils are not considered bio-diesel, and are

unacceptable for use as fuel in any concentration in Kubota engines.

Bio-diesel fuel blends up to B20 must comply with the following standards:

• EN14214 (European standard) and/or ASTM D-6751 (American standard).

• All applicable engines may operate with bio-diesel fuel up to a maximum B20

(20% bio- diesel blend) concentration.

Page 68

OPERATION

Operating Conditions with B20 Bio-diesel Fuel Blends

Engine Warranty

Damages, performance or service concerns determined to be caused by the use of bio-diesel fuel not meeting the specifications outlined above are not considered to be defects in material or factory workmanship and are not covered under warranty. The same applies to damages or other concerns induced by not complying with the recommended operating conditions of Kubota engines with bio-diesel fuel.

HANDLING FUEL

WARNING

Diesel fuel is flammable and explosive under certain conditions.

• NEVER refuel with the engine running.

• Always refuel outdoors or in a well ventilated area.

• Fill the fuel tank with diesel fuel ONLY. Filling the fuel tank with gasoline may result in a fire and will damage the engine.

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

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

• Wipe up all spills immediately.

• Keep sparks, open flames or any other form of ignition (match, cigarette, static electricity source) well away when refueling.

• NEVER remove the fuel cap while the engine is running.

• NEVER overfill the fuel tank. Do not fill the tank neck.

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

Page 69

OPERATION

STARTING THE ENGINE

NOTICE

NEVER use an engine starting aid such as ether. Engine damage will result.

The ignition system is marked by the OFF q, LIGHTS ON w, POSITION LIGHTS ON

Before operating this vehicle in cold weather, review the cold weather operation information on page 68. Always wait for the glow plug indicator light to turn off before cranking the engine.

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

, and START r symbols.

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

3. Place the transmission in PARK.

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

5. Turn the ignition switch to the LIGHTS ON position and wait for the glow plug indicator light to turn off.

Page 70

OPERATION

6. Turn the ignition key to the START position. Engage the starter for a maximum of five seconds. Release the key when the engine starts. Turn the key to either LIGHTS ON or POSITION LIGHTS ON.

7. If the engine does not start within five seconds, return the ignition switch to the OFF position and wait five seconds. Repeat steps 6 and 7 until the engine starts.

NOTICE

Operating the vehicle immediately after starting could cause engine damage.

Allow the engine to warm up for several minutes before operating the vehicle.

After letting the engine warm up in this way, operate the vehicle at medium

speed without load for several minutes to further warm up the engine.

STOPPING THE ENGINE

For maximum engine life, allow the engine to idle, without load, for 5 minutes. This will allow the engine components that operate at high temperatures, such as the exhaust system, to cool slightly before the engine is shut down.

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

2. Place the transmission in PARK.

3. Engage the park brake.

4. Slowly release the brake pedal and make sure the transmission is in PARK before exiting the vehicle.

5. Turn the engine off and remove the key to prevent unauthorized use.

WARNING

A rolling vehicle can cause serious injury. Always place the transmission in

PARK and engage the park brake when stopping the engine.

COLD WEATHER OPERATION

Cold weather operation can result in fuel gelling if the incorrect fuel type is used. Use the following fuel blending guideline to prevent this from occurring.

FUEL BLENDING GUIDELINE

Temperature No. 2 No. 1

-9° C (+15° F) 100% 0%

Page 71

OPERATION

FUEL BLENDING GUIDELINE

Down to -29° C (-20° F) 50% 50%

Below -29° C (-20° F) 0% 100%

COLD STARTING GUIDELINES

Temp. -7° C to -9°

(+20° F to

+15° F)

Fuel #2 Diesel 50/50 mix #1/#2 diesel #1 Diesel

5W-40

Synthetic

Diesel

Engine Oil

Battery

condition/

connections

Proper glow

plug usage

(wait for the

light)

Optional Advised Required

-9° C to -15° C

(+15° F to

+5° F)

Charged battery (12.8 VDC)

Wait for light at all temps

-15° C to

-29° C

(+5° F to

-20° F)

-29° C to

(-20° F to

-32° C

-25° F)

Oil pan

heater

Not needed

Optional (helps to reduce

cranking)

NOTICE

Do not allow the starter motor to run continuously for more than 20 seconds.

NOTICE

Be sure to warm up the engine, not only in winter, but also in warmer seasons.

An insufficiently warmed-up engine can short its service life.

NOTICE

If the temperature is going to drop below -15° C (5° F), detach the battery from

the machine and keep it indoors in a safe area. Reinstall it just before the next

operation.

Page 72

OPERATION

BRAKING

1. Release the throttle pedal completely.

TIP

When the throttle pedal is released completely and the engine speed drops

near an idle, the vehicle has no engine braking.

2. Press on the brake pedal evenly and firmly.

TIP

If the throttle pedal and brake pedal are applied simultaneously, engine power

may be limited.

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

Page 73

OPERATION

HAULING CARGO

WARNING

Overloading the vehicle or carrying or towing cargo improperly can alter

vehicle handling and may cause loss of control or brake instability. Always

follow these precautions when hauling cargo:

Never exceed the stated load capacity for this vehicle.

REDUCE SPEED AND ALLOW GREATER DISTANCES FOR BRAKING

WHEN HAULING CARGO.

NEVER EXCEED THE MAXIMUM WEIGHT CAPACITY of the vehicle. When determining the weight you are adding to the vehicle, include the weight of the operator, passenger, accessories, loads in the rack or box and the load on the

trailer tongue. The combined weight of these items must not exceed the

maximum weight capacity.

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

When operating over rough or hilly terrain, reduce speed and cargo to maintain

stable driving conditions.

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

Slow down and drive in the lowest gear available.

SECURE ALL LOADS BEFORE OPERATING. Unsecured loads can create

unstable operating conditions, which could result in loss of control of the

vehicle.

OPERATE ONLY WITH STABLE AND SAFELY ARRANGED LOADS. When

handling off-centered loads that cannot be centered, securely fasten the load

and operate with extra caution.

Always attach the tow load to the hitch point designated for your vehicle.

HEAVY LOADS CAN CAUSE BRAKING AND CONTROL PROBLEMS. Use

extreme caution when applying brakes with a loaded vehicle. Avoid terrain or

situations that may require backing downhill.

USE EXTREME CAUTION when operating with loads that extend over the

rack sides. Stability and maneuverability may be adversely affected, causing

vehicle rollover.

DO NOT TRAVEL FASTER THAN THE RECOMMENDED SPEEDS. Vehicle

should never exceed 10 MPH (16 km/h) while towing a load on a level grass

surface. Vehicle speed should never exceed 5 MPH (8 km/h) when towing

loads in rough terrain, while cornering, or while ascending or descending a hill.

If the vehicle is capable, never exceed 43 MPH (70 km/h) if total payload

exceeds 335 lbs. (152 kg).

Carrying a passenger in the cargo box could result in a fall from the vehicle or

contact with moving components. Never allow a passenger to ride in the cargo

box.

Your vehicle has been designed to carry or tow specific capacities. Reduce speed and allow a greater distance for braking when carrying cargo.

Page 74

OPERATION

Loads should be centered on the vehicle and carried as low as possible in the box. For stability on rough or hilly terrain, reduce both speed and cargo. Exercise caution if the cargo load extends over the side of the box.

Always read and understand the load distribution warnings listed on warning labels and in this manual. Never exceed the maximum capacities specified for your vehicle.

BELT LIFE

To extend belt life, use low gear when hauling or towing heavy cargo.

TOWING LOADS

WARNING

Towing improperly can alter vehicle handling and may cause loss of control or

brake instability.

Always follow these precautions when towing:

1. Never load more than 68 kg (150 lbs.) tongue weight on the towing bracket.

2. When towing a disabled vehicle, place the disabled vehicle’s transmission in neutral. Do not operate the vehicle faster than 16 km/h (10 MPH) when towing.

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

4. Do not tow more than the recommended weight for the vehicle.

5. Attach a trailer to the trailer hitch bracket only. Do not attach a trailer to any other location, which could result in loss of control of the vehicle.

6. The total load (operator, accessories, cargo and weight on hitch) must not exceed the maximum weight capacity of the vehicle.

TOTAL

TOWED

LOAD

WEIGHT

(15°

GRADE)

TOTAL

HITCH

VERTICAL

WEIGHT

MAXIMUM

TOWING

SPEED

MODEL

MAXIMUM

BRAKED TRAILER

MASS

MAXIMUM

BRAKED TRAILER

MASS

RANGER

Diesel

730 kg

(1609 lbs.)

1000 kg

(2205 lbs.)

386 kg

(850 lbs.)

68 kg

(150 lbs)

16 km/h

(10 MPH)

Page 75

OPERATION

DUMPING THE CARGO BOX

To dump the cargo box, do the following:

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

2. Apply the brakes.

3. Shift the gear selector to the Park position.

4. Turn the key to the off position.

5. Dismount vehicle.

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

7. Open the tailgate.

8. Stand clear and pull up on the cargo box release lever.

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

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

11. Close the tailgate.

WARNING

Operating the vehicle while the cargo box is raised could result in severe injury.

The box could close unexpectedly and cause injury to the driver or passenger.

The rear tires will also catch the rear of a raised box, damaging the vehicle and

creating hazardous driving conditions. Never operate this vehicle with the

cargo box in the raised position.

Page 76

OPERATION

ALL WHEEL DRIVE/REAR DIFFERENTIAL SYSTEM

ENGAGING AWD

NOTICE

Switching to AWD while the rear wheels are spinning may cause severe drive

shaft and clutch damage. Always switch to AWD while the rear wheels have

traction or are at rest.

All-Wheel Drive (AWD)

Differential Lock

Differential Unlock

Press the top of the switch to engage All Wheel Drive (AWD). The 4X4 indicator illuminates in the rider information center to indicate that the vehicle is in AWD. When the AWD switch is on, the front gearcase will automatically engage any time the rear wheels lose traction. When the rear wheels regain traction, the front gearcase will automatically disengage. There is no limit to the length of time the vehicle may remain in AWD. Initially, the vehicle's electronic system will not enable the AWD until the engine RPM is below 3100. Once enabled, the AWD remains enabled until the AWD switch is turned off. If the switch is turned off while the front gearcase is moving, it will not disengage until the rear wheels regain traction.

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

Page 77

OPERATION

DISENGAGING AWD

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

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

To disengage AWD, do the following:

1. Stop the vehicle.

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

3. Stop completely.

4. Shift into low gear and drive forward.

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

LOCKING THE DIFFERENTIAL

Move the rocker switch to the center position to lock the differential and operate in two wheel drive (2WD). Locking the differential in slippery or low traction conditions helps improve traction. When the rear differential is locked, both rear wheels rotate at the same speed.

Page 78

OPERATION

UNLOCKING THE DIFFERENTIAL (TURF MODE)

When operating in TURF mode, the inside rear wheel will rotate independently from the outside wheel during turns. Operate in TURF mode only as needed to protect smooth, level surfaces from tire damage. DO NOT operate in TURF mode when climbing or descending hills, when sidehilling, or when operating on uneven, loose, or slippery terrain such as sand, gravel, ice, snow, obstacles, and water crossings. Always operate in AWD on these types of terrain.

WARNING

Operating in TURF mode when on sloped, uneven, or loose terrain could

cause loss of control and result in serious injury or death. One rear wheel may

slip and lose traction or may lift up and grab when it touches the ground again.

Press the bottom of the switch to unlock the differential and allow the rear drive wheels to operate independently (1WD). When the rear differential is unlocked, the rear wheels can rotate at different speeds. Unlock the differential to make maneuvering easier and minimize damage to turf.

NOTICE

Damage to the differential can occur if it is engaged while the vehicle is

traveling at high speeds or while the rear wheels are spinning. Slow the vehicle

to nearly stopped before engaging the differential.

WARNING

Never operate in TURF mode while operating on a hill or other irregular terrain.

Always move the AWD switch to AWD before ascending or descending a hill.

Page 79

OPERATION

ACTIVE DESCENT CONTROL (ADC) SYSTEM

The ADC system allows engine braking to all four wheels when the vehicle descends a hill or incline.

• Always operate in low gear and engage ADC 4X4 when transporting heavy

loads and/or when towing.

• Always operate in low gear and engage ADC 4X4 before ascending or

descending a hill.

ENGAGING ACTIVE DESCENT CONTROL

The ADC system will automatically engage when both of the following conditions occur:

• The drive mode must be in the ADC 4X4 position

• The transmission must be in gear (high, low or reverse)

DISENGAGING ACTIVE DESCENT CONTROL

The ADC system will automatically disengage if at least one of the following conditions occur:

• The drive mode is changed from the ADC 4X4 position

• The transmission is shifted to neutral or park

Page 80

OPERATION

DRIVING PROCEDURES

NEW OPERATOR DRIVING PROCEDURES

1. Read and understand the owner's manual and all warning and instruction labels before operating this vehicle.

2. Visit the Recreational Off-Highway Vehicle Association web site and take the free on-line training course. Visit www.rohva.org or call 866-267-2751. Hands-on training is also available through ROHVA.

3. Perform the pre-ride inspection.

4. Do not tow or carry cargo during this period.

5. Select an open area that allows room to familiarize yourself with vehicle operation and handling.

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

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

8. Always make sure all cab doors are closed and latched when riding in this vehicle.

9. Place the transmission in PARK.

10. Start the engine.

11. Apply the brakes and shift into low gear.

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

13. Keeping both hands on the steering wheel, slowly release the brakes and depress the throttle with your right foot to begin driving.

14. Drive slowly at first. On level surfaces, practice starting, stopping, turning, maneuvering, using the throttle and brakes and driving in reverse. Learn how the vehicle handles when making both left and right turns at a slow speed.

WARNING

Operating in TURF mode (if equipped) when on sloped, uneven, or loose

terrain could cause loss of control and result in serious injury or death. One

rear wheel may slip and lose traction or may lift up and grab when it touches

the ground again.

15. Increase speed only after mastering all maneuvers at a slow speed.

16. After you become skilled at making turns and begin to operate at faster speeds, follow these precautions:

Page 81

OPERATION

• Avoid sharp turns.

• Never turn while applying heavy throttle.

• Never make abrupt steering maneuvers.

• Operate at speeds appropriate for your skills, the conditions and the terrain.

• DO NOT do power slides, “donuts”, jumps or other driving stunts.

DRIVING WITH A PASSENGER

1. Perform the pre-ride inspection.

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

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

4. Make sure all cab doors (if equipped) are properly secured.

5. Do not carry more than the recommended number of passengers for your vehicle.

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

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

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

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

Page 82

OPERATION

DRIVING ON SLIPPERY SURFACES

WARNING

Skidding or sliding can cause loss of control or rollover (if tires regain traction

unexpectedly). When operating on slippery surfaces such as ice or loose

gravel, reduce speed and use extra caution to reduce the chance of skidding or

sliding out of control. Do not operate on excessively slippery surfaces.

When driving on slippery surfaces such as wet trails, loose gravel, or ice, be alert for the possibility of skidding and sliding. Follow these precautions when encountering slippery conditions:

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

2. Slow down before entering slippery areas.

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

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

NOTICE

Severe damage to the drive train may occur if the AWD is engaged while the

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

AWD.

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

apply the brakes during a skid.

Page 83

OPERATION

DRIVING OVER OBSTACLES

Follow these precautions when operating over obstacles:

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

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

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

4. Move the drive mode switch to low mode if needed.

5. Avoid operating over large obstacles such as large rocks and fallen trees. If unavoidable, use extreme caution and operate slowly.

6. Always have all passengers dismount and move away from the vehicle before operating over an obstacle that could cause a rollover.

DRIVING UPHILL

Whenever traveling uphill, follow these precautions:

1. Avoid excessively steep hills.

2. ADC Models: Always operate in low gear and engage ADC 4X4 before ascending or descending a hill.

3. Always travel straight uphill.

4. Keep both feet on the floor.

5. Always check the terrain carefully before ascending any hill. Never climb hills with excessively slippery or loose surfaces.

6. Proceed at a steady rate of speed and throttle opening. Never open the throttle suddenly.

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

Page 84

OPERATION

DRIVING DOWNHILL

When driving downhill, follow these precautions:

1. Avoid excessively steep hills.

2. ADC Models: Always operate in low gear and engage ADC 4X4 before ascending or descending a hill.

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

4. Slow down.

5. Apply the brakes slightly to aid in slowing.

DRIVING ON A SIDEHILL (SIDEHILLING)

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

If crossing a sidehill is unavoidable, follow these precautions:

1. Slow down.

2. Exercise extreme caution.

3. Avoid crossing the side of a steep hill.

4. ADC Models: Always operate in low gear and engage ADC 4X4 before ascending or descending a hill.

Page 85

OPERATION

DRIVING THROUGH WATER

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

NOTE

If your vehicle becomes immersed or is operated in water that exceeds the

floor level, service is required before starting the engine. Your dealer can

provide this service. If it's impossible to bring the vehicle in before starting the

engine, perform the service outlined in the Spark Arrester section, and take the

vehicle in for service at the first opportunity.

Follow these procedures when operating through water:

1. Determine water depths and current before entering water.

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

3. Proceed slowly, avoiding rocks and obstacles.

4. Avoid operating through deep or fast-flowing water.

WARNING

The large tires on your vehicle 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 vehicle

5. After leaving water, always dry the brakes by applying light pressure to the pedal repeatedly until braking action is normal.

NOTE

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

outlined in the Periodic Maintenance Chart. Give special attention to engine oil,

transmission oil, front and rear gearcases (if equipped), and all grease fittings.

Page 86

OPERATION

DRIVING IN REVERSE

Follow these precautions when operating in reverse:

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

2. Always avoid backing downhill.

3. Back slowly.

4. Apply the brakes lightly for stopping.

5. Avoid turning at sharp angles.

6. Never open the throttle suddenly.

PARKING THE VEHICLE

To park the vehicle, do the following:

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

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

3. Place the transmission in PARK.

4. Engage the park brake.

5. Turn the engine off.

6. Slowly release the brake pedal and make sure the transmission is in PARK before exiting the vehicle

7. Remove the ignition key to prevent unauthorized use.

PARKING ON AN INCLINE

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

1. Apply the brakes.

2. Place the transmission in PARK.

3. Engage the parking brake (if equipped).

4. Turn the engine off.

5. Slowly release the brake pedal and make sure the transmission is in PARK before exiting the vehicle.

6. Block the rear wheels on the downhill side.

Page 87

WINCH GUIDE

These safety warnings and instructions apply if your vehicle came equipped with a winch or if you choose to add an accessory winch to your vehicle.

WARNING

Improper winch use can result in SEVERE INJURY or DEATH. Always follow

all winch instructions and warnings in this manual.

Your winch may have a cable made of either wire rope or specially designed synthetic rope. The term “winch cable” will be used for either unless noted otherwise.

WINCH SAFETY PRECAUTIONS

1. Read all sections of this manual.

2. Never use alcohol or drugs before or while operating the winch.

3. Never allow children under 16 years of age to operate the winch.

4. Always wear eye protection and heavy gloves when operating the winch.

5. Always keep body, hair, clothing and jewelry clear of the winch cable, fairlead and hook when operating winch.

6. Never attempt to “jerk” a load attached to the winch with a moving vehicle. See the Shock Loading section on page 93.

7. Always keep the area around the vehicle, winch, winch cable, and load clear of people (especially children) and distractions while operating the winch.

8. Always turn the vehicle ignition power OFF when it and the winch are not being used.

9. Always be sure that at least five (5) full turns of winch cable are wrapped around the winch drum at all times. The friction provided by this wrapped cable allows the drum to pull on the winch cable and move the load.

10. Always apply your vehicle’s park brake and/or park mechanism to hold the vehicle in place during winching. Use wheel chocks if needed.

11. Always align the vehicle and winch with the load directly in front of the vehicle as much as possible. Avoid winching with the winch cable at an angle to the winching vehicle’s centerline whenever possible.

12. If winching at an angle is unavoidable, follow these precautions:

a. Look at the winch drum occasionally. Never let the winch cable “stack” or

accumulate at one end of the winch drum. Too much winch cable at one end of the winch drum can damage the winch and the winch cable.

Page 88

WINCH GUIDE

b. If stacking occurs, stop winching. Follow step 15 of Winch Operation to

feed and rewind the cable evenly before continuing the winch operation.

13. Never winch up or down at sharp angles. This can destabilize the winching vehicle and possibly cause it to move without warning.

14. Never attempt to winch loads that weigh more than the winch’s rated capacity.

15. The winch motor may become hot during winch use. If you winch for more than 45 seconds, or if the winch stalls during operation, stop winching and permit the winch to cool down for 10 minutes before using it again.

16. Never touch, push, pull or straddle the winch cable while winching a load.

17. Never let the winch cable run through your hands, even if wearing heavy gloves.

18. Never release the clutch on the winch when the winch cable is under load.

19. Never use the winch for lifting or transporting people.

20. Never use the winch to hoist or suspend a vertical load.

21. Never immerse or submerse your winch in water. Your dealer can provide service on your winch if this occurs.

22. Always inspect your winch and winch cable before each use.

23. Never winch the hook fully into the winch. This can cause damage to winch components.

24. Unplug the remote control from the vehicle when the winch is not in use to prevent inadvertent activation and use by unauthorized persons.

25. Never grease or oil the winch cable. This will cause the winch cable to collect debris that will shorten the life of the cable.

Page 89

WINCH GUIDE

WINCH OPERATION

Read the Winch Safety Precautions in the preceding pages before using your winch.

TIP

Consider practicing the operation and use of your winch before you actually

need to use it in the field.

WARNING

Improper winch use can result in SEVERE INJURY or DEATH. Always follow

all winch instructions and warnings in this manual.

Each winching situation is unique.

• Take your time to think through the winching you are about to do.

• Proceed slowly and deliberately.

• Never hurry or rush during winching.

• Always pay attention to your surroundings.

• You may need to change your winching strategy if it is not working.

• Always remember that your winch is very powerful.

• There are simply some situations that you and your winch will not be able to deal with. Do not be afraid to ask others to help when this happens.

1. Always inspect the vehicle, winch, winch cable and winch controls for any signs of damage or parts in need of repair or replacement before each use.

Pay particular attention to the first 3 feet (1 meter) of winch cable if the winch is being used (or has been used) for lifting an accessory plow assembly.

Promptly replace any worn or damaged cable.

2. Never operate a winch or a vehicle in need of repair or service.

3. Always apply your vehicle’s park brake and/ or park mechanism to hold the vehicle in place during winching. Use wheel chocks if needed.

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WINCH GUIDE

4. Always use the hook strap when handling the hook.

WARNING

Never put your fingers into the hook. This could lead to SEVERE INJURY.

• Attach the hook itself onto the load or use a tow strap or chain to secure the load to the winch cable.

TIP

A “tow strap” is NOT intended to stretch. A “recovery strap” is designed to

stretch.

WARNING

Never use a recovery strap when winching due to the excessive energy that

can be released if the winch cable breaks. This can result in SEVERE INJURY

or DEATH. See the Shock Loading section on page 93.

• Never hook the winch cable back onto itself. This will damage the winch cable and may result in winch cable failure.

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WINCH GUIDE

WARNING

Replace the winch cable at the first sign of damage to prevent SEVERE

INJURY or DEATH in the event of failure. For your safety, always replace

POLARIS winch parts (including the cable) with genuine POLARIS

replacement parts available at your authorized POLARIS dealer, or other

qualified dealer.

• If possible, keep the winch cable aligned with the centerline of the winching vehicle. This will help the spooling of the winch cable and reduce the load on the fairlead.

• If freeing a stuck vehicle by attaching to a tree, use an item such as a tow strap to avoid damaging the tree during winch operation. Sharp cables and chains can damage and even kill trees. Please remember to TreadLightly® (treadlightly.org).

• Before operating the winch, be sure that the safety latch on the winch cable hook is fully seated when the load is attached.

• Never operate your winch with a damaged hook or latch. Always replace damaged parts before using the winch.

5. Never remove the hook strap from the hook.

6. Release the winch clutch and pull out the winch cable.

7. Pulling out as much cable as possible maximizes the winch’s pulling capacity. Always be sure that at least five (5) full turns of winch cable are wrapped around the winch drum at all times. The friction provided by this wrapped cable allows the drum to pull on the winch cable and move the load.

8. Read and adhere to the following information for winch damping to ensure safe winch use.

a. In order to absorb energy that could be released by a winch cable failure,

always place a “damper” on the winch cable. A damper can be heavy jacket, tarp, or other soft, dense object. A damper can absorb much of the energy released if a winch cable breaks when winching. Even a tree limb can help as a damper if no other items are available to you.

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WINCH GUIDE

b. Lay the damper on top of the mid-point of the winch cable length that is

spooled out.

c. On a long pull, it may be necessary to stop winching so that the damper

can be repositioned to the new mid-point of the winch cable. Always release the tension on the winch cable before repositioning the damper.

d. Avoid being directly in line with the winch cable whenever possible. Also,

never permit others to stand near or in line with the winch cable during winch operation.

9. Never hook the winch cable back onto itself. This will damage the winch cable and may result in winch cable failure.

10. Never use straps, chains or other rigging items that are damaged or worn.

11. The ONLY time a winch-equipped vehicle should be moving when using the winch is when that vehicle itself is stuck. The winch equipped vehicle should NEVER be in motion to “shock” load the winch cable in an attempt to move a second stuck vehicle. See the Shock Loading section on page 93. For your safety, always follow these guidelines when winching a vehicle free:

a. Release the winch clutch and spool out the necessary length of winch

cable.

b. Align the winch cable as close as possible to the winching vehicle’s

centerline.

c. Attach the winch cable hook to the anchor point or the stuck vehicle’s

frame following instructions in this manual.

d. Re-engage the clutch on the winch.

e. Slowly winch in the slack in the winch cable.

f. Select the proper vehicle gear to propel the stuck vehicle in the direction

of winching.

g. Shift to the lowest gear available on the stuck vehicle.

h. Slowly and carefully apply vehicle throttle and winch together to free the

vehicle.

i. Stop winching as soon as the stuck vehicle is able to propel itself without

the help of the winch.

j. Detach the winch cable hook.

k. Rewind the winch cable evenly back onto the winch drum following the

instructions in this manual.

12. Never attempt to winch another stuck vehicle by attaching the winch cable to a suspension component, brush guard, bumper or cargo rack. Vehicle damage may result. Instead, attach the winch to a strong portion of the vehicle frame or hitch.

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WINCH GUIDE

13. Extensive winching will run down the battery on the winching vehicle. Let the winching vehicle’s engine run while operating the winch to prevent the battery from running low if winching for long periods.

14. The winch motor may become hot during winch use. If you winch for more than 45 seconds, or if the winch stalls during operation, stop winching and permit the winch to cool down for 10 minutes before using it again.

15. After winching is complete, especially if winching at an angle, it may be necessary to re-distribute the winch cable across the winch drum. You will need an assistant to perform this task.

a. Release the clutch on the winch.

b. Feed out the winch cable that is unevenly bunched up in one area.

c. Re-engage the winch clutch.

d. Have an assistant pull the winch cable tightly with about 100 lbs. (45 kg)

of tension using the hook strap.

e. Slowly winch the cable in while your assistant moves the end of the winch

cable back and forth horizontally to evenly distribute the winch cable on the drum.

f. Doing this reduces the chances of the winch cable “wedging” itself

between lower layers of winch cable.

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WINCH GUIDE

WINCH CABLE CARE

WARNING

Use of worn or damaged cable could lead to sudden failure and SEVERE

INJURY.

For your safety, always replace POLARIS winch parts (including the cable) with genuine POLARIS replacement parts available at your authorized POLARIS dealer, or other qualified person.

1. Always inspect your winch before each use. Inspect for worn or loose parts including mounting hardware. Never use the winch if any part needs repair or replacement.

2. Always inspect your winch cable before each use. Inspect for worn or kinked winch cable.

A kinked winch cable made of wire rope is shown at right. Even after being “straightened out,” this cable has already been permanently and severely damaged. Promptly discontinue use of a winch cable in this condition.

A kinked winch cable made of wire rope that has been “straightened out” is shown at right. Even though it may look usable, the cable has been permanently and severely damaged. It can no longer transmit the load that it could prior to kinking. Promptly discontinue use of a winch cable in this condition.

A winch cable made of synthetic rope should be inspected for signs of fraying. Replace the cable if fraying is observed (shown below). Promptly discontinue use of a winch cable in this condition. Also replace the winch cable if there are fused or melted fibers. Such an area of the synthetic rope will be stiff and appear smooth or glazed. Promptly discontinue use of a winch cable in this condition.

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WINCH GUIDE

SHOCK LOADING

WARNING

Your winch cable is very strong but it is NOT designed for dynamic, or “shock”

loading. Shock loading may tension a winch cable beyond its strength and

cause the cable to break. The end of a broken winch cable under such high

loading can cause SEVERE INJURY or DEATH to you and other bystanders.

Winch cables are designed to NOT absorb energy. This is true of both wire-rope and synthetic-rope winch cables.

1. Never attempt to “jerk” a load with the winch. For example, never take up slack in the winch cable by moving the winching vehicle in an attempt to move an object. This is a dangerous practice. It generates high winch cable loads that may exceed the strength of the cable. Even a slowly moving vehicle can create large shock loads in a winch cable.

WARNING

SEVERE INJURY or DEATH can result from a broken winch cable.

2. Never quickly turn the winch ON and OFF repeatedly (“jogging”). This puts extra load on the winch, winch cable, and generates excessive heat from the motor. This is a form of shock loading.

3. Never tow a vehicle or other object with your winch. Towing an object with a winch produces shock loading of the cable even when towing at slow speeds. Towing from a winch also positions the towing force high on the vehicle. This can cause instability of the vehicle and possibly lead to an accident.

4. Never use recovery straps with your winch. Recovery straps are designed to stretch and can store energy. This stored energy in the recovery strap is released if a winch cable fails making the event even more hazardous. Similarly, never use elastic “bungie” cords for winching.

5. Never use the winch to tie down a vehicle to a trailer or other transportation vehicle. This type of use also causes shock loading that can cause damage to the winch, winch cable, or vehicles used.

Your winch cable is designed and tested to withstand the loads produced by the winch motor when operated from a stationary vehicle. Always remember that the winch and winch cable are NOT designed for shock loading.

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WINCH GUIDE

WINCH MAINTENANCE AND SERVICE SAFETY

WARNING

Improper or lack of winch maintenance and service could lead to SEVERE

INJURY or DEATH. Always follow all winch instructions and warnings in this

manual.

1. Always inspect your winch before each use. Inspect for worn or kinked winch cable. Also inspect for worn or loose parts including mounting hardware.

2. Permit your winch motor to cool down prior to servicing your winch.

3. Never work on your winch without first disconnecting the battery connections to prevent accidental activation of the winch.

4. For your safety, always replace POLARIS winch parts (including the cable) with genuine POLARIS replacement parts available at your authorized POLARIS dealer, or other qualified person.

5. Some winch models use wire rope as the winch cable. Other winches use a specially designed synthetic rope as the winch cable.

6. Never replace a synthetic-rope winch cable with a consumer-grade polymer rope such as can be purchased in a hardware store. Although they may look similar, they are NOT alike. A polymer rope not designed for winch use will stretch and store excessive energy when winching.

WARNING

Failure of a stretched rope under winching conditions will release all of the

stored energy. This will increase the chances of SEVERE INJURY or DEATH.

Page 97

EMISSION CONTROL SYSTEMS

NOISE EMISSION CONTROL SYSTEM

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

SPARK ARRESTER

Your POLARIS vehicle has a spark arrester that was designed for on-road and off-road operation. It is required that this spark arrester remain installed and functional when the vehicle is operated.

EXHAUST EMISSION CONTROL SYSTEM

Exhaust emissions are controlled by engine design. A fuel injection system controls fuel delivery. The engine and fuel injection components are set at the factory for optimal performance and are not adjustable.

Your engine is designed to operate on ultra low sulfur diesel fuel only. Use of any other fuel may result in your engine no longer operating in compliance with emissions requirements.

ELECTROMAGNETIC INTERFERENCE

This spark ignition system complies with Canadian ICES-002.

This vehicle complies with the EMC requirements of UN ECE Regulation 10.

Non-ionizing Radiation: This vehicle emits some electromagnetic energy. People with active or non-active implantable medical devices (such as heart monitoring or controlling devices) should review the limitations of their device and the applicable electromagnetic standards and directives that apply to this vehicle.

Page 98

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MAINTENANCE

PERIODIC MAINTENANCE

Any qualified repair shop or person may maintain, replace or repair the emission control devices or systems on your vehicle. An authorized POLARIS dealer can perform any service that may be necessary for your vehicle. POLARIS also recommends POLARIS parts for emissions-related service, however equivalent parts can be used.

It is a potential violation of the Clean Air Act if a part supplied by an aftermarket parts manufacturer reduces the effectiveness of the vehicle’s emission controls. Tampering with emission controls is prohibited by federal law.

Owners are responsible for performing the scheduled maintenance identified in this owner’s manual.

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, genuine POLARIS parts are available from your POLARIS dealer. Equivalent parts may be used for emissions-related service.

Service and adjustments are important for proper vehicle operation. If you’re not familiar with safe service and adjustment procedures, a qualified dealer can perform these operations.

Vehicles subjected to heavy or severe use patterns must be inspected and serviced more frequently.

SEVERE USE DEFINITION

• Frequent immersion in mud, water or sand

• Frequent or prolonged operation in dusty environments

• Short trip cold weather operation

• Racing or race-style high RPM use

• Prolonged low speed, heavy load operation

• Extended idle

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

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MAINTENANCE

MAINTENANCE CHART KEY

SYMBOL DESCRIPTION

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

D Have an authorized dealer or other qualified person perform these services.

WARNING

Improperly performing the procedures marked with a D could result in

component failure and lead to serious injury or death. Have an authorized

dealer or other qualified person perform these services.

PERIODIC MAINTENANCE CHART

Perform all services at whichever maintenance interval is reached first. Record maintenance and service in the Maintenance Log.

(WHICHEVER COMES FIRST)

ITEM

HOURS CLNDR

Engine Oil Level

XU Coolant -

Park Brake -

XU D

Engine Fan

Engine Fan Belt

Brake Pad Wear 10 H

Battery

25 H

MAINTENANCE INTERVAL

(MILES)

Daily

Monthly 160 (100) Inspect periodically

Monthly 320 (200)

REMARKS

Pre-ride Checklist; check level daily

Check level daily; replace coolant every 5 years

Inspect; adjust as needed

Inspect; replace as needed

Inspect, correct tension as needed; replace as needed

Check terminals; clean; test

Fuel System

Front Gearcase Fluid (Demand Drive)

Transmission Fluid (AGL)

Engine Oil / Filter Change (Break-In)

Inspect; cycle key to pressurize

25 H

25 H 1 M - Break-in oil level check

50 H 1 M

Monthly 320 (200)

1000

(625)

fuel pump; check lines and fittings for leaks and abrasion

Perform break-in oil / filter change