Polaris RANGER 500 Owner's Manual

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2019

OWNER’S MANUAL

RANGER® 500

RANGER® 570

RANGER® 570 EPS

RANGER CREW® 570

RANGER CREW® 570 EPS

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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

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

vehicle can expose you to chemicals including engine exhaust, carbon

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

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

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

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

or wash your hands frequently when servicing your vehicle.

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

For videos and more information

about a safe riding experience with

your Polaris vehicle, scan this QR

code with your smartphone.

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2019 Owner’s Manual

RANGER® 500 RANGER® 570

RANGER® 570 EPS

RANGER CREW® 570

RANGER CREW® 570 EPS

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

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

Printed in U.S.A.

2019 RANGER® Owner’s Manual 9928852

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WELCOME

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

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

• Snowmobiles

• All-terrain vehicles (ATVs)

• Low emission vehicles (LEVs)

• RANGER® utility vehicles

• BRUTUS® work vehicles

• SLINGSHOT® three wheel motorcycles

We believe POLARIS sets a standard of excellence for all utility and recreational vehicles manufactured in the world today. Many years of experience have gone into the engineering, design, and development of your POLARIS vehicle, making it the finest 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. Review the safety DVD that came with your vehicle. POLARIS also recommends that all drivers take the ROHVA safety e-course and a ROHVA hands-on safety training course. Visit www.rohva.org or call 866-267-2751.

• RZR® sport vehicles

• GEM® vehicles

• INDIAN® motorcycles

• POLARIS POWER® generators

• POLARIS DEFENSE® combat vehicles

• Timbersled® Snow Bikes

Your manual contains instructions for minor maintenance, but information about major repairs is outlined in the POLARIS Service Manual and can be performed by a factory certified Master Service Dealer® (MSD) Technician.

Your POLARIS dealer knows your vehicle best and is interested in your total satisfaction. Your POLARIS dealership can perform all of your service needs during, and after, the warranty period.

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WELCOME

Page 7

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

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

Features and Controls . . . . . . . . . . . . . . 31

Operation . . . . . . . . . . . . . . . . . . . . 49

Winch Guide. . . . . . . . . . . . . . . . . . . 71

Emission Control Systems . . . . . . . . . . . . . 81

Maintenance . . . . . . . . . . . . . . . . . . 83

Specifications . . . . . . . . . . . . . . . . . . 125

POLARIS Products . . . . . . . . . . . . . . . . 129

Troubleshooting . . . . . . . . . . . . . . . . . 131

Warranty . . . . . . . . . . . . . . . . . . . . 135

Maintenance Log . . . . . . . . . . . . . . . . 143

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INTRODUCTION

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

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

WARNING

WARNING indicates a hazardous situation that, if not avoided, may result in

death to the operator, bystanders or person(s) inspecting or servicing the

vehicle.

CAUTION

CAUTION indicates special precautions that must be taken to avoid vehicle

damage or property damage.

CAUTION

SAFETY ALERT CAUTION indicates a potential hazard that may result in

minor personal injury or damage to the vehicle.

IMPORTANT

IMPORTANT provides key reminders during disassembly, assembly, and

inspection of components.

NOTICE

NOTICE provides key information by clarifying instructions.

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

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

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INTRODUCTION

WARNING

Failure to heed the warnings and safety precautions contained in this manual

can result in severe injury or death. Your POLARIS vehicle is not a toy and can

be hazardous to operate. This vehicle handles differently than cars, trucks or

other off-road vehicles. A collision or rollover can occur quickly, even during

routine maneuvers like turning, or driving on hills or over obstacles, if you fail to

take proper precautions.

• Read this owner’s manual and review the safety DVD that came with your vehicle. A free extra copy of the DVD can be obtained by contacting your local POLARIS dealer. Understand all safety warnings, precautions and operating procedures before operating the vehicle. Keep this manual with the vehicle.

• Never operate this vehicle without proper instruction. Take an authorized training course. Visit www.rohva.org or call 866-267-2751.

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

• Always use the cab nets (or doors) while riding in this vehicle. Always keep hands, feet and all other body parts inside the vehicle at all times.

• Always wear a helmet, eye protection, gloves, long-sleeve shirt, long pants and over-the-ankle boots.

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

• Complete the New Operator Driving Procedures outlined in this manual. Never allow a guest to operate this vehicle until the guest has completed the New Operator Driving Procedures.

• Never permit a guest to operate this vehicle unless the guest has reviewed the owner’s manual and all safety labels and has completed a safety training

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INTRODUCTION

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 Identification Number

(VIN)

Vehicle Model Number:

Vehicle Identification Number (VIN):

Engine Serial Number:

Key Number

Engine Serial Number

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INTRODUCTION

EUROPEAN VIBRATION AND NOISE

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

The operating conditions of the machinery during testing:

The vehicles were in like-new condition. The environment was controlled as indicated by the test procedure(s).

The uncertainty of vibration exposure measurement is dependent on many factors, including:

• Instrument and calibration uncertainty

• Variations in the machine such as wear of components

• Variation of machine operators such as experience or physique

• Ability of the worker to reproduce typical work during measurements

• Environmental factors such as ambient noise or temperature

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SAFETY

SAFETY TRAINING

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

ROHVA (Recreational Off-Highway Vehicle Association) provides both an online safety e-course and a hands-on safety course. Visit www.rohva.org or call 866267-2751.

Your POLARIS vehicle is considered 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.

For more information about recreational off-road vehicle safety in the United States, visit www.rohva.org, call 866-267-2751 or call POLARIS at 800-342-3764.

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SAFETY

SAFE RIDING GEAR

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

RIDER COMFORT

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

Helmet

Eye Protection

Long Sleeves

Gloves

Long Pants

Over-the-Ankle Boots

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SAFETY

HELMET

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

Parents should verify that the young operator has a helmet that fits, and should obtain one of proper size if it does not fit before allowing operation.

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

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

EYE PROTECTION

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

GLOVES

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

BOOTS

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

CLOTHING

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

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SAFETY

SAFETY LABELS AND LOCATIONS

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

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

Seat Belt / Driver Warning

Shift Caution

Proper Use Warning

Max Payload Warning

MAXIMUM PAYLOAD WARNING

WARNING

RANGER NEVER EXCEED IF TOTAL PAYLOAD

EXCEEDS

MID-SIZE 30 mph (49 kph) 750 lbs. (340 kg)

MID-SIZE CREW 35 mph (56 kph) 1000 lbs. (453 kg)

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SAFETY

SHIFT CAUTION

CAUTION

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

SEAT BELT/DRIVE RESPONSIBLY WARNING

WARNING

Improper vehicle use can result in SEVERE INJURY or DEATH

Be Prepared

• Fasten seat belts.

• Wear an approved helmet and protective gear.

• ALWAYS use vehicle cab nets and/or doors if equipped.

• Each rider must be able to sit with back against seat, feet flat on the floor, and hands on steering wheel or handholds. Stay completely inside the vehicle.

Drive Responsibly Avoid loss of control and rollovers:

• Avoid abrupt maneuvers, sideways sliding, skidding, or fishtailing, and never do donuts.

• Slow down before entering a turn.

• Avoid hard acceleration when turning, even from a stop.

• Plan for hills, rough terrain, ruts, and other changes in traction and terrain. Avoid paved surfaces.

• Avoid side hilling (riding across slopes).

Be Sure Riders Pay Attention and Plan Ahead

If you think or feel the vehicle may tip or roll, reduce your risk to injury:

• Keep a firm grip on the steering wheel or handholds and brace yourself.

• Do not put any part of your body outside of the vehicle for any reason.

Rollovers have caused severe injuries and death, even on flat, open areas.

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SAFETY

PROPER USE WARNING

WARNING

Require Proper Use of Your Vehicle

Do your part to prevent injuries:

• Do not allow careless or reckless driving.

• Make sure operators are 16 or older with a valid driver’s license.

• Do not let people drive after using alcohol or drugs.

• Do not allow operation on public roads (unless designated for off-highway vehicle access) - collisions with cars and trucks can occur.

• Do not exceed seating capacity: 2 occupants.

Driving on public roads may be hazardous and could be a violation of the law.

PROPER USE WARNING (CREW)

WARNING

Require Proper Use of Your Vehicle

Do your part to prevent injuries:

• Do not allow careless or reckless driving.

• Make sure operators are 16 or older with a valid driver’s license.

• Do not let people drive after using alcohol or drugs.

• Do not allow operation on public roads (unless designated for off-highway vehicle access) - collisions with cars and trucks can occur.

• Do not exceed seating capacity: 6 occupants.

Driving on public roads may be hazardous and could be a violation of the law.

FUEL TRANSPORT WARNING

The Fuel Transport Warning located in the cargo box.

WARNING

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

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SAFETY

PASSENGER/TIRE PRESSURE WARNING

WARNING

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

• Never carry passengers in cargo box.

WARNING

IMPROPER TIRE PRESSURE OR OVERLOADING CAN CAUSE LOSS OF CONTROL RESULTING IN SERIOUS INJURY OR DEATH.

• Reduce speed and allow greater distance for braking when carrying cargo.

• Overloading or carrying tall, off-center, or unsecured loads will increase your risk of losing control. Loads should be centered and carried as low as possible in box.

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

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

RANGER® MIDSIZE MIDSIZE MIDSIZE CREW LI-ION EV / EV

MAXIMUM CARGO BOX LOAD

TIRE PRESSURE IN PSI (KPa)

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

Read Operation & Maintenance Manual for more detailed loading information.

500 lbs. (226 kg) 500 lbs. (226 kg) 500 lbs. (226 kg)

FRONT 10 (69) REAR 10 (69)

1000 lbs. (454 kg)

FRONT 10 (69) REAR 10 (69)

1250 lbs. (547 kg)

FRONT 20 (138) REAR 20 (138)

1000 lbs. (454 kg)

OPERATOR SAFETY

WARNING

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

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

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

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

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

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SAFETY

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

• Always use the cab nets (or doors) while riding in this vehicle.

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

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

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

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

• This vehicle is for off road use only. Never operate on public roads (unless marked for off-road use). Always avoid paved surfaces.

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

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

• Never attempt jumps or other stunts.

• Always inspect the vehicle before each use to make sure it's in safe operating condition.

• Always follow the inspection procedures described in this manual.

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

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

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

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

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

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

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

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

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SAFETY

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

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

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

• Always use the proper size and type of tires specified in this manual. Always maintain proper tire pressure as specified on safety labels. Failure to adhere to either may impact vehicle stability, driveline durability, or general vehicle handling.

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

• Always re-install plastics and heat shields after vehicle is serviced.

• Never exceed the stated load capacity for this vehicle. Cargo should be properly distributed and securely attached. Reduce speed and follow the instructions in this manual for hauling cargo or pulling a trailer. Allow a greater distance for braking.

• Always place the transmission in PARK before getting out of the vehicle. • Always engage the park brake (if equipped) when leaving the vehicle unattended.

• Always stop the engine before refueling. Make sure the refueling area is well ventilated and free of any source of flame or sparks.

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

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SAFETY

INTERNATIONAL VEHICLE SAFETY LABELS

GENERAL ALERT (7183794)

• Read the owner’s manual.

• Never allow anyone under 16 years of age to operate this vehicle.

• Never use alcohol or drugs before or while driving or riding.

• Do not allow operation on public roads (unless designated for offhighway vehicle access).

• Wear approved helmet, goggles, and protective clothing.

• Always wear seat belts.

• Always use the cab nets or doors.

• Never exceed seating capacity.

• Always follow proper operating procedures.

SHIFT ALERT (7183987)

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

APPLY BRAKE TO START. When this vehicle is not in operation, or unattended, place shift in the park position.

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SAFETY

PASSENGER / TIRE PRESSURE WARNING

WARNING

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

• Never carry passengers in cargo box.

• Read the Owner’s Manual.

• Never carry fuel on this vehicle.

WARNING

IMPROPER TIRE PRESSURE OR OVERLOADING CAN CAUSE LOSS OF CONTROL RESULTING IN SERIOUS INJURY OR DEATH.

• Reduce speed and allow greater distance for braking when carrying cargo.

• Overloading or carrying tall, off-center, or unsecured loads will increase your risk of losing control. Loads should be centered and carried as low as possible in box.

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

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

EV MID-SIZE MID-SIZE

CREW

MAXIMUM CARGO BOX LOAD

TIRE PRESSURE IN KPa (PSI)

MAXIMUM WEIGHT CAPACITY

INCLUDES WEIGHT OF OPERATOR, PASSENGER, CARGO AND ACCESSORIES

F - 138 (20)

R - 138 (20)

454 kg

(1000 lbs.)

226 kg

(500 lbs.)

F - 69 (10)

R - 69 (10)

F - 96 (14)

R - 96 (14)

547 kg

(1206 lbs.)

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SAFETY

CLUTCH COVER ALERT (7181427)

Keep body parts away from belt.

HITCH CAPACITY ALERT (7183975)

Read the owner’s manual. TRAILER MAXIMUM WEIGHT: 1700 N

ON LEVEL GROUND HITCH MAXIMUM VERTICAL WEIGHT:

1100 N

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SAFETY

SAFETY WARNINGS

WARNING

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

accident or rollover, which may result in serious injury or death. Heed all safety

warnings outlined in this section of the owner’s manual and in the safety DVD

provided with your vehicle. See the OPERATION section of the owner’s

manual for proper operating procedures.

OPERATING WITHOUT INSTRUCTION

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

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

All operators should review the safety DVD provided with this vehicle and take a ROHVA training course (www.rohva.org).

AGE RESTRICTIONS

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

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

USING ALCOHOL OR DRUGS

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

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

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SAFETY

FAILURE TO INSPECT BEFORE OPERATING

WARNING

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

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

inspection before each use of your vehicle to make sure it's in safe operating

condition. Always follow the inspection and maintenance procedures and

schedules described in this owner’s manual.

PROTECTIVE APPAREL

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

Always wear a helmet, eye protection, gloves, long-sleeve shirt, long pants and over-the-ankle boots.

SEAT BELTS

Riding in this vehicle without wearing the seat belt increases the risk of serious injury in the event of rollover, loss of control, other accident or sudden stop. Seat belts may reduce the severity of injury in these circumstances.

The operator MUST wear the seat belt at all times.

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SAFETY

CAB DOORS

Riding in this vehicle without closed and latched cab doors increases the risk of serious injury or death in the event of an accident or rollover. Always make sure all cab doors are closed and latched while riding in this vehicle. Cab doors are NOT intended to be used as arm rests. Always keep hands and feet inside the

vehicle at all times.

CARRYING A PASSENGER

This POLARIS vehicle is a single-rider vehicle. Carrying a passenger greatly reduces the operator's ability to control the vehicle, which may result in an accident or rollover. Carrying a passenger in the cargo box could result in a fall from the vehicle or contact with moving components. Never carry a passenger on this vehicle.

OPERATING WITH A LOAD ON THE VEHICLE

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

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

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

Always follow these guidelines:

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

Operator and/or cargo exceeds half the maximum weight capacity

Operating in rough terrain

Operating over obstacles

Climbing an incline

1. Slow down.

2. Verify tire pressure.

3. Use extra caution when operating.

Towing

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SAFETY

IMPROPER TIRE MAINTENANCE

Operating this vehicle with improper tires or with improper or uneven tire pressure could cause loss of control or accident. Always use the size and type of tires specified for your vehicle. Always maintain proper tire pressure as described in the owner's manual and on safety labels.

OPERATING ON PAVEMENT

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

OPERATING ON PUBLIC ROADS

Operating this vehicle on public streets, roads or highways could result in a collision with another vehicle. Never operate this vehicle on any public street, road or highway, including dirt and gravel roads (unless designated for offhighway use).

OPERATING AT EXCESSIVE SPEEDS

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

JUMPS AND STUNTS

Exhibition driving increases the risk of an accident or rollover. DO NOT do power slides, “donuts”, jumps or other driving stunts. Avoid exhibition driving.

TURNING IMPROPERLY

Turning improperly could cause loss of traction, loss of control, accident or rollover. Always follow proper procedures for turning as described in this owner’s manual.

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

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SAFETY

IMPROPER HILL CLIMBING

Improper hill climbing could cause loss of control or rollover. Use extreme caution when operating on hills. Always follow proper procedures for hill climbing as described in this owner's manual.

DESCENDING HILLS IMPROPERLY

Improperly descending a hill could cause loss of control or rollover. Always follow proper procedures for traveling down hills as described in this owner’s manual.

CROSSING HILLSIDES

Driving on a sidehill is not recommended. Improper procedure could cause loss of control or rollover. Avoid crossing the side of any hill unless absolutely necessary. If crossing a hillside is unavoidable, always follow proper procedures as described in this owner's manual.

STALLING WHILE CLIMBING A HILL

Stalling or rolling backwards while climbing a hill could cause a rollover. Maintain a steady speed when climbing a hill.

If you lose all forward speed:

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

If you begin rolling downhill:

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

OPERATING IN UNFAMILIAR TERRAIN

Failure to use extra caution when operating on unfamiliar terrain could result in an accident or rollover.

Unfamiliar terrain may contain hidden rocks, bumps, or holes that could cause loss of control or rollover.

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

OPERATING IMPROPERLY IN REVERSE

Improperly operating in reverse could result in a collision with an obstacle or person. Always follow proper operating procedures as outlined in this manual.

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

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SAFETY

SKIDDING OR SLIDING

Failure to use extra caution when operating on excessively rough, slippery or loose terrain could cause loss of traction, loss of control, accident or rollover. Do not operate on excessively slippery surfaces. Always slow down and use additional caution when operating on slippery surfaces.

Skidding or sliding due to loss of traction can cause loss of control or rollover (if tires regain traction unexpectedly). Always follow proper procedures for operating on slippery surfaces as described in this owner's manual.

OPERATING OVER OBSTACLES

Improperly operating over obstacles could cause loss of control or rollover. Before operating in a new area, check for obstacles. Avoid operating over large obstacles such as large rocks and fallen trees. Always follow the proper procedures outlined in this manual when operating over obstacles.

OPERATING THROUGH WATER

Operating through deep or fast-flowing water can cause loss of traction, loss of control, rollover or accident. Never operate in fast-flowing water or in water that exceeds the floor level of the vehicle.

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

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

OPERATING ON FROZEN BODIES OF WATER

Severe injury or death can result if the vehicle and/or the operator fall through the ice. Never operate the vehicle on a frozen body of water unless you have first verified that the ice is sufficiently thick to support the weight and moving force of the vehicle, you and your cargo, together with any other vehicles in your party.

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

Page 31

SAFETY

OPERATING A DAMAGED VEHICLE

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

POOR VISIBILITY

Operating this vehicle in darkness or inclement weather could result in a collision or accident, especially if operating on a road or street. This vehicle is not equipped with highway-approved lights. Operate this vehicle off-road only. Use caution and drive at reduced speeds in conditions of reduced visibility such as fog, rain and darkness. Clean headlights frequently and replace burned out headlamps promptly.

HOT EXHAUST SYSTEMS

WARNING

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

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

components. Always keep combustible materials away from the exhaust

system.

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

inspect the underside of the vehicle and areas near the exhaust system after

driving through tall grass, weeds, brush, and other tall ground cover. Promptly

remove any grass or debris clinging to the vehicle.

EXPOSURE TO EXHAUST

Engine exhaust fumes are poisonous and can cause loss of consciousness or death in a short time. Never start the engine or let it run in an enclosed area. Operate this vehicle only outdoors or in well-ventilated areas.

REFUELING

Gasoline is highly flammable and explosive under certain conditions.

• Always exercise extreme caution whenever handling gasoline.

• Always turn off the engine when refueling.

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

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

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

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

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

Page 32

SAFETY

IMPROPER CARGO LOADING

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

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

• Never exceed the stated load capacity for this vehicle.

• Cargo should be properly distributed and securely attached.

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

UNAUTHORIZED USE OF THE VEHICLE

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

EQUIPMENT MODIFICATIONS

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

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

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

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

FOR MORE INFORMATION ABOUT SAFETY

call POLARIS at 1-800-342-3764.

Page 33

FEATURES AND CONTROLS

COMPONENT LOCATIONS

ROPS Frame

Hip Bars

Front Bumper/Brush Guard

Headlights

Radiator

Tailgate

Cargo Box

Fuel Cap

Muffler

Cargo Box Release Lever

Storage Compartment (if Equipped)

Electric Compartment (if equipped)

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FEATURES AND CONTROLS

CONSOLE

Cup Holder

Instrument Cluster

MODE Button

Gear Selector (Shifter)

AWD Switch

Steering Wheel Adjustment Lever

12V Auxiliary Outlet

Ignition/Light Switch

Storage Compartment

AUXILIARY OUTLET

The vehicle is equipped with a 12-volt accessory outlet on the dash. Use the outlet to power an auxiliary light or other optional accessories or lights. For service, the dash outlet connection is under the dash.

Storage Tray

Page 35

FEATURES AND CONTROLS

SWITCHES

IGNITION SWITCH/LIGHT SWITCH

The ignition switch is a four-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.

Lights On Lights are on. Electrical circuits are on. Electrical equipment can

be used.

Lights Off Lights are off. Electrical circuits are on. Electrical equipment can

be used.

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

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

AWD/DIFFERENTIAL LOCK SWITCH

The AWD/Differential Lock Switch has three positions:

• All Wheel Drive (AWD)

• Differential Lock/Two Wheel Drive (2WD)

• Differential Unlock (1WD/Turf Mode)

AWD/ADC DRIVE MODE SWITCH

The AWD/ADC Drive Mode switch controls AWD through drive mode options which display in the information center of the gauge. Drive mode options include:

• All Wheel Drive (AWD/4X4)

• ADC All Wheel Drive (ADC 4X4)

• TURF Mode (1WD)

• Two Wheel Drive (2WD/2X4)

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FEATURES AND CONTROLS

STANDARD TURF SWITCH (IF EQUIPPED)

The standard Turf switch has two positions:

• Differential Unlock (1WD/Turf Mode)

• Differential Lock/Two Wheel Drive (2WD)

GEAR SELECTOR

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

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

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FEATURES AND CONTROLS

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

TIP

Maintaining shift linkage adjustment is important to assure proper transmission

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

NOTICE

Do not attempt to shift the transmission while the vehicle is moving or damage

to the transmission could result. Always shift when the vehicle is stationary and

the engine is at idle.

USING LOW GEAR

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

• Operating in rough terrain or over obstacles

• Loading the vehicle onto a trailer

• Towing heavy loads

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FEATURES AND CONTROLS

STEERING WHEEL

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

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

Always make sure the steering wheel position does not impede proper operation of the brake pedal, throttle pedal and all other controls.

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FEATURES AND CONTROLS

ELECTRONIC POWER STEERING (EPS)

Electronic power steering (if equipped) engages when the ignition key is turned to the ON position. EPS remains engaged whether the vehicle is moving or idle. To conserve battery power, the EPS will shut down 5 minutes after the engine is stopped if the key remains in the ON position. The EPS warning indicator will illuminate to indicate the EPS has shut down. Turn the key off and on to reset the unit. If the light remains on after starting the engine, the EPS system is inoperative. Your POLARIS dealer can assist.

FOOT PEDALS

BRAKE PEDAL

Depress the brake pedal starting the engine.

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

1. Turn the ignition switch to the ON position.

2. Apply the brakes. The brake light should come on after about 10 mm (0.4 in.) of pedal travel.

to slow or stop the vehicle. Apply the brakes while

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FEATURES AND CONTROLS

THROTTLE PEDAL

Push the throttle pedalwdown 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.

This vehicle is equipped with a throttle release switch, which is designed to reduce the risk of a frozen or stuck throttle. If the throttle cable should stick in an open position when the operator releases the throttle pedal, engine speed will be limited, and power to the rear wheels will be reduced.

PARK BRAKE LEVER (IF EQUIPPED)

Always apply the service brakes before engaging or releasing the park brake. To help prevent the vehicle from rolling, set the park brake when parking the vehicle. When the park brake is set and the park brake indicator is illuminated, engine speed is limited. If the accelerator is applied, this limiting feature prevents operation, which protects the park brake pads from excessive wear.

TIP

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

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

moved. Check for disconnection, then see your dealer or other qualified

service person promptly if this feature fails to operate properly.

1. To set the park brake, apply the brakes.

2. Pull the park brake lever upward as far as possible.

3. To release the park brake, apply the brakes. Press the park brake release inward and move the lever downward as far as possible.

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FEATURES AND CONTROLS

SEAT

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.

SEAT BELTS

This vehicle is equipped with three-point lap and diagonal seat belts for the operator and passenger. Always make sure the seat belts are secured for all riders before operating. The driver’s seat belt is equipped with a seat belt interlock. Vehicle speed will be limited to 15 MPH (24 km/h) if the seat belt is not secured.

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

WARNING

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

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

To wear the seat belt properly, follow this procedure:

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

downward and across your chest

Page 42

FEATURES AND CONTROLS

2. Push the latch plateqinto the bucklewuntil it clicks.

3. Release the strap, it will self tighten.

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

SEAT BELT INSPECTION

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

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

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

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

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

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

CAB NETS (IF EQUIPPED)

Riding in this vehicle without using the cab nets (or doors, if equipped) increases the risk of serious injury or death in the event of an accident or rollover. Cab nets (or doors) must be used by both operator and passengers at all times. Make sure all latches are secure before operating the vehicle.

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

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FEATURES AND CONTROLS

SECURING THE NET

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

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

OPENING THE NET

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

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

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

ROLLOVER PROTECTIVE STRUCTURE (ROPS)

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

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

WARNING

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

a manner that could result in vehicle rollover.

STORAGE COMPARTMENTS

A storage compartment is located under the driver’s seat on CREW models.

TRAILER RECEIVER 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.

Page 44

FEATURES AND CONTROLS

EXTREME USE 30 AH BATTERY (NON-EPS MODELS ONLY)

If your factory-installed battery cannot maintain a charge because of operation in extreme cold or with multiple electrical accessories, you may need to purchase a 30 AH battery and a battery strap bracket. Your POLARIS dealer can assist. Your dealer can provide any installation procedures that may differ for an extreme use battery. See page 92 for the part numbers of POLARIS products.

1. Fully charge the new battery before installing it.

2. To install the 30 AH battery, remove the existing battery.

3. Remove the plastic spacer at the bottom of the battery compartment. Save the spacer for future use.

4. Install the new battery.

Page 45

INSTRUMENT CLUSTER

FEATURES AND CONTROLS

Speedometer

Indicator Lamps

Mode Button

Rider Information Center

Page 46

FEATURES AND CONTROLS

INDICATOR LAMPS

LAMP INDICATES CONDITION

Vehicle Speed When standard mode is selected, speed displays in

miles per hour.

When metric mode is selected, speed displays in kilometers per hour.

Over Temperature

Electric Power Steering (EPS) Warning (if equipped)

Neutral This lamp illuminates when the transmission is in

High Beam This lamp illuminates when the headlamp switch is set

Helmet/Seat Belt

This lamp illuminates to indicate an overheated engine. If the indicator flashes, the overheating condition remains, and the system will automatically reduce engine power.

This indicator illuminates briefly when the key is turned to the ON position. If the light remains on, the EPS system is inoperative. Your dealer can assist.

neutral and the ignition key is in the ON position.

to high beam.

This lamp is a reminder to the operator to ensure all riders are wearing helmets and seat belts before operating. The driver’s seat belt is equipped with a seat belt interlock. Vehicle speed will be limited to 15 MPH (24 km/h) if the seat belt is not secured.

Check Engine This indicator appears if an Electronic Fuel Injection

(EFI) related fault occurs. Do not operate the vehicle if this warning appears. Serious engine damage could result. Your dealer can assist.

Page 47

FEATURES AND CONTROLS

RIDER INFORMATION CENTER

The rider information center is located in the instrument cluster. All segments will light up for one second at start-up. If the instrument cluster fails to illuminate, a battery over-voltage may have occurred and the instrument cluster may have shut off to protect the electronic speedometer. If this occurs, your dealer can provide proper diagnosis.

The information center is set to display standard units of measurement and a 12hour clock at the factory.

Gear Indicator This indicator displays gear shifter position.

Fuel Gauge The segments of the fuel gauge show the level of fuel in the

fuel tank. When the last segment clears, a low fuel warning is activated. All segments including the fuel icon will flash. Refuel immediately.

Information Display Area

Under/Over Voltage

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

Service Indicator

4x4 Indicator This indicator illuminates when the 4X4 system is engaged

This area displays odometer, trip meter, engine hour meter and programmable service hour interval.

This warning usually indicates that the vehicle is operating at an RPM too low to keep the battery charged. It may also occur when the engine is at idle and high electrical load (lights, cooling fan, accessories) is applied. Drive at a higher RPM or recharge the battery to clear the warning.

A flashing wrench symbol alerts the operator that the preset service interval has been reached. Your dealer can provide scheduled maintenance.

(switch is on 4X4, AWD or ADC 4X4).

Turf Mode Indicator (if equipped)

This indicator illuminates when the operator unlocks the differential.

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FEATURES AND CONTROLS

MODE BUTTON

The yellow button located near the instrument cluster is used to toggle through mode options available.

DISPLAY UNITS

The display can be changed to display either standard or metric units of measurement.

TIP

To exit the set-up mode at any time, wait 10 seconds. The display

automatically exits and returns to the odometer display.

MEASUREMENT STANDARD METRIC

Distance Miles Kilometers

Fuel U.S. Gallons Liters, Imperial Gallons

Temperature Fahrenheit Celsius

Time 12–Hour Clock 24–Hour Clock

To change the display units, do the following:

1. Turn the key to the OFF position.

2. Press and hold the MODE button while turning the key to the ON position.

3. When the display flashes the distance setting, tap the MODE button to advance to the desired setting.

4. Press and hold the MODE button to save the setting and advance to the next display option.

5. Repeat the procedure to change remaining display settings.

CLOCK MODE

TIP

The clock must be reset any time the battery has been disconnected or

discharged.

To set the clock time, do the following:

1. Turn the key to the ON position. Use the MODE button to toggle to the

odometer display.

2. Press and hold the MODE button until the hour segment flashes. Release

the button.

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FEATURES AND CONTROLS

3. With the segment flashing, tap the MODE button to advance to the desired setting.

4. Press and hold the MODE button until the next segment flashes. Release the button.

5. Repeat steps 3-4 twice to set the 10-minute and 1-minute segments. After completing the 1-minute segment, step 4 will save the new settings and exit the clock mode.

6. Turn the key to the OFF position.

ODOMETER MODE

The odometer records and displays the distance traveled by the vehicle.

TRIP METER MODE

The trip meter records the distance traveled by the vehicle if reset before each trip. To reset, select the trip meter mode. Press and hold the MODE button until the meter resets to zero. In the Rider Information Center, the trip meter display contains a decimal point, but the odometer displays without a decimal point.

HOUR METER MODE

This mode logs the total hours the engine has been in operation.

TACHOMETER MODE

The engine RPM is displayed digitally.

TIP

Small fluctuations in the RPM from day to day may be normal because of

changes in humidity, temperature and elevation.

PROGRAMMABLE SERVICE INTERVAL

When the hours of engine operation equal the programmed service interval setting, the wrench icon will flash for 5 seconds each time the engine is started. When this feature is enabled, it provides a convenient reminder to perform routine maintenance. The service interval is programmed at 50 hours at the factory.

To change the service interval, do the following:

1. Press the MODE button until remaining service hours display.

2. Press and hold the MODE button.

3. When the service hours flash, press and release the MODE button to advance the hours to the desired setting (including OFF). Press and hold the MODE button to set the new service hour interval.

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FEATURES AND CONTROLS

DIAGNOSTIC DISPLAY MODE

The EFI diagnostic display mode is for informational purposes only. Your POLARIS dealer can provide for all major repairs.

The diagnostic mode is accessible only when the check engine warning indicator activates after the key has been turned on. Leave the key on if you want to view the active code (failure code).

The diagnostic mode becomes inaccessible if the key is turned off and on and the warning indicator is no longer active. This allows the determination of persistent as well as intermittent faults.

Inactive codes are stored in the history of the unit.

ENGINE ERROR CODES

The error screen displays only when the CHECK ENGINE light is on or when it goes on and off during one ignition cycle. Error codes are not stored. When the key is turned OFF, the code and message is lost, but will reappear if the fault reoccurs after restarting the engine.

If the CHECK ENGINE light illuminates, retrieve the error codes from the display.

1. If the error codes are not displayed, use the MODE button to toggle until “Ck ENG” displays on the main line of the display.

2. Press and hold the MODE button to enter the diagnostics code menu.

3. Record the three numbers displayed in the gear position, clock and odometer displays.

4. Press the MODE button to advance to the next error code.

5. Press and hold the MODE button to exit the diagnostics code menu.

6. Your authorized POLARIS dealer can provide code details and diagnosis.

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OPERATION

WARNING

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

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

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

manual.

VEHICLE BREAK-IN PERIOD

The break-in period for your new vehicle is the first 20 hours of operation, or the time it takes to use the first 2 tanks full of gasoline. No single action on your part is as important as a proper break-in period. Careful treatment of a new engine will result in more efficient performance and longer life for the engine. Perform the following procedures carefully.

NOTICE

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

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

speeds during the first 3 hours of use.

ENGINE AND DRIVETRAIN BREAK-IN

1. Fill the fuel tank with gasoline. Always exercise extreme caution whenever handling gasoline.

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

3. Complete the New Operator Driving Procedures.

4. Avoid aggressive use of the brakes.

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

6. Pull only light loads.

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

8. During the break-in period, change both the oil and the filter at 25 hours or one month.

9. Check fluid levels of transmission and all gearcases after the first 25 hours of operation and every 100 hours thereafter.

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OPERATION

BRAKE SYSTEM BREAK-IN

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

PVT BREAK-IN (CLUTCHES/BELT)

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

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

PRE-RIDE INSPECTION

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

ITEM REMARKS PAGE

Brake system/pedal travel Ensure proper operation page 37

page 105

Brake fluid Ensure proper level page 105

Front suspension Inspect, lubricate if necessary page 87

Rear suspension Inspect, lubricate if necessary page 87

Steering Ensure free operation -

Tires Inspect condition and pressure page 109

Wheels/fasteners Inspect, ensure fastener tightness page 109

Frame nuts, bolts, fasteners Inspect, ensure tightness -

Fuel and oil Ensure proper levels page 87

Coolant level Ensure proper level page 96

Coolant hoses Inspect for leaks -

Throttle Ensure proper operation page 38

Indicator lights/switches Ensure proper operation page 33

page 44

Intake pre-filters Inspect, clean -

Headlamps Check operation, apply POLARIS dielectric

grease when lamp is replaced

page 112

Page 53

OPERATION

ITEM REMARKS PAGE

Brake light/tail lamps Check operation -

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

is secure

Seat Belt Check length of belt for damage, check latches

for proper operation

Cab Doors (If equipped) Check doors and latches for wear or damage. -

Grass & Leaves Remove grass, leaves, and other flammable

material or debris, especially near the HOT exhaust system.

page 39

SAFE OPERATION PRACTICES

1. Visit the Recreational Off-Highway Vehicle Association web site and take the free on-line training course. Complete the recommended safety training before operating this vehicle. Visit www.rohva.org or call 866-267-2751.

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

3. Never carry a passenger on this vehicle.

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

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

6. Operate this vehicle off-road only. Never operate this vehicle on any public street, road or highway, including dirt and gravel roads (unless designated for off-highway use).

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

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

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

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

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

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OPERATION

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

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

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

KNOW YOUR RIDING AREA/TREAD LIGHTLY

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

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

TRAIL ETIQUETTE

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

COLD WEATHER OPERATION

If the vehicle is used year-round, check the oil level frequently. A rising oil level could indicate the accumulation of contaminates such as water or excess fuel in the bottom of the crankcase. Water in the bottom of the crankcase can lead to engine damage and must be drained. Water accumulation increases as outside temperature decreases.

STARTING THE ENGINE

1. Position the vehicle on a level surface outdoors or in a well ventilated area.

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

3. Place the transmission in PARK.

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

5. Turn the ignition key past the ON/RUN position to START. Engage the starter for a maximum of five seconds. Release the key when the engine starts.

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OPERATION

6. If the engine does not start within five seconds, return the ignition switch to the OFF position 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.

NOTICE

Operating the vehicle immediately after starting could cause engine damage.

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

STOPPING THE ENGINE

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

2. Place the transmission in PARK.

3. Turn the engine off.

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

WARNING

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

PARK when stopping the engine.

BRAKING

1. Release the throttle pedal completely. (When the throttle pedal is released completely and engine speed slows to near idle, the vehicle has no engine braking.)

2. Press on the brake pedal evenly and firmly. Practice starting and stopping (using the brakes) until you're familiar with the controls.

PARKING THE VEHICLE

1. Stop the vehicle on a level surface. 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.

2. Place the transmission in PARK.

3. Turn the engine off.

4. Engage the parking brake (if equipped).

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OPERATION

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

6. Remove the ignition key to prevent unauthorized use.

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OPERATION

DRIVING PROCEDURES

NEW OPERATOR DRIVING PROCEDURES

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

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

3. Perform the pre-ride inspection.

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

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

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

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

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

9. Place the transmission in PARK.

10.Start the engine.

11. Apply the brakes and shift into low gear.

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

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

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

WARNING

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

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

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

the ground again.

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

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

• Avoid sharp turns.

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OPERATION

• Never turn while applying heavy throttle.

• Never make abrupt steering maneuvers.

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

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

DRIVING WITH A PASSENGER

1. Perform the pre-ride inspection.

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

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

4. Make sure all passengers secure their seat belt.

5. Make sure all cab nets (or doors) are properly secured.

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

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

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

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

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

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OPERATION

DRIVING ON SLIPPERY SURFACES

WARNING

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

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

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

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

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

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

2. Slow down before entering slippery areas.

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

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

NOTICE

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

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

AWD.

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

apply the brakes during a skid.

DRIVING OVER OBSTACLES

Follow these precautions when operating over obstacles:

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

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

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

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

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OPERATION

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

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

DRIVING UPHILL

Whenever traveling uphill, follow these precautions:

1. Avoid excessively steep hills.

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

3. Always travel straight uphill.

4. Keep both feet on the floor.

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

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

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

DRIVING DOWNHILL

When driving downhill, follow these precautions:

1. Avoid excessively steep hills.

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

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

4. Slow down.

5. Apply the brakes slightly to aid in slowing.

DRIVING ON A SIDEHILL (SIDEHILLING)

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

If crossing a sidehill is unavoidable, follow these precautions:

1. Slow down.

2. Exercise extreme caution.

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OPERATION

3. Avoid crossing the side of a steep hill.

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

DRIVING THROUGH WATER

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

NOTE

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

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

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

engine, perform the service outlined on page 104, and take the vehicle in for

service at the first opportunity.

Follow these procedures when operating through water:

1. Determine water depths and current before entering water.

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

3. Proceed slowly, avoiding rocks and obstacles.

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

WARNING

The large tires on your vehicle may cause the vehicle to float in deep or fast-

flowing water, which could result in loss of control and lead to serious injury or

death. Never cross deep or fast-flowing water with your vehicle

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

NOTE

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

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

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

DRIVING IN REVERSE

Follow these precautions when operating in reverse:

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

2. Always avoid backing downhill.

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OPERATION

3. Back slowly.

4. Apply the brakes lightly for stopping.

5. Avoid turning at sharp angles.

6. Never open the throttle suddenly.

PARKING THE VEHICLE

To park the vehicle, do the following:

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

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

3. Place the transmission in PARK.

4. Turn the engine off.

5. Engage the park brake (if equipped).

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

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

PARKING ON AN INCLINE

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

1. Apply the brakes.

2. Place the transmission in PARK.

3. Engage the parking brake (if equipped).

4. Turn the engine off.

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

6. Block the rear wheels on the downhill side.

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OPERATION

HAULING CARGO

WARNING

Overloading the vehicle or carrying or towing cargo improperly can alter

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

follow these precautions when hauling cargo:

Never exceed the stated load capacity for this vehicle.

REDUCE SPEED AND ALLOW GREATER DISTANCES FOR BRAKING

WHEN HAULING CARGO.

NEVER EXCEED THE MAXIMUM WEIGHT CAPACITY of the vehicle. When

determining the weight you are adding to the vehicle, include the weight of the

operator, accessories, loads in the rack or box and the load on the trailer

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

weight capacity.

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

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

stable driving conditions.

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

Slow down and drive in the lowest gear available.

SECURE ALL LOADS BEFORE OPERATING. Unsecured loads can create

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

vehicle.

OPERATE ONLY WITH STABLE AND SAFELY ARRANGED LOADS. When

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

and operate with extra caution. Always attach the tow load to the hitch point

designated for your vehicle.

HEAVY LOADS CAN CAUSE BRAKING AND CONTROL PROBLEMS. Use

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

situations that may require backing downhill.

USE EXTREME CAUTION when operating with loads that extend over the

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

vehicle rollover.

DO NOT TRAVEL FASTER THAN THE RECOMMENDED SPEEDS. Vehicle

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

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

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

Never exceed 43 MPH (70 km/h) if total payload exceeds 335 lbs. (152 kg).

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

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

box.

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

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OPERATION

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

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

MAXIMUM CARGO CAPACITY

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.

MODEL MAXIMUM

CAPACITIES (LEVEL

GROUND)

RANGER® 500 1000 lbs. (454 kg) 500 lbs. (227 kg)

CARGO BOX

BELT LIFE

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

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OPERATION

TOWING LOADS

WARNING

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

brake instability.

Always follow these precautions when towing:

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

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

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

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

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

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

TOTAL TOWED

LOAD WEIGHT

(LEVEL

GROUND)

1500 lbs.

(681 kg)

TOTAL TOWED LOAD WEIGHT

(15° GRADE)

850 lbs.

(386 kg)

TOTAL HITCH

VERTICAL

WEIGHT

150 lbs.

(68.1 kg)

MAXIMUM

TOWING

SPEED

10 MPH

(16 km/h)

DUMPING THE CARGO BOX

To dump the cargo box, do the following:

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

2. Apply the brakes.

3. Set the park brake (if equipped).

4. Turn the key to the off position.

5. Dismount vehicle.

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

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OPERATION

7. Release the tailgate latches.

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.

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

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

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

11. Close the tailgate.

WARNING

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

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

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

creating hazardous driving conditions. Never operate this vehicle with the

cargo box in the raised position.

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ALL WHEEL DRIVE (AWD) SYSTEM

The standard All Wheel Drive system is controlled by the AWD switch. When the switch is in the 2X4 position in two-wheel drive at all times. When the switch is in the AWD position is in all wheel drive and the 4X4 indicator in the instrument cluster will be on.

When in AWD, the demand drive unit will automatically engage any time the rear wheels lose traction. When the rear wheels regain traction, the demand drive unit will automatically disengage. There is no limit to the length of time the vehicle may remain in AWD.

, the vehicle is

, the vehicle

All-Wheel Drive (AWD)

Two-Wheel Drive (2WD)

OPERATION

ENGAGING/DISENGAGING AWD

The AWD switch may be turned on or off while the vehicle is moving.

• Press the top of the rocker switch to engage AWD.

• Press the bottom of the switch to operate in two wheel drive.

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 demand drive unit is moving, it will not disengage until the rear wheels regain traction.

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

NOTICE

Switching to AWD while the rear wheels are spinning or slipping may cause

severe drive shaft and gearcase damage. Always switch to AWD while the rear

wheels have traction or are at rest.

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OPERATION

ALL WHEEL DRIVE/REAR DIFFERENTIAL SYSTEM

If your model is equipped with a lockable differential, you can choose to operate with an open differential or a closed differential.

ENGAGING AWD

Press the top of the switch to engage All Wheel Drive (AWD). The 4X4 indicator illuminates in the rider information center to indicate that the vehicle is in AWD.

When the AWD switch is on, the front gearcase will automatically engage any time the rear wheels lose traction. When the rear wheels regain traction, the front gearcase will automatically disengage. There is no limit to the length of time the vehicle may remain in AWD.

Initially, the vehicle's electronic system will not enable the AWD until the engine RPM is below 3100. Once enabled, the AWD remains enabled until the AWD switch is turned off. If the switch is turned off while the front gearcase is moving, it will not disengage until the rear wheels regain traction.

All-Wheel Drive (AWD)

Differential Lock

Differential Unlock

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.

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.

DISENGAGING AWD

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

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

To disengage AWD, do the following:

1. Stop the vehicle.

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OPERATION

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

3. Stop completely.

4. Shift into low gear and drive forward.

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

LOCKING THE DIFFERENTIAL

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

UNLOCKING THE DIFFERENTIAL (TURF MODE)

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

WARNING

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

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

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

the ground again.

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

NOTICE

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

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

to nearly stopped before engaging the differential.

WARNING

Never operate in TURF mode (if equipped) while operating on a hill or other irregular terrain. Always move the AWD switch to AWD before ascending or

descending a hill.

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OPERATION

ALL WHEEL DRIVE/ACTIVE DESCENT CONTROL SYSTEM

ADC models are equipped with a drive mode switch that controls the AWD system. The AWD/ADC Drive Mode switch controls AWD through drive mode options which display in the information center of the gauge.

DRIVE MODE OPERATION

Use the drive mode switch to engage AWD (4X4), ADC 4X4, TURF mode or 2X4. The vehicle automatically engages 4X4 when operating in reverse if the drive mode is set to either AWD (4X4) or ADC 4X4.

• Always operate in low gear and engage ADC 4X4 when transporting heavy loads and/or when towing.

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

WARNING

Operate in TURF mode only as needed to protect smooth, level surfaces from

tire damage. DO NOT operate in TURF mode when climbing or descending

hills, when sidehilling, or when operating on uneven, loose, or slippery terrain

such as sand, gravel, ice, snow, obstacles, and water crossings.

DRIVE MODE SWITCH

Press and release the top of the switch

to toggle through the drive mode

options, which display in the information center of the gauge for several seconds.

Press and release the bottom of the switch option.

to toggle to a previous

When the switch is released, the drive mode displayed in the information center is the active drive mode.

NOTICE

Switching to 4X4 or ADC 4X4 while the rear wheels are spinning may cause

severe drive shaft and gearcase damage. Always switch to 4X4 or ADC 4X4

while the rear wheels have traction or are at rest.

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OPERATION

DRIVE MODE INDICATOR

The Drive Mode Indicator displays the active drive mode. The Drive Mode Indicator will match the information displayed in the Rider Information Center. An amber light flashes when drive mode selection is pending. Once in the selected drive mode, a solid amber light will show next to the active drive mode.

ACTIVE DESCENT CONTROL (ADC) SYSTEM (IF EQUIPPED)

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

• Always operate in low gear and engage ADC 4X4 when transporting heavy loads and/or when towing.

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

ENGAGING ACTIVE DESCENT CONTROL

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

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

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

DISENGAGING ACTIVE DESCENT CONTROL

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

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

• The transmission is shifted to neutral or park.

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Page 73

WINCH GUIDE

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

WARNING

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

all winch instructions and warnings in this manual.

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

WINCH SAFETY PRECAUTIONS

1. Read all sections of this manual.

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

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

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

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

6. Never attempt to “jerk” a load attached to the winch with a moving vehicle. See the Shock Loading section on page 78.

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

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

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

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

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

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

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

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

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WINCH GUIDE

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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WINCH GUIDE

WINCH OPERATION

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

TIP

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

need to use it in the field.

WARNING

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

all winch instructions and warnings in this manual.

Each winching situation is unique.

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

• Proceed slowly and deliberately.

• Never hurry or rush during winching.

• Always pay attention to your surroundings.

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

• Always remember that your winch is very powerful.

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

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

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

Promptly replace any worn or damaged cable.

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

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

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WINCH GUIDE

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

WARNING

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

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

TIP

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

stretch.

WARNING

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

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

or DEATH. See the Shock Loading section on page 78.

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

WARNING

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

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

POLARIS winch parts (including the cable) with genuine POLARIS

replacement parts available at your authorized POLARIS dealer.

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

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WINCH GUIDE

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

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

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

5. Never remove the hook strap from the hook.

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

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

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

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

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

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

spooled out.

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

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

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

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

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

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WINCH GUIDE

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

11. The ONLY time a winch-equipped vehicle should be moving when using the winch is when that vehicle itself is stuck. The winch equipped vehicle should NEVER be in motion to “shock” load the winch cable in an attempt to move a second stuck vehicle. See the Shock Loading section on page 78. For your safety, always follow these guidelines when winching a vehicle free:

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

cable.

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

centerline.

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

frame following instructions in this manual.

d. Re-engage the clutch on the winch.

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

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

of winching.

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

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

vehicle.

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

the help of the winch.

j. Detach the winch cable hook.

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

instructions in this manual.

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

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

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

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

a. Release the clutch on the winch.

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WINCH GUIDE

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

c. Re-engage the winch clutch.

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

of tension using the hook strap.

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

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

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

between lower layers of winch cable.

WINCH CABLE CARE

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

WARNING

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

INJURY.

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

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

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

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

A winch cable made of synthetic rope should be inspected for signs of fraying. Replace the cable if fraying is observed (shown at right). Promptly discontinue use of a winch cable in this condition.

Also replace the winch cable if there are fused or melted fibers. Such an area of the synthetic rope will be stiff and appear smooth or glazed. Promptly discontinue use of a winch cable in this condition.

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WINCH GUIDE

SHOCK LOADING

WARNING

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

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

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

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

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

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

WARNING

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

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

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

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

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

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

Page 81

WINCH GUIDE

WINCH MAINTENANCE AND SERVICE SAFETY

WARNING

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

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

manual.

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

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

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

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

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

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

WARNING

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

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

Page 82

Page 83

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 vehicle has a spark arrester that was tested and qualified to be in accordance with the USFS standard 5100-1C. Federal law requires that this spark arrester 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 420. 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 inside of the lower left frame tube (below driver’s foot area).

ELECTROMAGNETIC INTERFERENCE

This spark ignition system complies with Canadian ICES-002.

This vehicle complies with the EMC requirements of European directives 97/24/ EC and 2004/108/EC.

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

Page 84

Page 85

MAINTENANCE

PERIODIC MAINTENANCE CHART

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

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

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

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

Inspect, clean, lubricate, adjust and replace parts as necessary. When inspection reveals the need for replacement parts, genuine POLARIS parts are available from your POLARIS dealer. Equivalent parts may be used for emissions-related service.

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

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

SEVERE USE DEFINITION

• Frequent immersion in mud, water or sand

• Frequent or prolonged operation in dusty environments

• Short trip cold weather operation

• Racing or race-style high RPM use

• Prolonged low speed, heavy load operation

• Extended idle

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

Page 86

MAINTENANCE

MAINTENANCE CHART KEY

SYMBOL DESCRIPTION

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

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

E Emission Control System Service (California)

WARNING

Improperly performing the procedures marked with a D could result in

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

dealer or other qualified person perform these services.

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

XU E

MAINTENANCE INTERVAL

(WHICHEVER COMES FIRST)

ITEM

HRS CLNDR

Steering - Pre-Ride -

Front-suspension - Pre-Ride -

Rear-suspension - Pre-Ride -

Tires - Pre-Ride -

Brake fluid level - Pre-Ride -

Brake pedal travel - Pre-Ride -

Brake systems - Pre-Ride -

Wheels /fasteners - Pre-Ride -

Frame fasteners - Pre-Ride -

Engine Oil Level - Pre-Ride -

Air filter, pre-filter

Daily

MILES

(KM)

REMARKS

Make adjustments as needed.

Inspect; clean often; replace as needed

XU E

XU D

Coolant -

Head lamp / tail lamp / worklight

Air filter -

Brake pad wear

10 H

Daily

Weekly

Monthly

- Check level

Check operation; apply

dielectric grease to electrical connections if replacing lamps

Inspect; replace as needed

Inspect periodically

Page 87

ITEM

MAINTENANCE INTERVAL

(WHICHEVER COMES FIRST)

HRS CLNDR

MILES

(KM)

MAINTENANCE

REMARKS

Battery

Fuel System

XU Front Gearcase oil 25 H

XU Transmission fluid 25 H

XU General lubrication 50 H 3 M -

Engine oil change (break-in)

Shift Linkage

Steering

Front Suspension

Rear Suspension

20 H

25 H

50 H 6 M -

50 H 6 M - Lubricate

Monthly

Check terminals; clean; test

Inspect; Cycle the Key to pressurize the fuel pump; check lines and fittings for leaks and abrasion.

Perform a break-in oil level check

Perform a break-in oil change at one month

Lubricate all grease fittings, pivots, cables, etc.

Inspect, lubricate, adjust

D E

XU Front Gearcase oil 100 H 6 M -

XU Transmission fluid 100 H 6 M

D E

Throttle Pedal 50 H 6 M

Air intake ducts/ flange

Drive belt 50 H 6 M

Cooling system

Engine oil and filter change

Oil lines and fasteners

Fuel System

50 H 6 M

50 H 6 M -

100 H 6 M

100 H 6 M -

100 H 12 M

500 (800)

1000

(1600)

1000

(1600)

1000

(1600)

Inspect; adjust; lubricate; replace if necessary

Inspect ducts for proper sealing/air leaks

Inspect coolant strength seasonally; pressure test system yearly

Change oil and filter; (perform a break-in oil change at one month)

Inspect for leaks and loose fittings

Inspect level; change yearly

Change fluid

Cycle the key to prime and pressurize the fuel system. Check for leaks at fuel cap, fuel line / rail, and fuel pump; Replace lines every 2 years

Page 88

MAINTENANCE

ITEM

MAINTENANCE INTERVAL

(WHICHEVER COMES FIRST)

HRS CLNDR

MILES

(KM)

REMARKS

XU Radiator 100 H 12 M -

D E

D Clutches 100 H 12 M

D Brake fluid 200 H 24 M -

Cooling Hoses

Engine mounts

Exhaust muffler /pipe

Spark plug

Wiring

Front wheel bearings

100 H 12 M -

100 H 12 M

100 H 12 M -

1000

(1600)

1000

(1600)

Inspect; clean external surfaces

Inspect for leaks; clean external surfaces

Inspect

inspect; replace as needed

Inspect for wear, routing, security; apply dielectric grease to connectors subjected to water, mud, etc.

Inspect; clean; replace worn parts

Inspect; replace as needed

Change every two years

Spark arrestor

D E

XU = Perform these procedures more often for vehicles subjected to severe use. E= Emission Control System Service (California) D = Have an authorized dealer perform these services.

*Service Note: Under extreme use, change demand drive fluid every 25 hours. "Extreme Use" is defined as constant ADC operation on hilly or mountainous terrain, or if ADC is the primary mode of AWD operation.

Valve clearance 500 H -

Toe adjustment

Headlight aim

- 60 M - Clean out

5000

(8000)

Inspect; adjust

Inspect periodically; adjust when parts are replaced

Adjust as needed

Page 89

MAINTENANCE

LUBRICATION RECOMMENDATIONS

Check and lubricate all components at the intervals outlined in the Periodic Maintenance Chart, 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 PS-4 5W-50 4-Cycle Oil Add to proper level on dipstick.

See page 87.

Brake Fluid DOT 4 Brake Fluid Maintain level between fill

lines. See page 105.

Transmission Oil (Main Gearcase)

Demand Drive Fluid (Front Gearcase)

Prop Shaft U-Joint Grease Locate fittings and grease.

AGL Gearcase Lubricant & Transmission Fluid

Demand Drive Fluid See page 92.

See page 91.

ENGINE OIL

Always check and change the oil at the intervals outlined in the Periodic Maintenance Chart. Always use the recommended engine oil. Always change the oil filter whenever changing oil.

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.

OIL RECOMMENDATIONS

POLARIS recommends the use of POLARIS PS-4 5W-50 4-Cycle Oil or a similar oil. Refer to the Specifications section for capacities.

Oil may need to be changed more frequently if POLARIS PS-4 engine oil is not used. Follow the manufacturer's recommendations for ambient temperature operation. See the Polaris Products section for part numbers.

NOTICE

Mixing brands or using a non-recommended oil may cause serious engine

damage. Always use the recommended oil. Never substitute or mix oil brands.

Page 90

MAINTENANCE

OIL CHECK

The oil dipstick and fill tube is located on the engine. Access the dipstick through the right rear wheel well.

To check the oil, do the following:

1. Position the vehicle on a level surface.

2. Place the transmission in PARK.

3. Always clean away all dirt and debris from the dipstick area removing the dipstick. Remove the dipstick. Wipe it dry with a clean cloth.

4. Reinstall and tighten the dipstick.

5. Remove the dipstick and check the oil level.

6. Add the recommended fluid as needed. Maintain the oil level in the safe range between the FULL

7. Reinstall and tighten the dipstick.

and ADD

marks. Do not overfill.

before

Page 91

OIL AND FILTER CHANGE

MAINTENANCE

Always check and change the oil at the intervals outlined in the Periodic Maintenance Chart.

The engine drain plug the oil and filter

1. Position the vehicle on a level surface. Place the transmission in PARK. Apply the brakes.

2. Start the engine. Allow it to idle for two to three minutes. Stop the engine.

3. Clean the area around the drain plug.

, do the following:

is located on the bottom of the crankcase. To change

CAUTION

The sealing surfaces on drain plug and crankcase should be clean and free of

burrs, nicks or scratches.

4. Place a drain pan beneath engine crankcase and remove the drain plug.

5. Allow the oil to drain completely.

6. Reinstall the sealing washer on the drain plug.

TIP

The sealing surfaces on drain plug and crankcase should be clean and free of

burrs, nicks or scratches.

Page 92

MAINTENANCE

7. Reinstall the drain plug. Torque to 12 ft. lbs. (16 Nm).

8. Using a cap-style oil filter wrench, turn the filter counter-clockwise to remove it.

9. Using a clean dry cloth, clean the filter sealing surface on the crankcase. Make sure the old filter o-ring is completely removed.

10.Lubricate the o-ring on the new filter with a film of fresh engine oil. Check to make sure the oring is in good condition.

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

12.Always clean away all dirt and debris from the dipstick area before removing the dipstick. Remove the dipstick (or the oil fill cap on the top of the engine) and fill the sump with two quarts (1.9 l) of recommended oil.

13.Reinstall and tighten the dipstick (and the oil fill cap, if applicable).

14.Make sure the transmission is in PARK. Apply the brakes.

15.Start the engine. Allow it to idle for one to two minutes.

16.Stop the engine. Inspect for leaks.

17.Re-check the oil level on the dipstick and add oil as necessary to bring the level to the upper mark on the dipstick.

18.Dispose of used filter and oil properly.

Page 93

MAINTENANCE

GEARCASES

TRANSMISSION (MAIN GEARCASE)

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

OIL CHECK

The fill plug is located on the rear of the gearcase. Maintain the fluid level at the bottom of the fill plug hole.

To check the transmission fluid, do the following:

1. Position the vehicle on a level surface.

2. Remove the fill plug

3. Check the fluid level.

4. Add the recommended fluid to the bottom of the fill plug hole. Do not overfill.

5. Reinstall the fill plug. Torque to specification.

FLUID CHANGE

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

1. Remove the fill plug

2. Place a drain pan under the drain plug

3. Remove the drain plug. Allow the fluid to drain completely.

4. Clean and reinstall the drain plug. Torque to specification.

5. Add the recommended fluid to the bottom of the fill plug hole. Do not overfill.

6. Reinstall the fill plug. Torque to specification.

7. Check for leaks. Discard used fluid properly.

Page 94

MAINTENANCE

FRONT GEARCASE (DEMAND DRIVE)

Always check and change the demand drive fluid at the intervals outlined in the Periodic Maintenance Chart. 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.

ADC Models: Change the front gearcase fluid every 25 hours if the ADC unit is exposed to extreme use. Extreme use includes any of the following:

• Operation in ADC mode for prolonged periods.

• Constant ADC operation on hilly or mountainous terrain.

• ADC is the primary mode of all-wheel-drive operation.

TIP

If the front gearcase makes excessive noise during ADC operation, change the

demand drive fluid. If the noise continues, please see your dealer or other

qualified service person for service.

OIL CHECK

The front gearcase fill plugqis located on the right side of the front gearcase.

1. Position the vehicle on a level surface.

2. Remove the fill plugq. 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

5. Remove the drain plug. Drain the oil.

6. Clean and reinstall the drain plug. Torque to specification.

7. Add the recommended fluid to the bottom of the fill plug hole. Do not overfill.

8. Reinstall the fill plug. Torque to specification.

on the bottom right-hand side.

Page 95

9. Check for leaks.

10.Discard used oil properly.

GEARCASE SPECIFICATION CHART

GEARCASE LUBRICANT CAPACITY

FILL PLUG TORQUE

MAINTENANCE

DRAIN PLUG/ LEVEL CHECK PLUG TORQUE

Transmission (Main Gearcase)

Demand Drive Unit (Front Gearcase)

AGL Gearcase Lubricant & Transmission Fluid

Demand Drive Fluid

41 oz.

(1200 ml)

9.3 oz.

(275 ml)

10-14 ft. lbs.

(14-19 Nm)

8-10 ft. lbs.

(11-13.6 Nm)

10-14 ft. lbs.

(14-19 Nm)

11 ft. lbs.

(15 Nm)

Page 96

MAINTENANCE

SPARK PLUGS

SPARK PLUG RECOMMENDATIONS

Refer to the Specifications section for the recommended spark plug type for your vehicle. Always torque spark plugs to specification.

NOTICE

Using non-recommended spark plugs can result in serious engine damage.

Always use POLARIS-recommended spark plugs or their equivalent.

SPARK PLUG GAP/TORQUE

MODEL ELECTRODE GAP NEW OR USED PLUG

TORQUE

RANGER 500 .03-.04” (.7–.9 mm) 14.8 ft. lbs (20 Nm)

RANGER 570 .03-.04” (.7–.9 mm) 9 ft. lbs. (12 Nm)

RANGER CREW 570 .03-.04” (.7–.9 mm) 9 ft. lbs. (12 Nm)

SPARK PLUG INSPECTION

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.

CAUTION

A hot exhaust system and engine can cause burns. Wear protective gloves

when removing a spark plug for inspection.

To inspect the spark plugs, do the following:

1. Lift the cargo box to access the spark plugs.

2. Remove the spark plug cap. Using the spark plug wrench provided in the tool kit, remove the plug by rotating it counter-clockwise.

3. Reverse the procedure for spark plug installation.

4. Torque to specification.

Page 97

MAINTENANCE

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.

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 oil or poor fuel quality.

Page 98

MAINTENANCE

COOLING SYSTEM

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.

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

POLARIS recommends the use of POLARIS Antifreeze 50/50 Premix. This antifreeze is already premixed and ready to use. Do not dilute with water.

To ensure that the coolant maintains its ability to protect the engine, we recommend that the system be completely drained every five (5) years and fresh Antifreeze 50/50 Premix added.

Any time the cooling system has been drained for maintenance or repair, replace the coolant with fresh Antifreeze 50/50 Premix. If the recovery bottle has run dry, the level in the radiator should be inspected. Add coolant as needed.

RADIATOR AND COOLING FAN

Always check and clean the screen and radiator fins at the intervals outlined in the Periodic Maintenance Chart. 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.

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 99

RADIATOR COOLANT LEVEL

MAINTENANCE

1. Lift the hood.

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.

2. Slowly remove the radiator cap

3. View the coolant level through the opening.

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

TIP

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.

Page 100

MAINTENANCE

5. Reinstall the pressure cap. Use of a non-standard pressure cap will not allow the recovery system to function properly. Your POLARIS dealer can provide the correct replacement part.

OVERFLOW BOTTLE COOLANT LEVEL

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

1. Position the vehicle on a level surface.

2. Lift the hood. View the coolant level in the overflow bottlew.

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

TIP

If coolant must be added often, or if the overflow bottle runs completely dry,

there may be a leak in the system. Your dealer can inspect the cooling system.

Polaris RANGER 500 Owner's Manual

Specifications and Main Features

Frequently Asked Questions

User Manual