Polaris Ranger 400 User Manual

RANGER 400

Owner's Manual

for Maintenance and Safety

WARNING

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

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

WARNING

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

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

WELCOME

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

• Snowmobiles

• All-terrain vehicles (ATVs)

• RANGER

• Victory Motorcycles

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

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

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

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

We also take great pride in our complete line of apparel, parts and accessories, available through our online store at www.purepolaris.com. Have your accessories and clothing delivered right to your door!

utility vehicles

(MSD) technician.

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

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

Printed in U.S.A. 2012 RANGER 400 Owner’s Manual P/N 9923509

TABLE OF CONTENTS

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

Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Features and Controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Emission Control Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

POLARIS Products. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

Maintenance Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

INTRODUCTION

WARNING

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

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

The safety alert symbol indicates a potential personal injury hazard. WARNING

A WARNING indicates a hazardous situation which, if not avoided, may result in death or serious injury. CAUTION

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

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

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

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

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

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

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

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

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

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

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

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

INTRODUCTION

VIN

Key

Number

####

Vehicle Identification Numbers

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

Vehicle Model Number: _______________________________________________________________________

Frame VIN: _________________________________________________________________________________

Engine Serial Number: ________________________________________________________________________ (label on side of engine)

Key Number: _______________________________________________________________________________

European Vibration and Noise

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

The operating conditions of the machinery during testing: The vehicles were in like-new condition. The environment was controlled as indicated by the

test procedure(s). The uncertainty of vibration exposure measurement is dependent on many factors, including:

• Instrument and calibration uncertainty

• Variations in the machine such as wear of components

• Variation of machine operators such as experience or physique

• Ability of the worker to reproduce typical work during measurements

• Environmental factors such as ambient noise or temperature

SAFETY



Clutch Cover

Warning

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.

Passenger/Tire Pressure Warning

WARNING

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

• Never carry passengers in cargo box.

WARNING IMPROPER TIRE PRESSURE OR OVERLOADING CAN

CAUSE LOSS OF CONTROL RESULT ING IN SERIOUS INJURY OR DEATH.

• Reduce speed and allow greater distance for braking when

carrying cargo.

• Overloading or carrying tall, off-center, or unsecured loads will

increase your risk of losing control. Loads should be centered and carried as low as possible in box.

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

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

RANGER 4 x 4 Crew LSV-EV

MAXIMUM CARGO BOX LOAD 500 lbs. TIRE PRESSURE IN PSI (KPa) FRONT 10 (69) MAXIMUM WEIGHT CAPACITY

INCLUDES WEIGHT OF OPERATOR, PASSENGER, CARGO AND ACCESSORIES

Read Operation and Maintenance Manual for more detailed loading information.

(226 kg)

REAR 12 (83)

1000 lbs.

(454 kg)

500 lbs.

(226 kg)

FRONT 14 (97)

REAR 16 (110)

1250 lbs.

(547 kg)

500 lbs.

(226 kg)

FRONT 20 (138)

REAR 20 (138)

1000 lbs.

(454 kg)

Clutch Cover Warning

WARNING

• Moving parts hazard under belt-clutch guard. To prevent serious injury, do not operate vehicle with guard removed.

• Do not modify engine or clutch. Doing so can cause part failure, possible imbalance, and excessive engine RPM which can result in serious injury or death.

7175488

7177690

SAFETY

Discretionary

Warning

Age 16

Warning

Shift Caution

Safety Labels and Locations

Age 16 Warning

Operating this vehicle if you are under the age of 16 increases your chance of severe injury or death.

NEVER operate this vehicle if you are under age 16 and NEVER operate this vehicle without a valid driver’s license.

7175566

Shift Caution

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.

7176170

Discretionary Warning

WARNING Improper vehicle use can result in Severe Injury or Death. NEVER Operate:

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

• After or while using Alcohol or Drugs.

• On hills steeper than 15 degrees 15.

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

• With more than ONE passenger, or a passenger under age twelve or who cannot comfortably reach the floor and hand holds.

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

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

ALWAYS:

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

• Wear a helmet and eye protection and keep hands and feet in vehicle at all times.

• Reduce speed and use extra caution when carrying a passenger.

• Avoid sharp turns or turns while applying heavy throttle.

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

• Make sure passenger reads and understands all safety labels.

• Watch for branches or other hazards that could enter vehicle.

LOCATE AND READ OWNER’S MANUAL. FOLLOW ALL INSTRUCTIONS AND WARNINGS.

7176169

SAFETY

051039

0006.31

Safe Riding Gear

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

Helmet

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

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

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

Eye Protection

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

Gloves

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

Boots

Wear sturdy footwear. Do not ride a POLARIS vehicle with bare feet.

Clothing

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

SAFETY

WARNING

Operator Safety

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

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

• Never allow anyone under age 16 to operate this vehicle and never allow anyone without a

valid driver's license to operate this vehicle.

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

vehicle.

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

be able to comfortably reach the floor and hand holds.

• The driver and any passenger must wear helmet, eye protection and seat belt at all times.

All riders should also wear long sleeves, long pants and sturdy footwear.

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

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

• Always keep both hands on the steering wheel and both feet on the floorboards of the

vehicle during operation.

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

product labels.

• To reduce tipover risk, be especially careful when encountering obstacles and slopes and

when braking on hills or during turns.

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

surfaces.

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

• Never operate at excessive speeds. Always travel at a speed proper for the terrain,

visibility and operating conditions, and your experience.

• Never attempt jumps or other stunts.

• Always inspect your vehicle each time you use it to make sure it's in safe operating

condition. Always follow the inspection and maintenance procedures and schedules 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.

SAFETY

Operator Safety

• 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 open the throttle suddenly or make sudden gear changes. Never go over the top of a hill at high speed.

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

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

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

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

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

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

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

• Never exceed the stated load capacity for this vehicle. Cargo should be properly 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 stop the engine before refueling. Make sure the refueling area is well ventilated and free of any source of flame or sparks. Gasoline is extremely flammable. See page 13 for fuel safety warnings.

• Always remove the ignition key when the vehicle is not in use to prevent unauthorized use or accidental starting.

FOR MORE INFORMATION ABOUT SAFETY, call

POLARIS at 1-800-342-3764.

SAFETY

Operator Safety

Equipment Modifications

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

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

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

SAFETY

WARNING

Operator Safety

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

Age Restrictions

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

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

Operating Without Instruction

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

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

Using Alcohol or Drugs

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

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

Seat Belts

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

Protective Apparel

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

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

SAFETY

Operator 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 overturn. Always use the cab nets while riding in this vehicle.

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

Failure to Inspect Before Operating

Failure to inspect and verify that the vehicle is in safe operating condition before operating increases the risk of an accident.

Always inspect your RANGER before each use to make sure it's in safe operating condition. Always follow all inspection and maintenance procedures and schedules described in the owner's manual.

Handling Gasoline

Gasoline is highly flammable and explosive under certain conditions.

• Always exercise extreme caution whenever handling gasoline.

• Always stop the engine when refueling.

• Always refuel outdoors or in a well ventilated area.

• Remove flammable material containers from box before filling.

• Do not smoke or allow open flames or sparks in or near the area where refueling is perfor med or

where gasoline is stored.

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

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

clothing.

• Turn the fuel valve off whenever the vehicle is stored or parked.

Operating With a Load on the Vehicle

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

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

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

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

on the vehicle.

Always follow these guidelines:

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

Passenger and/or cargo exceeds half the maximum weight capacity 1. Slow down. Operating in rough terrain Operating over obstacles Climbing an incline Towing

2. Verify tire pressure.

3. Use extra caution when operating.

SAFETY

Operator Safety

Exposure to Exhaust

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

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

Operating a Damaged Vehicle

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

Operating at Excessive Speeds

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

Operating on Pavement

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

Avoid operating the vehicle on pavement. If it's unavoidable, travel slowly and avoid sudden turns or stops.

Operating on Public Roads

Operating this vehicle on public streets, roads or highways could result in a collision with another vehicle.

Never operate this vehicle on any public street, road or highway, including dirt and gravel roads. In some areas it's unlawful to operate this vehicle on public streets, roads and highways.

Turning Improperly

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

Jumps and Stunts

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

Operating in Unfamiliar Terrain

Failure to use extra caution when operating on unfamiliar terrain could result in an accident or overturn. Unfamiliar terrain may contain hidden rocks, bumps, or holes that could cause loss of control or overturn.

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

SAFETY

Operator Safety

Improper Hill Climbing

Climbing hills improperly can cause loss of control or vehicle overturn. Always follow proper procedures for climbing hills as described in the owner's manual. See page 30.

Stalling While Climbing a Hill

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

If all forward speed is lost:

• Apply the brakes.

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

If you begin rolling downhill:

• Never apply engine power.

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

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

Improper Tire Maintenance

Operating this vehicle with improper tires or with improper or uneven tire pressure could cause loss of control or accident.

Always use the size and type of tires specified for your vehicle. Always maintain proper tire pressure as described in the owner's manual and on safety labels.

Operating on Slippery Terrain

Failure to use extra caution when operating on excessively rough, slippery or loose terrain could cause loss of traction, loss of control, accident or overturn.

Do not operate on excessively slippery surfaces. Always reduce speed and use additional caution when operating on slippery surfaces.

Operating on Frozen Bodies of Water

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

Unauthorized Use of the Vehicle

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

Hot Exhaust Systems

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

FEATURES AND CONTROLS

ROPS Cab

Frame

Console

Hip Bar

Cargo Box

Fuel Tank Cap

Headlights

Front Bumper/Brush Guard

Radiator

Cab Net

Tailgate

Latch

Releases

Receiver

Hitch

CV Boot/Rear Caliper

Muffler

(Spark Arrester)

Tailgate

Component Locations

Your vehicle is equipped with cab nets on both sides of the vehicle. Cab nets must be used by both operator and passenger at all times. The vehicle illustrated below is shown without cab nets only to allow component identification. Always use the cab nets..

FEATURES AND CONTROLS

Indicator

Lights

Cup

Holder

Storage

Compartment

12V Auxiliary

Outlet

Storage

Tray

Gear Selector

(Shifter)

High Gear

Low Gear

Neutral Gear

Reverse

Gear

High

Temperature

Park Gear

Component Locations

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 hood.

Indicator Lights

FEATURES AND CONTROLS

Gear Selector

Component Locations

Gear Selector

H: High Gear L: Low Gear N: Neutral R: Reverse P: Park Low gear is the primary driving range for the RANGER.

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

Whenever the vehicle is left unattended, always place the transmission in PARK. 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.

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

dealer if you experience any shifting problems.

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

Using Low Range

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

• Operating in rough terrain or over obstacles

• Loading the vehicle onto a trailer

• Towing heavy loads

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

Switches

Ignition Switch

Light Switch

AWD/Differential Switch

Choke

Knob

Ignition Switch/Light Switch

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

FEATURES AND CONTROLS

OFF The engine is off. Electrical circuits are off, except Acc,

LIGHTS ON Lights are on. Electrical circuits are on. Electrical equip-

LIGHTS OFF Lights are off. Electrical circuits are on. Electrical equip-

START Turn the key to the START position to engage the electric

12V.

ment can be used.

starter. Turn the key to the LIGHTS ON position after starting the engine.

A WD/Differential Lock Switch

The AWD/Differential 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). See page 36 for AWD operating instructions.

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.

See page 35 for Differential Lock operating instructions.

FEATURES AND CONTROLS

Throttle

Pedal

Brake Pedal

Trailer Hitch Bracket

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

To avoid injury and property damage, always heed the warnings and towing capacities outlined on pages 32-33.

Brake Pedal

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

Throttle Pedal

Push the pedal down to increase engine speed. Spring pressure returns the pedal to the rest position when released. Always check that the throttle pedal returns normally before starting the engine. Make sure there's adequate throttle pedal freeplay. See page 56 for throttle pedal adjustment procedures.

Fuel Cap

The fuel tank filler cap is located on the righthand side of the vehicle near the passenger seat. When refueling, always use either leaded or unleaded gasoline with a minimum pump octane number of 87 R+M/2 octane. Do not use fuel

with ethanol content greater than 10 percent, such as E-85 fuel.

Seat Removal

Pull up on the front of the seat and slide it toward the front of the vehicle. Install the seat by sliding the tabs into the rear of the seat base. Push down firmly on the front

of the seat until the pins are fully seated into the grommets.

FEATURES AND CONTROLS

Buckle

Latch Plate

Seat Belts

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

The center of the seat is NOT equipped with a seat belt. Never allow a passenger to ride between the operator and passenger seats.

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

To wear the seat belt properly, follow this procedure:

1. For 3-point belts, pull the seat belt latch downward and

across your chest toward the buckle at the inner edge of the seat. The belt should fit snugly across your hips and diagonally across your chest. Make sure the belt is not twisted.

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

3. Release the strap, it will self tighten.

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

buckle's center.

Seat Belt Inspection

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

1. Push the latch plate into the buckle until it clicks. The latch plate must slide smoothly

into the buckle. A click indicates that it's securely latched.

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

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

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

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

Do not use bleach, dye or household detergents.

FEATURES AND CONTROLS

Net Rod

Top

Latch

Rod Mount

Net Rod

Cab Nets

Riding in this vehicle without using the cab nets increases the risk of serious injury or death in the event of an accident or overturn. Cab nets must be used by both operator and 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 with new cab nets, available from your authorized Polaris dealer.

Securing a Net

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

FEATURES AND CONTROLS

ROPS Cab

Frame

Roll-Over Protection System (ROPS)

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

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

operating practices outlined in this manual to avoid vehicle rollover.

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

OPERATION

WARNING

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

Break-In Period

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

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

Engine and Drivetrain Break-in

1. Fill the fuel tank with gasoline. Heed the gasoline warnings on page 13.

2. Check the oil level. See page 42. Add the recommended oil as needed to maintain the oil

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

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

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

6. Pull only light loads.

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

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

level between the safe and add marks.

vehicle operation and handling.

inspection checklist. See page 25.

PVT Break-in (Clutches/Belt)

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

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

OPERATION

Pre-Ride Inspection

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

Item Remarks Page

Brake system/pedal travel Ensure proper operation 20 Brake fluid Ensure proper level 57

Park gear Ensure vehicle does not roll when in PARK. Ensure Front suspension Inspect, lubricate if necessary 41

Rear suspension Inspect, lubricate if necessary 41 Steering Ensure free operation 58 Tires Inspect condition and pressure 6

Wheels/fasteners Inspect, ensure fastener tightness 59 Frame nuts, bolts, fasteners Inspect, ensure tightness Fuel and oil Ensure proper levels 20

Coolant level Ensure proper level 49 Coolant hoses Inspect for leaks Throttle Ensure proper operation 56 Indicator lights/switches Ensure operation 17

Air filter, pre-filter Inspect, clean 53 Air box sediment tube Drain deposits whenever visible 53 Headlamp Check operation, apply POLARIS dielectric grease

Brake light/tail lamp Check operation, apply POLARIS dielectric grease Seat Belts Check length of belt for damage, check latches for Cab Nets Check for wear or damage, ensure proper installation 22

PARK light illuminates.

when lamp is replaced when lamp is replaced proper operation

61 62 21

OPERATION

Choke

Knob

FULL ON

HALF ON

OFF

Starting the Engine

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

2. Turn the fuel valve on.

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

4. Apply the brakes. Place the transmission in PARK.

5. Do not use the choke if starting a warm engine. Excessive use of the choke can cause

spark plugs to become wet fouled.

6. If the engine is cold, pull the choke knob out until it

stops.

7. Turn the ignition key to START. Engage the starter

for a maximum of five seconds. Release the key when the engine starts. Turn the key to the LIGHTS ON position before driving.

8. Do not press the throttle pedal while starting the

engine. If the engine does not start within five seconds, release the ignition switch and wait five seconds. Repeat steps 7 and 8 until the engine starts.

9. If a warm engine has cooled to a point where it does

not readily start, intermittent use of the choke (half way out) may be necessary. If the engine is overchoked when warm, depress the throttle pedal fully while cranking to aid in starting. Release the throttle pedal immediately after the engine starts. If the engine does not start and all conditions are favorable, change the spark plug and try again.

10. After the engine starts, push the choke knob in half

way.

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

smoothly.

12. Push the choke knob in.

NOTICE: Operating the vehicle immediately after starting could cause engine damage. Allow the

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

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