Polaris Ranger 4x4 500 EFI Owner's Manual

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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.

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WELCOME

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

• Snowmobiles

• All-terrain vehicles (ATVs)

• RANGER utility vehicles

• Victory motorcycles We believe Polaris sets a standard of excellence for all utility and recre-

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

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

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

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!

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

Copyright 2008 Polaris Sales Inc. All information contained within this publication is based on the latest product information at the time of publication. Due to constant improvements in the design and quality of production components, some minor discrepancies may result between the actual vehicle and the information presented in this publication. Depictions and/or procedures in this publication are intended for reference use only. No liability can be accepted for omissions or inaccuracies. Any reprinting or reuse of the depictions and/or procedures contained within, whether whole or in part, is expressly prohibited.

Printed in U.S.A. 2009 RANGER 4X4 500 EFI Owner’s Manual P/N 9921868

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TABLE OF CONTENTS

Vehicle Identification Numbers . . . . . . . . . . . . . 4

Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Features and Controls . . . . . . . . . . . . . . . . . . . 22

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Emission Control Systems . . . . . . . . . . . . . . . 53

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

Specifications. . . . . . . . . . . . . . . . . . . . . . . . . 106

Polaris Products. . . . . . . . . . . . . . . . . . . . . . . 108

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . 109

Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113

Maintenance Log . . . . . . . . . . . . . . . . . . . . . . 117

Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120

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VEHICLE IDENTIFICATION NUMBERS

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

Vehicle Model Number: ___________________________________________________

Frame VIN: ____________________________________________________________

Engine Serial Number: ___________________________________________________

Key Number ____________________________________________________________

Engine Serial Number

VIN

Key

Number

####

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SAFETY

Safety Decals and Locations

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

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

Container/Passenger/Tire Pressure Warning

WARNING

Remove flammable material containers from box before filling.

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

• Never carry passengers in cargo box.

Maximum 2X4 Box Load 850 lbs. (386 kg)

Maximum 4X4 Box Load 1000 lbs. (455 kg)

Maximum 6X6 Box Load 1200 lbs. (545 kg)

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

TIRE PRESSURE IN PSI (KPa):

RANGER - 2X4 and 4X4 FRONT 10 (69) REAR 10 (69) RANGER - 6X6 FRONT 10 (69) CENTER 10 (69) REAR 10 (69)

MAXIMUM WEIGHT CAPACITY INCLUDES WEIGHT OF OPERATOR, PASSENGER, CARGO AND ACCESSORIES.

RANGER 2X4 and 4X4 is 1500 LBS. (682 KG) RANGER 6X6 is 1750 LBS. (795 KG)

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.

Read Owner's Manual for more detailed loading information.

7174886

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SAFETY

Safety Decals and Locations

Clutch Cover Warning

WARNING NO STEP

• 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.

7172563

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 or without a valid driver’s license.

7175566

Clutch Cover

Warning

Discretionary

Warning

Age 16

Warning

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SAFETY

Safety Decals and Locations

Discretionary Warning

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

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

• After or while using Alcohol or Drugs.

• On hills steeper than 15 degrees 15°.

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

• With more than two passengers, or passengers under age five.

• 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, the cab frame is not designed or intended to provide rollover protection. Vehicle rollover could cause severe injury or death.

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

• Reduce speed and use extra caution when carrying passengers.

• Avoid sharp turns or turns while applying heavy throttle.

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

• Make sure 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.

7175565

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SAFETY

Operator Safety

Age Restrictions

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

Know Your Vehicle

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

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

We strongly advise you 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.

WARNING

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

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

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

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SAFETY

Operator Safety

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.

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SAFETY

Operator Safety

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

• Never allow anyone without a valid driver's license to operate this vehicle.

• Minimum age recommendation for passengers is five years old. Passengers under five years of age require special restraints which are not available with this vehicle. Driver and passenger should wear their seat belts at all times.

• 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.

• Helmets are recommended whenever driving this vehicle in an aggressive manner. Eye protection is recommended at all times.

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

• 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.

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.

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SAFETY

Operator Safety

• Always follow proper procedures for turning as described in this

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

• 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 trav-

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

• Always check for obstacles before operating in a new area. Never

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

• Always be careful of skidding or sliding. On slippery surfaces such as

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

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

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

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

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

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

Always maintain proper tire pressure as specified on page 5 and in the specifications section beginning on page 106.

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SAFETY

Operator Safety

• 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 wear the seat belts when operating this vehicle. Seat belts reduce the severity of injury in case of a sudden stop or collision.

• Always keep arms and legs inside the cab frame while the vehicle is in motion.

• Always engage the park brake before getting out of the vehicle. See page 28.

• Always apply the brakes before engaging or releasing the park brake.

• Always turn off the engine before refueling. Make sure the refueling area is well ventilated and free of any source of flame or sparks. Gasoline is extremely flammable. See page 21 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 1-800342-3764.

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SAFETY

Operator Safety

Equipment Modifications

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

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

NOTE: The addition of certain accessories, including (but not limited to) mow-

ers, 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.

WARNING

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

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

Do not make any modifications to your RANGER.

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SAFETY

Operator Safety

WARNING

POTENTIAL HAZARD Stalling, rolling backwards while

climbing a hill WHAT CAN HAPPEN Vehicle overturn HOW TO AVOID THE HAZARD Maintain a steady speed when

climbing a hill. If you lose all forward speed: Apply the brakes 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.

Engage the park brake after fully stopped. If you begin rolling backwards: Never apply engine power. Apply the brakes gradually. When fully stopped, engage the park brake. In the event of an accident, have a qualified service dealer check the

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

WARNING

POTENTIAL HAZARD Operating this vehicle on paved surfaces WHAT CAN HAPPEN Loss of control HOW TO AVOID THE HAZARD This vehicle's tires are designed for off-road use only, not for use on

pavement. Paved surfaces may seriously affect handling and control of the vehicle, and may cause the vehicle to go out of control.

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

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SAFETY

Operator Safety

WARNING

POTENTIAL HAZARD Operating this vehicle without proper instruction WHAT CAN HAPPEN Loss of control, accident HOW TO AVOID THE HAZARD The risk of an accident is greatly increased if the

operator does not know how to operate the vehicle properly in different situations and on different types of terrain.

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

WARNING

POTENTIAL HAZARD Operating this vehicle on public streets, roads or highways WHAT CAN HAPPEN Collision with another vehicle HOW TO AVOID THE HAZARD Never operate this vehicle on any public street, road or highway, including

dirt or gravel. In many states it's illegal to operate vehicles of this type on public streets,

roads and highways.

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SAFETY

Operator Safety

WARNING

POTENTIAL HAZARD Operating this vehicle after consuming alcohol

or drugs WHAT CAN HAPPEN Could seriously affect your judgment. Could cause you to react more slowly. Could affect your balance and perception. Could result in an accident. HOW TO AVOID THE HAZARD Driving a RANGER requires your full attention. DO NOT drink alcohol or use

drugs or medications before or while driving. They will reduce your alertness and slow your reaction time. In most states and provinces, it's prohibited by law to drive while intoxicated or under the influence of drugs.

WARNING

POTENTIAL HAZARD Operating this vehicle at excessive speeds WHAT CAN HAPPEN Loss of control, accident HOW TO AVOID THE HAZARD Always travel at a speed proper for the terrain, visibility and operating

conditions, and your experience.

Page 20

SAFETY

Operator Safety

WARNING

POTENTIAL HAZARD Attempting jumps and other stunts WHAT CAN HAPPEN Loss of control, accident and/or vehicle overturn HOW TO AVOID THE HAZARD Never attempt jumps and other stunts. Avoid exhibition driving.

WARNING

POTENTIAL HAZARD Operating on frozen bodies of water. WHAT CAN HAPPEN Severe injury or death can result if the vehicle and/or the operator fall through

the ice. HOW TO AVOID THE HAZARD Never operate the RANGER on a frozen body of water.

Page 21

SAFETY

Operator Safety

WARNING

POTENTIAL HAZARD Failure to inspect the vehicle before operating Failure to properly maintain the vehicle WHAT CAN HAPPEN Accident, equipment damage HOW TO AVOID THE HAZARD Always inspect your RANGER before each use to make sure it's in safe

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

described in the Owner's Manual.

WARNING

POTENTIAL HAZARD Failure to use extra caution when operating this vehicle on unfamiliar terrain WHAT CAN HAPPEN Loss of control, vehicle overturn HOW TO AVOID THE HAZARD Travel slowly and use extra caution when operating on unfamiliar terrain. Always be alert to changing terrain conditions when operating the vehicle.

You may come upon hidden rocks, bumps, or holes suddenly, without enough time to react.

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SAFETY

Operator Safety

WARNING

POTENTIAL HAZARD Failure to follow the minimum age recommendations for this vehicle WHAT CAN HAPPEN Serious injury or death (the child or others) HOW TO AVOID THE HAZARD Only persons with a valid driver's license should operate a Polaris RANGER. Even though a child may be within the age group for which some vehicles are

recommended, he or she may not have the skills, abilities, or judgment needed to operate the vehicle safely and may be involved in a serious accident.

WARNING

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

pressure WHAT CAN HAPPEN Loss of control, accident and/or overturn HOW TO AVOID THE HAZARD Always use the size and type of tires specified in the Owner's Manual for this

vehicle. Always maintain proper tire pressure as described on the decal and in the Owner's Manual. See pages 5 and 106.

Page 23

SAFETY

Operator Safety

WARNING

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

WARNING

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

CAUTION

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.

Page 24

SAFETY

Fuel Safety

WARNING

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

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

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

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

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

Page 25

FEATURES AND CONTROLS

Component Locations

Some Polaris vehicles are equipped with special features such as the cab frame. Not all models come with all features. Refer to the specifications section beginning on page 106.

Cab Frame

(if Equipped)

Console

Hip Bar

Cargo Box

Seat Belt

Fuel Tank Cap

Headlights

Front Bumper/Brush Guard

Radiator

Page 26

FEATURES AND CONTROLS

Component Locations

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 46-49.

Tailgate

Latch Release

Receiver

Hitch

CV Boot/Rear Caliper

Muffler

(Spark Arrestor)

Tailgate

Page 27

FEATURES AND CONTROLS

Console

Auxiliary Outlets

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

Fuel Gauge/Hour Meter

Lighted bars in the upper display indicate fuel level. Hours of engine operation since manufacture are indicated in the lower display.

Indicator

Lights

Cup

Holder

Storage

Compartment

12V Auxiliary

Outlets

Storage

Tray

Gear Selector

(Shifter)

Park Brake

Lever

Fuel Gauge

Page 28

FEATURES AND CONTROLS

Indicator Lights

The indicator light panel is located on the console.

Gear Selector

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

NOTE: Low gear is the primary

driving range for the RANGER. High gear is intended for use on hardpacked surfaces with light loads.

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

NOTE: Maintaining shift linkage adjustment is important to assure proper

transmission function. See your dealer if you experience 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.

High

Gear

Low Gear

(if equipped)

Neutral

Gear

Reverse

Gear

High

Temperature

Brakes

Page 29

FEATURES AND CONTROLS Switches

Ignition Switch

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

OFF The engine is off. Electrical circuits are off, except Acc, 12V.

ON Electrical circuits are on. Electrical equipment can be used.

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

The key returns to the ON position when released.

WARNING

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

Ignition Switch

Light Switch

AWD/Differential Switch

Page 30

FEATURES AND CONTROLS

Switches

Light Switch

The ignition switch key must be in the ON/ RUN position to operate the headlights. Use the light switch to turn the headlights on or off.

AWD/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 rocker switch to engage All Wheel Drive (AWD). See page 52 for AWD operating instructions.

Move the rocker switch to the center position to lock the differential and operate in two wheel drive (2WD). See page 51 for Differential Lock operating instructions.

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.

OFF

AWD

2WD

OFF

Page 31

FEATURES AND CONTROLS

Park Brake Lever

To help prevent the vehicle from rolling, engage the park brake when parking the vehicle. When the park brake is fully engaged and the park brake indicator is illuminated, engine speed is limited to 1300 RPM in all gears, except neutral. If throttle is applied, this limiting feature prevents operation, which protects the park brake pads from excessive wear.

NOTE: 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. Check for disconnection, then see your dealer promptly if this feature fails to operate properly.

Inspect and adjust park brake cable tension after the first 25 hours of operation and every 100 hours thereafter to ensure proper cable tension. See page 86.

Always apply the service brakes before engaging or releasing the park brake.

1. Apply the brakes.

2. Pull the park brake lever

downward as far as possible.

3. To release the park brake,

apply the brakes. Press the park brake release inward and move the lever upward as far as possible.

WARNING

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

Page 32

FEATURES AND CONTROLS

Seat Belts

The RANGER is equipped with lapstyle seat belts for the operator and passenger.

To wear the seat belt properly, follow this procedure:

1. Place the belt across your lap as

low on your hips as possible. Make sure that the belt is not twisted.

2. Push the latch plate into the buckle

until it clicks.

3. Release the strap, it will self

tighten.

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

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

center.

WARNING

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

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

Page 33

FEATURES AND CONTROLS

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.

Fuel Cap

The fuel tank filler cap is located on the right-hand 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 E-85 fuel.

Page 34

FEATURES AND CONTROLS

Adjustable Steering Wheel

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

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

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 83 for throttle pedal adjustment procedures.

Throttle

Pedal

Brake Pedal

Page 35

OPERATION

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 breakin period. Careful treatment of a new engine will result in more efficient performance and longer life for the engine. Perform the following procedures carefully.

NOTICE

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

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

Page 36

OPERATION

Break-In Period

Engine and Drivetrain Break-in

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

21.

2. Check the oil level. See page 61. Add the recommended oil as

needed to maintain the oil level in the normal (safe) operating range.

3. Drive slowly at first. Select an open area that allows room to famil-

iarize yourself with vehicle operation and handling.

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

5. Perform regular checks on fluid levels, controls and areas outlined

on the daily pre-ride inspection checklist. See page 34.

6. Pull only light loads.

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

hours.

8. Inspect and adjust park brake cable tension after the first 25 hours of

operation and every 100 hours thereafter to ensure proper cable tension. See page 86.

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.

Page 37

OPERATION

Pre-Ride Inspection

WARNING

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

Item Remarks Page

Brake system/pedal travel Ensure proper operation 31

Brake fluid Ensure proper level 84

Front suspension Inspect, lubricate if necessary 59

Rear suspension Inspect, lubricate if necessary 59

Steering Ensure free operation 86

Tires Inspect condition and pressure 5

Wheels/fasteners Inspect, ensure fastener tightness 88

Frame nuts, bolts, fasteners Inspect, ensure tightness -

Fuel and oil Ensure proper levels 30

Coolant level Ensure proper level 72

Coolant hoses Inspect for leaks -

Throttle Ensure proper operation 82

Indicator lights/switches Ensure operation 25

Air filter, pre-filter Inspect, clean 78

Air box sediment tube Drain deposits whenever visible 78

Headlamp Check operation, apply Polaris dielec-

tric grease when lamp is replaced

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

tric grease when lamp is replaced

Page 38

OPERATION

Starting Engine

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

2. Apply the brakes.

3. Engage the park brake.

4. Shift the transmission to neutral.

NOTE: Do not press the throttle pedal while starting the engine.

5. Turn the ignition key past the ON/RUN position to START. Engage

the starter for a maximum of five seconds. Release the key when the engine starts.

6. If the engine does not start within five seconds, release the ignition

switch and wait five seconds. Repeat steps 5 and 6 until the engine starts.

7. Vary the engine RPM slightly with the throttle to aid in warm up

until the engine idles smoothly.

WARNING

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

NOTICE

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

Page 39

OPERATION

Stopping the Engine

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

2. Turn the engine off.

3. Apply the brakes.

4. Engage the park brake.

WARNING

A rolling vehicle can cause serious injury. Always engage the park brake after stopping the engine.

Page 40

OPERATION

Braking

1. Release the throttle pedal completely.

2. Press on the brake pedal evenly and firmly.

3. Practice starting and stopping (using the brakes) until you're famil-

iar with the controls.

NOTE: When the throttle pedal is released completely and the engine speed

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

WARNING

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

Page 41

OPERATION

Driving Procedure

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

2. After starting the engine and allowing it to warm up, apply the ser-

vice brakes, and shift the transmission into gear.

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

4. Release the park brake.

5. Keeping both hands on the steering wheel, slowly release the brakes

and depress the throttle with your right foot to begin driving.

6. Drive slowly. Practice maneuvering and using the throttle and

brakes on level surfaces.

NOTE: Low gear is the primary range for operating the RANGER. High gear is

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

Page 42

OPERATION

Driving On Slippery Surfaces

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

1. Slow down when entering slippery areas.

2. Maintain a high level of alertness, reading the trail and avoiding

quick, sharp turns, which can cause skids.

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

skid.

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

vehicle.

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.

WARNING

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

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

surfaces.

Page 43

OPERATION

Driving Uphill

Whenever traveling uphill, follow these precautions:

1. Always travel

straight uphill.

2. Avoid steep hills

(15° maximum).

3. Keep both feet on

the floor.

4. Proceed at a

steady rate of speed and throttle opening.

WARNING

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

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

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

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

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

15° maximum

Page 44

OPERATION

Driving on a Sidehill (Sidehilling)

Driving Downhill

Whenever descending a hill, follow these precautions:

1. Proceed directly downhill.

2. Slow down.

3. Apply the brakes slightly to aid in slowing.

WARNING

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

WARNING

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

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

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

Page 45

OPERATION

Driving Through Water

You r P o l a ris RANGER can operate through water up to a maximum recommended depth equal to the floorboards. Follow these procedures when operating through water:

1. Always determine

water depths and current before entering.

2. Choose a crossing

where both banks have gradual inclines.

3. Proceed slowly, avoiding rocks and obstacles.

4. After leaving water, always dry the brakes by applying light pres-

sure to the pedal repeatedly until braking action is normal.

NOTE: After running your vehicle in water, it's critical that you perform the ser-

vices outlined in the Periodic Maintenance Chart beginning on page

54. Give special attention to engine oil, transmission oil, front and rear gearcases, and all grease fittings.

WARNING

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

NOTICE

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

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

Floorboard

Page 46

OPERATION

Driving Over Obstacles

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

WARNING

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

Page 47

OPERATION

Driving in Reverse

Follow these guidelines when operating in reverse:

1. Back slowly.

2. Apply the brakes lightly for stopping.

3. Avoid turning at sharp angles.

4. Always avoid backing downhill.

5. Never open the throttle suddenly while backing.

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

WARNING

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

Page 48

OPERATION

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 gear.

3. Engage the park brake.

4. Turn the engine off.

5. Block the rear wheels on the downhill side.

WARNING

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

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

Page 49

OPERATION

Hauling Cargo

WARNING

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

REDUCE SPEED AND ALLOW GREATER DISTANCES FOR BRAKING WHEN HAULING CARGO.

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

When operating over rough or hilly terrain, reduce speed and cargo to maintain stable driving conditions.

Always operate the vehicle with extreme care when hauling or towing loads. Slow down and drive in the lowest gear available. SECURE ALL LOADS BEFORE OPERATING. Unsecured loads can create

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

OPERATE ONLY WITH STABLE AND SAFELY ARRANGED LOADS. When handling off-centered loads that cannot be centered, securely fasten the load and operate with extra caution. Always attach the tow load to the hitch point designated for your vehicle.

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

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

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

Page 50

OPERATION

Hauling Cargo

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

Model Maximum Capacities

(Level Ground)

Cargo Box

RANGER 4X4 500 EFI 1500 lbs. (681 kg) 1000 lbs. (454 kg)

WARNING

Driving with passengers in the cargo box can result in severe injury or death.

Never allow passengers to ride in the cargo box. Passengers must always ride in the cab with seat belts fastened securely.

Page 51

OPERATION

Dumping the Cargo Box

1. Select a level site to

dump the cargo box. Do not attempt to dump or unload the vehicle while parked on an incline.

2. Apply the brakes.

3. Engage the park

brake.

4. Dismount the vehicle.

5. Ensure that the cargo

is positioned evenly or toward the front of the cargo box.

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

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

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

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

WARNING

Operating the vehicle while the cargo box is raised could result in severe injury. The box could close unexpectedly and cause injury to the driver or passenger. The rear tires 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.

WARNING

If the weight distribution on the box is located toward the rear of the box when the release lever is pulled forward, the box may dump unexpectedly and cause serious injury to the operator or bystanders.

Never operate the dump lever without ensuring that the load is positioned evenly or at the front of the box.

Release Lever

Page 52

OPERATION

Towing Loads

Belt Life

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

WARNING

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

Never load more than 150 lbs. (68.1 kg) tongue weight on the towing bracket. Do not operate the vehicle faster than 10 mph (16 km/h) when towing. See

page 46. Towing a trailer increases braking distance. Do not tow more than the recommended weight for the vehicle. See the

towing capacity chart below and the specifications charts beginning on page

106. Attach a trailer to the trailer hitch bracket only. Do not attach a trailer to any

other location or you may lose control of the vehicle. Never tow a trailer on a grade steeper than 15°.

Model Total Towed

Load Weight

(Level Ground)

To t a l To w e d

Load Weight

(15° grade)

To t a l H i t c h

Vertical

Weight

Maximum

To w i n g

Speed

RANGER 4X4

500 EFI

1500 lbs.

(681 kg)

850 lbs.

(386 kg)

150 lbs.

(68.1 kg)

10 mph

(16 kph)

Page 53

OPERATION

Parking the Vehicle

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

2. Turn the engine off.

3. Engage the park brake.

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

WARNING

A rolling vehicle can cause property damage and serious injury. Always engage the park brake when stopping the engine.

WARNING

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

Page 54

OPERATION

Differential Operation Modes

The 4X4 rear axle is equipped with a lockable differential that allows the operator to choose between an open differential or a closed differential.

AWD

Press the top of the rocker switch to engage All Wheel Drive (AWD). When in AWD, the rear wheels rotate at the same speed. The front wheels also rotate at the same speed. See page 52 for AWD operating instructions.

2WD/Rear Differential Locked

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.

OFF/Differential Unlocked

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.

Page 55

OPERATION

All Wheel Drive (AWD)

The illuminated amber AWD switch indicates 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.

Disengaging AWD

Under certain conditions, it may be possible for the front gearcase to remain locked unnecessarily. This condition causes increased steering effort and some vehicle speed restriction. If the front gearcase remains locked after following these instructions, return the vehicle to your dealer for service.

1. Stop the vehicle.

2. Operate in reverse for at least 10 feet.

3. Stop completely.

4. Shift into low gear and drive forward.

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.

Page 56

EMISSION CONTROL SYSTEMS

Noise Emission Control System

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

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

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

Operation of off-road vehicles on public lands in the U.S.A. is regulated by 43 CFR 8343.1(c). Violations are subject to monetary penalties. Federal regulations can be viewed online at www.gpoaccess.gov/ecfr/.

Crankcase Emission Control System

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

Exhaust Emission Control System

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

The emissions label is located on the frame under the seat.

Electromagnetic Interference

This spark ignition system complies with Canadian ICES-002. This vehicle complies with the EMC requirements of European direc-

tives 97/24/EC and 2004/108/EC.

Page 57

MAINTENANCE

Periodic Maintenance Chart

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

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

Record maintenance and service in the Maintenance Log beginning on page 117.

NOTE: Service and adjustments are important for proper vehicle operation. If

you're not familiar with safe service and adjustment procedures, have a qualified dealer perform these operations.

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

Severe Use Definition

• Frequent immersion in mud, water or sand

• Racing or race-style high RPM use

• Prolonged low speed, heavy load operation

• Extended idle

• Short trip cold weather operation

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

Page 58

MAINTENANCE

Periodic Maintenance Chart

Maintenance Chart Key

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

E Emission Control System Service - 4 Cycle (California)

Q Have an authorized Polaris dealer perform these services.

WARNING

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

Page 59

MAINTENANCE

Periodic Maintenance Chart

Perform all services at whichever maintenance interval is reached first.

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

E Emission-Related Service.

Q Have an authorized Polaris dealer perform these services.

Item Maintenance Interval

(whichever comes first)

Remarks

Hours Calendar Miles

(Km)

Steering - Pre-Ride - Make adjustments as need

ed. See Pre-Ride Checklist on page 34.

X Front suspension - Pre-Ride - X Rear suspension - Pre-Ride -

Tires - Pre-Ride -

X Brake fluid level - Pre-Ride - X Brake pedal travel

Brake system - Pre-Ride -

Wheels/fasteners - Pre-Ride -

Frame fasteners - Pre-Ride -

X Engine oil level - Pre-Ride - XEAir filter, pre-filter - Daily - Inspect; clean often; replace

as needed

XEAir box sediment

tube

- Daily - Drain deposits when visible

Coolant (if applicable)

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

Headlamp/tail lamp

- Daily - Check operation; apply dielectric grease if replacing

XEAir filter,

main element

- Weekly - Inspect; replace as needed

Brake pad wear 10 H Monthly - Inspect periodically

Battery 20 H Monthly - Check terminals; clean; test

X Front Gearcase Oil

(if equipped)

25 H Monthly - Inspect level; change yearly

X Middle Gearcase

Oil (if equipped)

25 H Monthly - Inspect level; change yearly

X Rear gearcase oil

(if equipped)

25 H Monthly - Inspect level; change yearly

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

Page 60

MAINTENANCE

Periodic Maintenance Chart

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

E Emission-Related Service.

Q Have an authorized Polaris dealer perform these services.

Item Maintenance Interval

(whichever comes first)

Remarks

Hours Calendar Miles

(Km)

XEEngine breather

filter (if equipped)

25 H Monthly - Inspect; replace if necessary

X Engine oil change

(break-in)

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

at one month

Park brake cable tension

25 H 1 M - Check tension, adjust

X General

lubrication

50 H 3 M - Lubricate all fittings, pivots,

cables, etc.

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

Steering 50H 6 M - Lubricate

X Front Suspension 50 H 6 M - Lubricate X Rear Suspension 50 H 6 M - Lubricate

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

replace if necessary

E Throttle body air

intake ducts/flange

50 H 6 M - Inspect duct for proper seal-

ing/air leaks

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

needed

Cooling system (if applicable)

50 H 6 M - Inspect coolant strength

seasonally; pressure test system yearly

Park brake cable tension

100 H 6 M - Check tension, adjust

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

at one month

X Oil filter change 100 H 6 M - Replace with oil change

Page 61

MAINTENANCE

Periodic Maintenance Chart

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

E Emission-Related Service.

Q Have an authorized Polaris dealer perform these services.

Item Maintenance Interval

(whichever comes first)

Remarks

Hours Calendar Miles

(Km)

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

lines, fuel valve, pump, throttle body; replace lines every 2 years

Fuel filter 100 H 12 M - Replace yearly

X Radiator

(in applicable)

100 H 12 M - Inspect; clean external

surfaces

X Cooling Hoses 100 H 12 M - Inspect for leaks X Engine mounts 100 H 12 M - Inspect

Exhaust muffler/ pipe

100 H 12 M - Inspect

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

Ignition timing 100 H 12 M - Inspect

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

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

Clutches (drive and driven)

100 H 12 M - Inspect; clean; replace worn

parts

Front wheel bearings

100 H 12 M - Inspect; replace as needed

Brake fluid 200 H 24 M - Change every two years

Spark arrestor 300 H 36 M - Clean out

Idle speed - Adjust as needed

Toe adjustment - Inspect periodically; adjust

when parts are replaced

Auxiliary brake (if equipped)

- Inspect daily; adjust as needed

Headlight aim - Adjust as needed

Page 62

MAINTENANCE

Lubrication Recommendations

Check and lubricate all components at the intervals outlined in the Periodic Maintenance Chart beginning on page 54, or more often under severe use, such as wet or dusty conditions. Items not listed in the chart should be lubricated at the general lubrication interval.

Item Lube Method

Engine Oil Polaris Premium 4 Synthetic

0W40

See page 61.

Brake Fluid DOT 4 See page 84.

Main Gearcase Oil (Transmission)

Premium AGL Synthetic Gearcase Lube

See page 65.

Front Gearcase Oil Premium Demand Drive Hub

Fluid

See page 67.

Rear Gearcase Oil Premium ATV Angle Drive

Fluid

See page 68.

Front Prop Shaft Yoke Polaris Premium U-Joint

Lube

Locate fittings and grease (3 pumps maximum).

Prop Shaft U-Joint

Page 63

MAINTENANCE

Engine Oil

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

Premium 4 Synthetic Oil

Polaris Premium 4 All Season Synthetic engine oil has been specially formulated for use in Polaris 4-cycle engines. It's a fully synthetic, high performance, multi-viscosity oil designed to provide the ultimate in lubrication performance and protection. See page 108 for the part numbers of Polaris products.

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

Although Polaris Premium 4 is the only oil recommended for use in this engine, use of any API certified "SH" oil is allowable as long as it's 0W-

40. Oil may need to be changed more frequently if Polaris Premium 4 is not used. Follow the manufacturer's recommendations for ambient temperature operation.

NOTICE

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

WARNING

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

Page 64

MAINTENANCE

Engine Oil

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

Oil Check

The oil tank is located under the seat.

1. Position the vehicle on a level surface.

2. Apply the brakes. Start the

engine and allow it to idle for 20-30 seconds. Stop the engine.

3. Remove the seat. See page

30.

4. Remove the dipstick. Wipe

it dry with a clean cloth.

5. Reinstall the dipstick.

Screw it in completely.

NOTE: The dipstick must be

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

Remove the dipstick. Make sure that the oil level is between the full and add marks. Add oil if necessary. Do not overfill.

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

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

Add

{

Safe Range

Full

Page 65

MAINTENANCE

Engine Oil

Oil and Filter Change

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

1. Position the vehicle on a level surface.

2. Run the engine for two to

three minutes until warm. Stop the engine.

3. Clean the area around the

drain plug.

4. Place a drain pan beneath oil

tank.

5. Remove the drain plug.

Allow the oil to drain completely.

6. Install a new sealing washer

on the drain plug.

NOTE: The sealing surfaces on

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

7. Reinstall the drain plug.

Torque to 14 ft. lbs. (19 Nm).

8. Disconnect the lower oil delivery hose and remove the screen fitting

from the oil tank. Clean the fitting.

NOTE: The fitting threads must be sealed with LOCTITE PST 505 or PTFE

seal tape.

9. Reinstall the screen fitting and rotate the fitting clockwise a mini-

mum of 2 1/2 turns into the tank threads. Continue to rotate the fitting until the nipple of the fitting aligns with the mark on the tank.

NOTE: Do not over-tighten. Maximum torque for the screen fitting is 25 ft. lbs.

(34 Nm).

CAUTION

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

Sealing

Washer

Drain

Plug

Screen

Fitting

Orientation

Mark

Page 66

MAINTENANCE

Engine Oil

Oil and Filter Change

10. Reattach the oil line.

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

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

13. Lubricate the gasket on the new filter with a film of new engine oil. Make sure the gasket is in good condition. Make sure the gasket from the old filter is not still on the engine.

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

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

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

and free of burrs, nicks or scratches.

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

17. Remove the dipstick and fill the tank with two quarts (1.9 l) of the recommended oil.

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

19. Prime the oil pump using the procedure on page 64. Then stop the engine and inspect for leaks.

20. Check the oil level on the dipstick. Add oil as necessary to bring the level to the upper mark on the dipstick.

21. Dispose of used filter and oil properly.

Page 67

MAINTENANCE

Engine Oil

Oil and Filter Change

Oil Pump Priming

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

1. Clamp or pinch off the vent line approximately 2" (5 cm) from the oil tank, between the end of the oil tank vent fitting and the vent line's pressure relief slit.

2. Start the engine. Allow it to idle

for 10-20 seconds.

3. Remove the vent line clamp. If the line is bled properly, you should

hear a rush of air, indicating that the line is properly primed and ready for operation.

NOTE: If you do not hear air, the line has not bled. Repeat the priming proce-

dure.

Clamp

Pressure

Relief Slit

Tank

(5 cm)

Page 68

MAINTENANCE

Gearcases

Gearcase Specification Chart

Transmission (Main Gearcase)

Always check and change the transmission oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 54. Maintain the oil level even with the bottom thread of the fill plug hole.

Refer to the Gearcase Specifications Chart for recommended lubricants, capacities and torque specifications. See page 108 for the part numbers of Polaris products.

Oil Check

The fill plug is located at the rear of the vehicle.

1. Position the vehicle on a level surface.

2. Remove the fill plug.

3. Check the oil level.

4. Add the recommended oil as

needed.

5. Reinstall the fill plug. Torque

to specification.

Gearcase Lubricant Capacity Fill Plug

To r q u e

Drain Plug

To r q u e

Main Gearcase

(Transmission)

Premium AGL

Synthetic

Gearcase Lube

43.6 oz.

(1290 ml)

14 ft. lbs.

(19.4 Nm)

14 ft. lbs.

(19.4 Nm)

Front Gearcase Premium Demand

Drive Hub Fluid

9.3 oz.

(275 ml)

8-10 ft. lbs.

(11-13.6 Nm

11 ft. lbs.

(15 Nm)

Rear Gearcase Premium ATV

Angle Drive Fluid

18 oz.

(532 ml)

40-50 ft. lbs.

(54-68 Nm

30-45 in. lbs.

(3-5 Nm)

Fill

Plug

Page 69

MAINTENANCE

Gearcases

Transmission (Main Gearcase)

Oil Change

The drain plug is located on the bottom of the transmission. Access the drain plug through the drain hole in the skid plate.

1. Remove the fill plug.

2. Place a drain pan under the drain plug.

3. Remove the drain plug. Drain the oil.

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

5. After the oil has drained completely, install a new sealing washer.

NOTE: Refer to the Gearcase Specifications Chart on page 65 for recom-

mended lubricants, capacities and torque specifications.

6. Reinstall the drain plug. Torque to specification.

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

8. Reinstall the fill plug. Torque to specification.

9. Check for leaks.

10. Dispose of used oil properly.

Drain Plug

Page 70

MAINTENANCE

Gearcases

Front Gearcase

Always check and change the front gearcase oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 54. Maintain the oil level even with the bottom thread of the fill plug hole.

Refer to the Gearcase Specifications Chart on page 65 for recommended lubricants, capacities and torque specifications. See page 108 for the part numbers of Polaris products.

Oil Check

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

1. Position the vehicle on a level surface.

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

3. Add the recommended oil as needed.

4. Reinstall the fill plug. Torque to specification.

Oil Change

1. Support the vehicle securely with a

jackstand.

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

3. Remove the fill plug.

4. Place a drain pan under the drain plug on the bottom right-hand side.

5. Remove the drain plug. Drain the oil.

6. Clean the drain plug. Reinstall the drain plug. Torque to specification.

7. Add the recommended oil.

8. Reinstall the fill plug. Torque to specification.

9. Check for leaks.

10. Discard used oil properly.

Drain Plug

Fill Plug

Page 71

MAINTENANCE

Gearcases

Rear Gearcase

Always check and change the rear gearcase oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 54.

Refer to the Gearcase Specifications Chart on page 65 for recommended lubricants, capacities and torque specifications. See page 108 for the part numbers of Polaris lubrication products.

Oil Check

Maintain the oil level even with the bottom thread of the fill plug hole.

1. Position the vehicle on a level surface.

2. Remove the fill plug.

Check the oil level.

3. Add the recommended oil

as needed.

4. Reinstall the fill plug.

Torque to specification.

Oil Change

1. Remove the fill plug.

2. Place a drain pan under the

drain plug.

3. Remove the drain plug.

Drain the oil.

4. Clean the drain plug. Reinstall the drain plug. Torque to specifica-

tion.

5. Add the recommended oil.

6. Reinstall the fill plug. Torque to specification.

7. Check for leaks.

8. Dispose of used oil properly.

Fill Plug

Drain Plug

Page 72

MAINTENANCE

Spark Plugs

Spark Plug Gap/Torque

Spark plug condition is indicative of engine operation. The spark plug firing end condition should be read after the engine is warmed up and the vehicle is driven at higher speeds. Immediately check the spark plug for correct color. See page 70.

NOTICE

Using non-recommended spark plugs can result in serious engine damage. Always use Polaris-recommended spark plugs. Refer to the specifications section beginning on page 106.

Model Electrode Gap New Plug

To r q u e

Used Plug

To r q u e

RANGER 4X4

500 EFI

.036" (.9 mm) 9-11 ft. lbs.

(12-15 Nm)

9-11 ft. lbs.

(12-15 Nm)

CAUTION

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

Page 73

MAINTENANCE

Spark Plugs

Spark Plug Condition

Normal Plug

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

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

caused by use of an improper spark plug or incorrect throttle body adjustments.

Wet Fouled Plug

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

Spark Plug Removal and Replacement

1. Remove the seat to access the engine compartment.

2. Remove the spark plug cap. Using the spark plug wrench provided

in the tool kit, remove the plug by rotating it counterclockwise.

3. Reverse the procedure for spark plug installation. Torque to specifi-

cation. See page 69.

Page 74

MAINTENANCE

Cooling System

Operation

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

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

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

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

Adding or Changing Coolant

To ensure that the coolant maintains its ability to protect the engine, we recommend that the system be completely drained every two years and a fresh mixture of antifreeze and water added. Polaris recommends the use of Polaris Premium 60/40 anti-freeze/coolant or a 50/50 mixture of high quality aluminum compatible anti-freeze/coolant and distilled water. Polaris Premium 60/40 is already premixed and ready to use. Do not dilute with water. See page 108 for the part numbers of Polaris products.

NOTE: Always follow the manufacturer's mixing recommendations for the

freeze protection required in your area.

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

Page 75

MAINTENANCE

Cooling System

Radiator and Cooling Fan

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

Overflow Bottle Coolant Level

Always check and change the coolant at the intervals outlined in the Periodic Maintenance Chart beginning on page 54. Maintain the coolant level between the minimum and maximum marks on the bottle (when the fluid is cool).

The overflow bottle is located in front of the right front wheel.

1. Position the vehicle on a level surface.

2. View the coolant level in the overflow bottle.

3. If the coolant level is below the

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

NOTE: If coolant must be added often,

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

NOTICE

Washing the vehicle with a high-pressure hose could damage the radiator fins and impair the radiator's effectiveness. Using a high-pressure system is not recommended.

Page 76

MAINTENANCE

Cooling System

Radiator Coolant Level

1. Lift the hood.

2. Slowly remove the radiator cap.

3. View the coolant level through the opening.

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

NOTE: This procedure is required

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

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

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

CAUTION

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

Page 77

MAINTENANCE

Polaris Variable Transmission (PVT) System

When To Use Low Range vs. High Range

Belt slip is responsible for creating excessive heat that destroys belts, wears clutch components and causes outer clutch covers to fail. Switch to low range while operating at slower speeds to extend the life of the PVT components (belt, cover, etc.).

WARNING

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

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

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

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

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

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

Condition Range to Use

Operating at speeds less than 7 MPH (11 km/h) Low

Towing heavy loads Low

Operating in rough terrain (swamps, mountains, etc.) Low

Operating at speeds greater than 7 MPH (11 km/h) High

Page 78

MAINTENANCE

PVT System

PVT Drying

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

1. Loosen the bottom screws that secure the clutch cover. Allow the water to drain. Tighten the screws.

2. Apply the brakes. Start the engine. Engage the park brake. Shift the

transmission to neutral.

3. Apply varying throttle for 10-15 seconds to expel the moisture and

air-dry the belt and clutches. Do not hold the throttle wide open for more than 10 seconds.

4. Allow the engine RPM to settle to idle speed. Apply the brakes.

Release the park brake and shift the transmission to the lowest available range.

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

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

Page 79

MAINTENANCE

Vehicle Immersion

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

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

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

if water is present.

3. Thoroughly dry the air pre-cleaner located under the hood.

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

the electric start.

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

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

dure.

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

whether you succeed in starting it or not.

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

page 75 for drying.

NOTICE

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

Page 80

MAINTENANCE

Seat Belts

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

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

2. Push the red button in the middle of the buckle to make sure it

releases freely.

3. Check the belt webbing for wear, cuts or damage. If any irregulari-

ties are found, have the seat belt system checked and/or replaced by an authorized Polaris dealer.

The RANGER seat belt is adjustable and should be adjusted for both the operator and passengers before driving. Although having the belt at 30° is typical for many people, it will not accommodate all body sizes and shapes. Make sure the seat belt is adjusted to the lowest possible lap position before riding.

1. To adjust, loosen the bolts.

2. Reposition both the buckle

and retractor. Tighten the bolts.

NOTE: The center belt does not self adjust. Before riding, pull on the strap to

secure the belt on the lap of the center passenger.

WARNING

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

Bolts

Page 81

MAINTENANCE

Filter Systems

Air Filter

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

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

2. Remove the air box

cover and inspect the gasket. It should adhere tightly to the cover and seal all the way around.

3. Remove the air filter.

4. Do not attempt to clean

the main element. Install a new air filter.

NOTE: Apply a small amount

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

5. Inspect the air box for oil or water deposits. If present, drain them

into a suitable container.

NOTE: Service the air filter more frequently if the vehicle is operated in wet

conditions or at high throttle openings for extended periods.

Fuel Filter

Your Polaris vehicle is equipped with an in-line fuel filter. Have your dealer replace it after every 100 hours of operation. Do not attempt to clean the fuel filter.

Air Filter

Page 82

MAINTENANCE

Filter Systems

Breather Filter and Hoses

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

2. Follow the right-hand

breather line out the side of the air box and locate the filter.

3. Remove and inspect the

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

4. Check hoses for cracks,

deterioration, abrasion, or leaks. Replace as needed.

5. Reinstall the filter with

the arrow pointing toward the engine. Secure the clamps.

NOTICE

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

Page 83

MAINTENANCE

Spark Arrestor

WARNING

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

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

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

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

Never go under the vehicle while it's inclined.

Page 84

MAINTENANCE

Spark Arrestor

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

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

2. Shift the transmission to neutral.

Apply the brakes. Start the engine.

3. Purge accumulated carbon from

the system by momentarily revving the engine several times.

4. If carbon is expelled, cover or

plug the exhaust outlet and rap on the pipe around the clean-out plugs while revving the engine several more times.

5. If particles are still suspected to be in the muffler, elevate the rear of

the vehicle one foot higher than the front. Apply the brakes. Engage the park brake. Block the wheels. Make sure the transmission is in neutral and repeat steps 3 and 4 until no more particles are expelled when the engine is revved.

6. Stop the engine. Allow the arrestor to cool.

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

Clean-Out

Plugs

Exhaust

Outlet

Page 85

MAINTENANCE

Throttle System

Throttle Freeplay

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

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

Throttle Freeplay Inspection

1. Apply the brakes. Engage the park brake. Shift the transmission to neutral.

2. Start the engine. Allow it to warm up thoroughly.

3. Measure the distance the throttle pedal moves before the engine

begins to pick up speed. Freeplay should be 1/16 to 1/8 inches (1.6-

3.2 mm).

WARNING

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

Always check the pedal for free movement and return before starting the engine and occasionally during operation. Never start or operate this vehicle if it has a sticking or improperly operating throttle pedal. Immediately contact your dealer for service if throttle problems arise.

Throttle

Pedal

Page 86

MAINTENANCE

Throttle System

Throttle Body/Idle RPM

Idle RPM is preset by the manufacturer. If the engine idle speed is not satisfactory, please see your Polaris dealer for adjustment.

Throttle Freeplay Adjustment

1. Remove the seat.

2. Locate the throttle cable adjuster.

3. Squeeze the end of the rubber boot and slide it far enough to expose the end of the inline cable adjuster.

4. Loosen the adjuster lock nut.

5. Rotate the boot to turn the adjuster until 1/16" to 1/8" (1.5-3 mm) of freeplay is achieved at the throttle pedal. See page 82.

NOTE: While adjusting, lightly flip the throttle pedal up and down.

6. Tighten the lock nut.

7. Squeeze the end of the rubber boot and slide it over the cable adjuster to its original position.

Cylinder Head/Cylinder Base Fastener Torque

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

Boot

Adjuster

Lock Nut

Page 87

MAINTENANCE

Brakes

The front and rear brakes are hydraulic disc type brakes. Press down on the brake pedal to engage the brakes. See page 31.

Brake Fluid

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

Change the brake fluid every two years and any time the fluid becomes contaminated, the fluid level is below the minimum, or if the type and brand of the fluid in the reservoir are unknown. See page 59 for fluid recommendations.

1. Position the vehicle on a level surface.

2. View the brake fluid level at the

reservoir in the driver’s side wheel well. The level should be between the upper (MAX) and lower (MIN) level lines.

3. If the fluid level is lower than

the upper level line, add brake fluid to the upper (MAX) line.

4. Apply the brake forcefully for a

few seconds and check for fluid leakage around the fittings.

WARNING

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

Maximum

Minimum

Page 88

MAINTENANCE

Brakes

Brake Inspection

1. Check the brake system for fluid leaks.

2. Check the brake pedal for

excessive travel or a spongy feel.

3. Check the friction pads for

wear, damage and looseness.

4. Inspect the brake disc spline

and pad wear surface for excessive wear.

5. Change pads when worn to

3/64" (1 mm).

Park Brake Inspection

1. Apply the brakes.

2. Pull the park brake lever

downward as far as possible.

3. Check the vehicle for

movement. The vehicle should not roll while parked. If the vehicle moves, adjust the park brake.

3/64" (1mm)

Park Brake Release

Page 89

MAINTENANCE

Brakes

Park Brake Adjustment

Inspect and adjust park brake cable tension after the first 25 hours of operation and every 100 hours thereafter to ensure proper cable tension. Loss of tension in the park brake cable may cause illumination of the park brake light and activation of the limiting feature. If this occurs, move the park brake lever to the forward-most position, then inspect and adjust park brake cable tension.

NOTE: If performing this service is difficult due to conditions or location, open

the hood and temporarily disconnect the park brake connector. This will inactivate the limiting function. Reconnect the connector as soon as possible, and adjust the park brake cable to proper tension.

1. Position the vehicle on a level surface.

2. Shift the transmission to neutral.

3. Loosen or tighten the nuts on the lever end of the park brake cable as needed.

Steering Wheel Inspection

Check the steering wheel for specified freeplay and smooth operation at the intervals outlined in the Periodic Maintenance Chart beginning on page 54.

1. Position the vehicle on a level surface.

2. Lightly turn the steering wheel left and right.

3. There should be 0.8"-1.0" (20-25 mm) of freeplay.

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

Page 90

MAINTENANCE

Suspension Adjustments

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

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

2. Reposition the shocks to the outside mounting holes.

3. Reinstall the shock mounting bolts. Torque to 30 ft. lbs. (40 Nm).

Spring Adjustment

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

Cam

Outside Mounting Holes

Inside Mounting Holes

Rear Suspension Shown

Adjustment is similar for Front Suspension

Page 91

MAINTENANCE

Tires

Tire Tread Depth

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

Axle and Wheel Nut Torque Specifications

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

NOTE: Do not lubricate the stud or the lug nut.

WARNING

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

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

Nut Type Location Nut Torque

Lug Nut Front and Rear 90 ft. lbs. (122 Nm)

2-Piece Flange Nut

Front and Rear 35 ft. lbs. (47 Nm)

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

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

1/8" (3 mm)

Page 92

MAINTENANCE

Tires

Wheel Removal

1. Apply the brakes. Engage the park brake.

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

3. Loosen the wheel nuts slightly.

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

frame.

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

WARNING

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

Page 93

MAINTENANCE

Tires

Wheel Installation

1. Place the transmission in gear.

2. Apply the brakes.

Engage the park brake.

3. Place the wheel in the

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

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

5. Carefully lower the vehicle to the ground.

6. Torque the wheel nuts to specification. See page 88.

Page 94

MAINTENANCE

Lights

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

Headlight Lamp Replacement

1. Open the hood.

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

3. Turn the lamp counterclockwise to remove it.

4. Install the new lamp.

NOTE: Make sure the tab on the lamp locates properly in the housing.

5. Reinstall the harness assembly into the headlight assembly.

WARNING

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

Hot components can cause burns to skin. Do not service the headlamps until they've cooled sufficiently.

Wiring Harness

Page 95

MAINTENANCE

Lights

Headlight Beam Adjustment

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

2. Measure the distance from the floor to the center of the headlight

and make a mark on the wall at the same height.

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

4. Observe the headlight aim. The most intense part of the headlight

beam should be aimed 8" (20 cm) below the mark placed on the wall in step 2.

NOTE: Include the weight of a rider on the seat while performing this step.

5. If a headlight needs adjustment, locate the adjustment screw under

the hood liner (access through the wheel well).

6. Loosen the screw, adjust the headlight, and tighten the screw.

7. Repeat steps 4-6 until the lamp is properly adjusted.

25 ft.

(7.6 m)

8" (20 cm)

Page 96

MAINTENANCE

Lights

Brake Lights

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

1. Turn the ignition switch to the ON position.

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

Indicator Lamp Replacement

1. Lift the hood.

2. Reach in behind the console panel and lift the release to unplug the light from the harness.

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

4. Locate the expired lamp. Using a screwdriver, rotate the lamp 1/4 turn counterclockwise.

5. Grip the lamp with a needle-nose pliers and remove it from the assembly.

6. Install the new lamp. Using a screwdriver, rotate the lamp 1/4 turn clockwise to seat it.

7. Snap the assembly back into the console panel. Reconnect the harness.

8. Close the hood.

Ta b

Release

Page 97

MAINTENANCE

Battery

Your vehicle may have either a sealed battery, which requires little maintenance, or a conventional battery. A sealed battery can be identified by its flat covers on the top of the battery. A conventional battery has six filler caps on the top of the battery.

Always keep battery terminals and connections free of corrosion. If cleaning is necessary, remove the corrosion with a stiff wire brush. Wash with a solution of one tablespoon baking soda and one cup water. Rinse well with tap water and dry off with clean shop towels. Coat the terminals with dielectric grease or petroleum jelly. Be careful not to allow cleaning solution or tap water into the battery.

Conventional Battery

WARNING

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

Antidote:

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

beaten egg, or vegetable oil. Call physician immediately. Eyes: Flush with water for 15 minutes and get prompt medical attention. Batteries produce explosive gases. Keep sparks, flame, cigarettes, etc.

away. Ventilate when charging or using in an enclosed space. Always shield eyes when working near batteries. KEEP OUT OF REACH OF CHILDREN.

Page 98

MAINTENANCE

Battery

Battery Removal

1. Open the hood.

2. On conventional batteries, remove the battery vent tube.

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

4. Disconnect the red (positive) battery cable last.

5. Lift the battery out of the vehicle. Be careful not to tip a conventional battery sideways, which could spill electrolyte.

WARNING

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

NOTICE

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

Page 99

MAINTENANCE

Battery

Battery Installation

Using a new battery that has not been fully charged can damage the battery and result in a shorter life. It can also hinder vehicle performance. Follow the battery charging instructions on page 98 before installing the battery.

1. Ensure that the battery is fully charged.

2. Place the battery in the battery holder. Make sure the positive terminal is toward the driver’s side of the vehicle.

3. With conventional batteries, install the battery vent tube (sealed batteries do not have a vent tube).

NOTE: The vent tube must be free of obstructions and securely installed.

Route the tube away from the frame and vehicle body to prevent contact with electrolyte.

4. On conventional batteries, coat the terminals with dielectric grease or petroleum jelly.

5. Connect and tighten the red (positive) cable first.

6. Connect and tighten the black (negative) cable last.

7. Verify that cables are properly routed.

WARNING

Battery gases could accumulate in an improperly installed vent tube and cause an explosion, resulting in serious injury or death. Always ensure that the vent tube is free of obstructions and is securely installed as recommended.

Page 100

MAINTENANCE

Battery

Battery Storage

Whenever the vehicle is not used for a period of three months or more, remove the battery from the vehicle, ensure that it's fully charged, and store it out of the sun in a cool, dry place. Check battery voltage each month during storage and recharge as needed to maintain a full charge. See page 98.

NOTE: Battery charge can be maintained by using a Polaris Battery Tender

charger or by charging about once a month to make up for normal selfdischarge. Battery Tender can be left connected during the storage period, and will automatically charge the battery if the voltage drops below a pre-determined point. See page 108 for the part numbers of Polaris products.

Battery Fluid (Conventional Battery)

A poorly maintained battery will deteriorate rapidly. Check the battery fluid level often. Maintain the fluid level between the upper and lower level marks.

Add only distilled water. Tap water contains minerals that are harmful to a battery.

Lower

Mark

Upper

Mark