Polaris Ranger 800 HD, Ranger 800 XP, Ranger 800 6X6, Ranger 800 Crew Owner's Manual

WARNING

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

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

WARNING

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

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

The text is printed on 100% recycled

with 40% post-consumer waste (PCW).

1

WELCOME

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

• Snowmobiles

• All-terrain vehicles (ATVs)

• RANGER

®

utility vehicles

• Victory Motorcycles

®

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

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

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

®

(MSD)

Technician.
Your POLARIS dealer knows your vehicle best and is interested in your

total satisfaction. Be sure to return to your dealership for all of your ser­vice needs during, and after, the warranty period.

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

2

POLARIS, THE WAY OUT, RANGER and RANGER CREW are registered trademarks
of POLARIS Industries Inc.

Copyright 2010 POLARIS Sales Inc. All information contained within this publication
is based on the latest product information at the time of publication. Due to constant
improvements in the design and quality of production components, some minor discrep­ancies may result between the actual vehicle and the information presented in this publi­cation. Depictions and/or procedures in this publication are intended for reference use
only. No liability can be accepted for omissions or inaccuracies. Any reprinting or reuse
of the depictions and/or procedures contained within, whether whole or in part, is
expressly prohibited.

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

Printed in U.S.A.
2011 RANGER 800 4X4 / 6X6 / CREW Owner’s Manual
P/N 9923125

3

TABLE OF CONTENTS

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

Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Features and Controls. . . . . . . . . . . . . . . . . . . 20

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Emission Control Systems . . . . . . . . . . . . . . . 56

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

Specifications. . . . . . . . . . . . . . . . . . . . . . . . . 104

POLARIS Products. . . . . . . . . . . . . . . . . . . . . 110

Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . .111

Declaration of Conformity. . . . . . . . . . . . . . . 115

Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116

Maintenance Log . . . . . . . . . . . . . . . . . . . . . . 123

Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125

4

INTRODUCTION

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

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

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

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

CAUTION
A CAUTION indicates a hazardous situation which, if not avoided, may result in

minor or moderate injury.
NOTICE

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

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

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

5

INTRODUCTION

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

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

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

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

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

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

• Always use the cab nets while riding in thi s vehicle.

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

WARNING

6

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 Model Number: __________________________________________________________

Frame VIN: ____________________________________________________________________

Engine Serial Number: ___________________________________________________________

Key Number__________________________________________________ __________________

Engine Serial Number

Key

Number

VIN (4X4, 6X6)

####

VIN (CREW)

7

SAFETY

Safety Labels and Locations

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

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

Container/Passenger/Tire Pressure Warning (4X4, 6X6)

WARNING
Remove flammable material containers from

box before filling.

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

• Never carry passengers in cargo box.

Maximum 4X4 Box Load 1000 lbs. (455 kg)*
Maximum 6X6 Box Load 1250 lbs. (567 kg),

Storage Box Load 250 lbs. (113 kg)
IMPROPER TIRE PRESSURE OR

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

TIRE PRESSURE IN PSI (KPa):

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

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

RANGER 4X4 is 1500 LBS. (682 KG)*
RANGER 6X6 is 2000 LBS. (907 KG)

Reduce speed and allow greater distance for braking when carrying cargo.
Overloading or carrying tall, off-center, or unsecured loads will increase your risk
of losing control. Loads should be centered and carried as low as possible in
box. For stability on rough or hilly terrain, reduce speed and cargo. Be careful if
load extends over the side of the box.

Read Owner's Manual for more detailed loading information.

7176334

* RANGER 4X4 models sold in California are designed and rated for a box capacity
of 600 lbs. (272 kg). The maximum weight capacity for these vehicles is 1100 lbs.
(499 kg).

H

8

SAFETY

Safety Labels and Locations

Container/Passenger/Tire Pressure Warning (CREW)

WARNING
Remove flammable material containers from box before filling.
WARNING
Passengers can be thrown off. This can cause serious injury or death.
Never carry passengers in cargo box.
WARNING
Multi-Passenger Maximum Box Load 1000 lbs. (455 kg)
WARNING
IMPROPER TIRE PRESSURE OR OVERLOADING can cause loss of control

resulting in SEVERE INJURY OR DEATH.
TIRE PRESSURE IN PSI (KPa):
MULTI-PASSENGER - FRONT 12 (83) REAR 16 (110)
MAXIMUM WEIGHT CAPACITY INCLUDES WEIGHT OF OPERATOR,

PASSENGERS, CARGO, AND ACCESSORIES.
MULTI-PASSENGER is 1750 LBS. (795 KG)
Reduce speed and allow greater distance for braking when carrying cargo.

Overloading or carrying tall, off-center, or unsecured loads will increase your risk
of losing control. Loads should be centered and carried as low as possible in
box. For stability on rough or hilly terrain, reduce speed and cargo. Be careful if
load extends over the side of the box.

Read Owner's Manual for more detailed loading information.

7175214

9

SAFETY

Safety Labels and Locations

Clutch Cover Warning

WARNING
NO STEP

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

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

7172563

Age 16 Warning

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

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

7175566

Shift Caution

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

7172674

Discretionary

Warning

Age 16

Warning

Shift

Caution

Clutch Cover

Warning

10

SAFETY

Safety Labels and Locations

Discretionary Warning (4X4/6X6)

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

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

• After or while using Alcohol or Drugs.

• On hills steeper than 15 degrees 15°.

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

• With more than two passengers, or passengers under age twelve or who
cannot comfortably reach the floor and hand holds.

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

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

ALWAYS:

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

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

• Reduce speed and use extra caution when carrying passengers.

• Avoid sharp turns or turns while applying he avy throttle.

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

• Make sure passenger reads and unde rstands all safety labels.

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

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

7176128

11

SAFETY

Safety Labels and Locations

Discretionary Warning (CREW)

WARNING
Improper vehicle use can result in SEVERE INJURY or DEATH.
NEVER Operate:

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

• After or while using Alcohol or Drugs.

• On hills steeper than 15 degrees 15°.

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

• With more than five passengers, or passengers under age twelve or who

cannot comfortably reach the floor and hand holds.

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

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

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

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

times.

• Reduce speed and use extra caution when carrying passengers.

• Avoid sharp turns or turns while applying he avy throttle.

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

• Make sure passenger reads and unde rstands all safety labels.

• Watch for branches or other hazards that could enter vehicle.
LOCATE AND READ OWNER’S MANUAL. FOLLOW ALL INSTRUCTIONS

AND WARNINGS

7176321

12

SAFETY

Operator Safety

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

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

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

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

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

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

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

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

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

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

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

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

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

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

• Never attempt jumps or other stunts.

WARNING

13

SAFETY

Operator Safety

• 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 unfa-

miliar 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 deale r

if it has been involved in an accident.

• Never operate this vehicle on hills too steep for the vehicle or for your

abilities. Practice on smaller hills before attempting larger hills.

• Always follow proper procedures for climbing hills as described in

this manual. Check the terrain carefully before attempting to climb a
hill. Never climb hills with excessively slippery or loose surfaces.
Never open the throttle suddenly or mak e sudden gear changes. Never
go over the top of a hill at high speed.

• Always follow the proper procedures outlined in this manual for trav-

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

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

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

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

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

14

SAFETY

Operator Safety

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

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

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

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

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

• Always engage the park brake before getting out of the vehicle. See
page 27.

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

• Always stop the engine before refueling. Remove flammable material
containers from the box before filling them with fuel. Make sure the
refueling area is well ventilated and free of any source of flame or
sparks. Gasoline is extremely flammable. See page 17 for fuel safety
warnings.

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

FOR MORE INFORMATION ABOUT SAFETY, call POLARIS at 1-800­342-3764.

15

SAFETY

Operator Safety

Equipment Modifications

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

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

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

16

SAFETY

Operator Safety

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

Age Restrictions

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

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

Operating Without Instruction

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

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

Using Alcohol or Drugs

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

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

Seat Belts

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

WARNING

17

SAFETY

Operator Safety

Cab Nets

Riding in this vehicle without using the cab nets increases the risk of serious
injury or death in the event of an accident or overturn. Always use the cab nets
while riding in this vehicle. Always keep hands and feet inside the vehicle at all

times.

Failure to Inspect Before Operating

Failure to inspect and verify that the vehicle is in safe operating condition before
operating increases the risk of an accident. Always inspect your RANGER
before each use to make sure it's in safe operating condition. Always follow all
inspection and maintenance procedures and schedules described in the owner's
manual.

Handling Gasoline

Gasoline is highly flammable and explosive under certain conditions.

• Always exercise extreme caution whenever handling gasoline.

• Always sto p the engine when refueling.

• Always refuel outdoors or in a well ventilated area.

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

fuel.

• Do not smoke or allow open flames or sparks in or near the area where refu-

eling 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.

Exposure to Exhaust

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

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

Operating a Damaged Vehicle

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

18

SAFETY

Operator Safety

Operating at Excessive Speeds

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

Operating on Pavement

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

Operating on Public Roads

Operating this vehicle on public streets, roads or highways could result in a
collision with another vehicle. Never operate this vehicle on any public street,
road or highway, including dirt and gravel roads. In some areas it's unlawful to
operate this vehicle on public streets, roads and highways.

Turning Improperly

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

Jumps and Stunts

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

Operating in Unfamiliar Terrain

Failure to use extra caution when operating on unfamiliar terrain could result in
an accident or overturn. Unfamiliar terrain may contain hidden rocks, bumps, or
holes that could cause loss of control or overturn. Travel slowl y and use extra
caution when operating on unfamiliar terrain. Always be alert to changing terrain
conditions.

Operating on Slippery Terrain

Failure to use extra caution when operating on excessively ro ugh, slippery or
loose terrain could cause loss of traction, loss of control, accident or overturn.
Do not operate on excessively slippery surfaces. Always reduce speed and use
additional caution when operating on slippery surfaces.

19

SAFETY

Operator Safety

Improper Hill Climbing

Climbing hills improperly can cause loss of control or vehicle overturn. Always
follow proper procedures for climbing hills as described in the owner's manua l.
See page 46.

Stalling While Climbing a Hill

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

If all forward speed is lost:

• Apply the brakes.

• Place the transmission in reverse and slowly allow the vehicle to roll straight

downhill while applying light brake pressure to control speed.

If you begin rolling downhill:

• Never apply engine power.

• Appl y the brakes gradually until the vehicle is fully stopped.

• Place the transmission in reverse and slowly allow the vehicle to roll straight

downhill while applying light brake pressure to control speed.

Improper Tire Maintenance

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

Operating on Frozen Bodies of Water

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

Unauthorized Use of the Vehicle

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

Hot Exhaust Systems

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

20

FEATURES AND CONTROLS

Component Locations

Your vehicle is equipped with cab nets on both sides of the vehicle. Cab
nets must be used by both operator and passengers at all times. Any
illustrations without cab nets are only to allow component identification.
Always use the cab nets.

Not all models come with all features. Refer to the specifications section
beginning on page 104.

Headlights

Front Bumper/Brush Guard

Radiator

ROPS Cab

Frame

Console

Hip Bar

Cargo Box

Fuel Tank Cap

Cab

Net

Net Rod Mount

Net Rod

Upper Net

Latch

21

FEATURES AND CONTROLS

Component Locations

Tailgate

Latch Release

Receiver

Hitch

CV Boot/Rear Caliper

Muffler (Spark Arrestor)

Tailgate

6X6 Storage Box

Storage

Compartment

22

FEATURES AND CONTROLS

Console

Auxiliary Outlets

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

On CREW models, an additional
receptacle is located on the rear
of the driver’s seat.

Cup Holder

12V Auxiliary

Outlets

Mode

Button

Storage

Tray

Instrument

Cluster

Gear Selector

(Shifter)

Park Brake

Lever

Storage

Compartment

12V Accessory

Outlet

23

FEATURES AND CONTROLS

Console

Mode Button

The MODE button is located on the instrument cluster. Use the MODE
button to toggle through mode options available in the instrument clus­ter. See pages 33-39.

Gear Selector

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

intended for use on hard-packed surfaces with light loads.
To shift gears, brake to a complete stop. When the engine is idling,

move the lever to the desired gear.

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

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

Tip: Maintaining shift linkage adjustment is important to assure proper transmis-

sion function. See your dealer if you experience any shifting problems.

24

FEATURES AND CONTROLS
Switches

Ignition Switch

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

Light Switch

The ignition switch key must be in the ON/
RUN position to operate the headlights.
Press the top of the rocker switch toward the
dash to place the headlights on high beam.
Move the rocker switch to the center position
to place the headlights on low beam. Press
the bottom of the rocker switch to turn off
the headlights.

OFF The engine is off. Electrical circuits are off, except Acc, 12V.
ON Electrical circuits are on. Electrical equipment can be used.
START Turn the key to the START position to engage the electric starter.

The key returns to the ON position when released.

Ignition Switch

Light

Switch

AWD/Differential Switch

HIGH

OFF

LOW

25

FEATURES AND CONTROLS

Switches

AWD/Differential Lock Switch

The AWD/Differential Switch has
three positions:

• All Wheel Drive (AWD)

• Differential Lock (2WD)

• Differential Unlock
Press the top of the rocker switch to

engage All Wheel Drive (AWD). See
page 54 for operating instructions.

Move the rocker switch to the center position to lock the differential and
operate in rear wheel drive. Press the bottom of the switch to unlock the
differential and allow the two rear drive wheels to operate indepen­dently. See page 55 for differential lock operating instructions.

AWD

Differential Lock

Differential Unlock

26

FEATURES AND CONTROLS

Trailer Hitch Bracket

This vehicle is equipped with a receiver hitch bracket for a trailer hitch.
To avoid injury and property damage, always heed the warnings and
towing capacities outlined on pages 50-52.

Brake Pedal

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

Throttle Pedal

Push the throttle pedal down to
increase engine speed. Spring pres­sure returns the pedal to the rest posi­tion when released. Alway s ch ec k
that the throttle pedal returns nor­mally before starting the engine.
Make sure there's adequate throttle
pedal freeplay. See page 83 for throt­tle pedal adjustment procedures.

Adjustable Steering Wheel

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

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

Throttle

Pedal

Brake
Pedal

27

FEATURES AND CONTROLS

Park Brake Lever

To help prevent the vehicle from roll­ing, engage the park brake when park­ing the vehicle. When the park brake is
fully engaged, “BRAKE” appears in
the rider information display. Engine
speed is limited to 1300 RPM in all
gears, except neutral. If throttle is
applied, this limiting feature prevents
operation, which protects the park brake pads from excessive wear.

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 promptly if this
feature fails to operate properly.

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

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

1. Apply the brakes.

2. Pull the park brake lever

downward as far as possible.

3. To release the park brake,

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

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

Trip 1

km

mi

RPM

FE

88

:

88

28

FEATURES AND CONTROLS

Seat Removal

Pull up on the front of the seat and slide it toward the front of the vehi­cle. Install the seat by sliding the tabs into the rear of the seat base. Push
down firmly on the front of the seat until the pins are fully seated into
the grommets.

Fuel Cap

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

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

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. See page 33 for EPS Warning Indicator information.

29

FEATURES AND CONTROLS

Cab Nets

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

Always inspect cab nets for tightness, wear and damage before each use
of the vehicle. Use the strap adjusters to tighten any loose straps.
Promptly replace worn or damaged cab nets with new cab nets, avail­able from your authorized Polaris dealer.

Securing a Net

1. After entering the vehicle,

insert the lower net rod into the
net mount on the floor. Make
sure the ball at the end of the
rod is properly secured in the
mount.

2. Connect the latch at the top

edge of the net to the receiver
latch mounted on the front
frame.

Opening a Net

1. To exit the vehicle, release the latch

at the top front edge of the cab net.

2. Rotate the net rearward and pull

upward on the lower net rod to
remove it from the mount.

3. Allow the net to hang freely outside

the vehicle while dismounting.

Latch

Rod

Net Mount

30

FEATURES AND CONTROLS

Seat Belts

This POLARIS vehicle is equipped with
three-point lap and diagonal seat belts on
all external seats.The center seat is
equipped with a lap-style seat belt. Always
make sure the seat belts are secured for all
riders before operating.

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

To wear the seat belt properly, follow this
procedure:

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

latch downward and across your chest
toward the buckle at the inner edge of
the seat. The belt should fit snugly
across your hips and diagonally across
your chest. Make sure the belt is not
twisted. For lap style belts, place the
belt across your lap as low on your
hips as possible. Make sure that the
belt is not twisted.

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

3. Release the strap, it will self-tighten.

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

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

center.

Buckle

Latch Plate

31

FEATURES AND CONTROLS

Seat Belts

Seat Belt Inspection

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

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

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

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

releases freely.

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

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

4. To clean dirt or debris from the seat belts, sponge the straps with

mild soap and water. Do not use bleach, dye or household deter­gents.

32

FEATURES AND CONTROLS

Rollover Protective Structure (ROPS)

The Rollover Protective Structure (ROPS) on this vehicle meets OSHA

1928.53 rollover performance requirements. Always have your autho-

rized POLARIS dealer thoroughly inspect the ROPS if it ever becomes
damaged in any way.

No device can assure occupant protection in the event of a rollover.

Always follow all safe operating practices outlined in this manual to
avoid vehicle rollover.

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

Storage Compartments

A storage compartment is located under the driver’s seat, and on CREW
models, under the left rear seat. On 6X6 models, a lockable storage box
is located behind the ROPS. Always make sure the cover is securely
latched before operating. The box is accessible from both sides of the
vehicle.

6X6 Storage

Box

ROPS

(all models)

Large Storage

Compartment

(CREW only)

Small Storage

Compartment

(left side only)

33

FEATURES AND CONTROLS

Instrument Cluster

High water pressure may
damage components. Wash
the vehicle by hand or with a
garden hose using mild soap.
Do not use alcohol to clean
the instrument cluster. Do not
allow insect sprays to contact
the lens.

Speedometer

The speedometer displays
vehicle speed in either miles
per hour (MPH) or kilometers
per hour (km/h). See page 36.

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

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

EPS Warning This indicator illuminates briefly when the key is

turned to the ON position. If the light remains on, the
EPS system is inoperative. See your authorized
POLARIS dealer for service.

Neutral This lamp illuminates when the transmission is in

neutral and the ignition key is in the ON position.

High Beam This lamp illuminates when the headlamp switch is

set to high beam.

Helmet/Seat
Belt

This lamp flashes for several seconds when the key is
turned to the ON position. The lamp is a reminder to
the operator to ensure all riders are wearing helmets
and seat belts before operating.

Check Engine This indicator appears if an EFI-related fault occurs.

Do not operate the vehicle if this warning appears.
Serious engine damage could result. See your dealer.

Rider Information

Center

Speedometer

Indicator

Lamps

MODE

Button

34

FEATURES AND CONTROLS

Instrument Cluster

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-vol tage may have occurred and the
instrument cluster may have shut off to protect the electronic speedome­ter. If this occurs, take the vehicle to your POLARIS dealer for proper
diagnosis.

The information center is set to display standard units of measurement
and a 12-hour clock at the factory. To chan ge to metric and/o r a 24-hour
clock, see page 37.

1. Gear Indicator - This indicator displays gear shifter position.

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

-- = Gear Signal Error (or shifter between gears)

Trip 1

km

mi

RPM

EF

88

:

88

1

2

65

4

7

3

35

FEATURES AND CONTROLS

Instrument Cluster

Rider Information Center

2. 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.

Tip: If the fuel icon fails to display, an open or short circuit has occurred in the

fuel sensor circuit. See your dealer.

3. Information Display Area - This area displays odometer, trip

meter, engine hour meter and programmable service hour interval.

4. Under / Over Voltage - 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.

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

page 37 for resetting instructions.

6. Service Indicator - A flashing wrench symbol alerts the operator

that the preset service interval has been reached. The vehicle should
be brought to your dealer for scheduled maintenance. See page 37
for resetting instructions.

7. 4X4 Indicator - This indicator illuminates when the 4X4 system is

engaged (switch is on 4X4).

36

FEATURES AND CONTROLS

Instrument Cluster

Rider Information Center

Use the MODE button to toggle through the information area options.

Display Units (Standard/Metric)

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 automati-

cally exits and returns to the odometer display.

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.

Standard Display Metric Display

Distance Miles Kilometers
Fuel U.S. Gallons Liters, Imperial Gallons
Temperature Fahrenheit Celsius
Time 12-Hour Clock 24-Hour Clock

37

FEATURES AND CONTROLS

Instrument Cluster

Rider Information Center

Clock Mode

Tip: The clock must be reset any time the battery has been disconnected or dis-

charged.

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.

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. T o 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.

38

FEATURES AND CONTROLS

Instrument Cluster

Rider Information Center

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. Use the following procedure to
change the service interval.

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.

Diagnostic Display Mode

The EFI diagnostic display mode is for informational purposes only.
Please see your POLARIS dealer 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.

39

FEATURES AND CONTROLS

Instrument Cluster

Rider Information Center

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. See an authorized POLARIS dealer for code details and diagnosis.

Suspect Parameter

Number (SPN)

Error Code

Number (0-9)

Failure Mode Indicator (FMI)

40

OPERATION

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

Break-In Period

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

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

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

Engine and Drivetrain Break-in

1. Fill the fuel tank with fuel. Review the fuel warnings on page 17.

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

the oil level in the normal (safe) operating range.

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

iarize yourself with vehicle operation and handling.

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

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

on the daily pre-ride inspection checklist. See page 41. During the
break-in period, change both the oil and the filter at 25 hours.

6. Pull only light loads.

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

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

PVT Break-in (Clutches/Belt)

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

WARNING

41

OPERATION

Pre-Ride Inspection

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

Item Remarks Page

Brake system/pedal travel Ensure proper operation 26

84
Brake fluid Ensure proper level 84
Front suspension Inspect, lubricate if necessary 61
Rear suspension Inspect, lubricate if necessary 61
Steering Ensure free operation 86
Tires Inspect condition and pressure 88
Wheels/fasteners Inspect, ensure fastener tightness 88
Frame nuts, bolts, fasteners Inspect, ensure tightness ­Fuel and oil Ensure proper levels 35

63
Coolant level Ensure proper level 74

75
Coolant hoses Inspect for leaks ­Throttle Ensure proper operation 82
Indicator lights/switches Ensure operation 24
Air filter, pre-filter Inspect, clean 79
Air box sediment tube Drain deposits whenever visible 79
Headlamp Check ope ration, apply POLARIS

dielectric grease when lamp is
replaced

90

Brake light/tail lamp Check operation, apply POLARIS

dielectric grease when lamp is
replaced

90

Seat Belts Check length of belt for damage,

check latches for proper operation

31
Cab Nets Check for wear or damage, ensure

proper installation

29

42

OPERATION

Starting the Engine

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

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

3. Apply the brakes. Engage the park brake.

4. Shift the transmission to neutral.

5. Do not press the throttle pedal while starting the engine. Turn the
ignition key past the ON/RUN position to START. Engage the
starter for a maximum of five seconds. Release the key when the
engine starts.

6. If the engine does not start within five seconds, release the ignition
switch and wait five seconds. Repeat steps 5 and 6 until the engine
starts.

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

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. Turn the engine off.

3. Engage the park brake.

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

Braking

1. Release the throttle pedal completely.

2. Press on the brake pedal evenly and firmly.

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

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

near an idle, the vehicle has no engine braking.

43

OPERATION

Driving Procedure

1. Wear a helmet and eye protection.

2. Perform the pre-ride inspection. See page 41.

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

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

5. Start the engine and allow it to warm up.

6. Apply the service brakes and shift the transmission into gear.

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

8. Release the park brake.

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

10. Drive slowly. Practice maneuvering and using the throttle and
brakes on level surfaces.

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

44

OPERATION

Driving with a Passenger

1. Perform the pre-ride inspection. See page 41.

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 an approved helmet and eye
protection.

4. Make sure all passengers secure their seat belt.

5. Make sure all cab nets are properly secured.

6. Do not carry more than the recommended number of passengers for
your vehicle. See pages 7-8.

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. A void 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.

45

OPERATION

Driving on Slippery Surfaces

Skidding or sliding can cause loss of control or overturn (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.

Whenever riding on slippery surfaces such as wet trails or loose gravel,
or during freezing weather, follow these precautions:

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.

WARNING

Sideways

skid

Turn in

direction of

skid

46

OPERATION

Driving Over Obstacles

Follow these precautions when operating over obstacles:

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

2. Look ahead and learn to

read the terrain. Be con­stantly alert for hazards
such as logs, rocks and
low hanging branches.

3. Travel slowly and use

extra caution when oper­ating on unfamiliar ter­rain. Not all obstacles are
immediately visible.

Driving Uphill

Whenever traveling uphill, follow these precautions:

1. Always travel straight
uphill.

2. Avoid steep hills (15°

maximum).

3. Keep both feet on the

floor.

4. Always check the terrain

carefully before ascend­ing any hill.

5. 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.

15° maximum

47

OPERATION

Driving on a Sidehill (Sidehilling)

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

If crossing a sidehill is unavoidable, follow these precautions:

1. Slow down.

2. Exercise extreme caution.

3. Avoid crossing the side of a steep hill (15° maximum).

Driving Downhill

When driving downhill,
follow these precautions:

1. Avoid steep hills (15°
maximum).

2. Drive straight down-

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

3. Slow down.

4. Apply the brakes slightly to aid in slowing.

15° maximum

48

OPERATION

Driving Through Water

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

NOTICE: Immersion can result in major damage if the vehicle isn't serviced

correctly and promptly. After immersion, always take the vehicle to
your dealer service. Do not start the engine! If it's impossible to bring
the vehicle to your dealer before starting the engine, perform the
service outlined on page 78, and take the vehicle to your dealer 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 fast­flowing water.

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

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

sure to the pedal repeatedly until braking action is normal.

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

services outlined in the Periodic Maintenance Chart beginning on
page 57. Give special attention to engine oil, transmission oil, all
gearcase fluids, and all grease fittings.

Floorboard

49

OPERATION

Driving in Reverse

Follow these precautions when operating in reverse:

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

2. Always avoid backing down-

hill.

3. Back slowly.

4. Apply the brakes lightly for

stopping.

5. Avoid turning at sharp angles.

6. Never open the throttle sud-

denly.

Parking the Vehicle

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

2. When parking inside a garage or other structure, be sure th at 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. Turn the engine off.

4. Engage the park brake.

5. 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

gear.

3. Engage the park brake.

4. Turn the engine off.

5. Block the rear wheels on

the downhill side.

15° maximum

50

OPERATION

Hauling Cargo

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

Never exceed the maximum weight capacity of the vehicle. When determining
the weight you are adding to the vehicle, include the weight of the ope rator,
passenger, accessories, loads in the rack or box and the load on the trailer
tongue. The combined weight of these items must not exceed the maximum
weight capacity.

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

Always load the cargo box with the load as far forward and as low as possible.
When operating over rough or hilly terrain, reduce speed and cargo to maintain

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

unstable operating conditions, which could result in loss of control of the vehicle.
OPERATE ONLY WITH STABLE AND SAFELY ARRANGED LOADS. When

handling off-centered loads that cannot be centered, securely fasten the load
and operate with extra caution. Always attach the tow load to the hitch poin t
designated for your vehicle.

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

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

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

WARNING

51

OPERATION

Hauling Cargo

The RANGER has been designed to carry or tow specific capacities.
Always read and understand the load distribution warnings li sted on th e
warning labels. The total load (operator, passenger, accessories, cargo
and weight on hitch) must not exceed the maximum weight capacity of
the vehicle. Never exceed the following capacities.

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.

* RANGER 4X4 models sold in California are designed and rated for a box capacity
of 600 lbs. (272 kg). The maximum weight capacity for these vehicles is 1100 lbs.
(499 kg).

Model Maximum Total

Weight Capacity

(Level Ground)

Maximum Cargo Box

Weight Capacity

RANGER 4X4 1500 lbs. (681 kg) * 1000 lbs. (454 kg)*
RANGER 6X6 2000 lbs. (907 kg) 1250 lbs. (567 kg) Cargo Box

250 lbs. (113 kg) Storage Box

RANGER CREW 1750 lbs. (794 kg) 1000 lbs. (454 kg)

52

OPERATION

Towing Loads

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. Do not operate the vehicle faster than 10 mph (16 km/h) when tow-

ing. See page 50. Towing a trailer increases braking distance.

3. Do not tow more than the recommended weight for the vehicle. See

the towing capacity chart below and the specifications charts begin­ning on page 104.

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

trailer to any other location or you may lose control of the vehicle.

5. Never tow a trailer on a grade steeper than 15°.

Belt Life

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

Model Total Towed

Load Weight

(Level Ground)

Total Towed

Load Weight

(15° grade)

Total Hitch

Vertical

Weight

Maximum

Towing

Speed

RANGER 4x4 2000 lbs.

(907 kg)

850 lbs.

(386 kg)

150 lbs.

(68.1 kg)

10 mph

(16 kph)

RANGER 6x6 2000 lbs.

(907 kg)

850 lbs.

(386 kg)

150 lbs.

(68.1 kg)

10 mph

(16 kph)

RANGER CREW 2000 lbs.

(907 kg)

850 lbs.

(386 kg)

150 lbs.

(68.1 kg)

10 mph

(16 kph)

53

OPERATION

Dumping the Cargo Box

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

2. Apply the brakes.

3. Place the transmission in gear.

4. Engage the park brake.

5. Dismount the vehicle.

6. Ensure that the cargo is posi-

tioned evenly or toward the
front of the cargo box.

7. Release the tailgate by pulling

up on the tailgate latch.

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.

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 th is vehicle
with the cargo box in the raised position.

Release Lever

54

OPERATION

All Wheel Drive (AWD)

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
AW D. See page 35.

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

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

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
AW D. 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.

1. Stop the vehicle.

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

3. Stop completely.

4. Shift into low gear and drive forward.

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

AWD

Differential Lock

Differential Unlock

55

OPERATION

All Wheel Drive (AWD)

Locking the Differential

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.

Locking the differential in slippery or low traction conditions helps
improve traction. Move the rocker switch to the center position (2WD)
to lock the differential and operate in rear wheel drive. On 6X6 models,

all four rear wheels will be drive wheels.

Press the bottom of the switch to unlock the differential and allow the
rear drive wheels to operate independen tly. This mode of operation is
well suited to turf driving or whenever aggressive traction is not
required. On 6X6 models, the center wheels will remain drive wheels.

4X4 Models

6X6 Models

56

EMISSION CONTROL SYSTEMS

Noise Emission Control System

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

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

Your POLARIS vehicle has a spark arrestor that was tested and quali­fied to be in accordance with the USFS standard 5100-1c. Federal law
requires that this spark arrestor be installed and functional when the
vehicle is operated on public lands.

Operation of off-road vehicles on public lands in the U.S.A. is regulated
by 43 CFR 420. Violations are subjec t to mo netary penalties. Federal
regulations can be viewed online at www.gpoaccess.gov/ecfr/.

Crankcase Emission Control System

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

Exhaust Emission Control System

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

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

Electromagnetic Interference

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

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

57

MAINTENANCE

Periodic Maintenance Chart

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

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

Record maintenance and service in the Maintenance Log beginning on
page 123.

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

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

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

Severe Use Definition

• Frequent immersion in mud, water or sand

• Racing or race-style high RPM use

• Prolonged low speed, heavy load operation

• Extended idle

• Short trip cold weather operation
Pay special attention to the oil level. A rise in oil level during cold

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

58

MAINTENANCE

Periodic Maintenance Chart

Maintenance Chart Key

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

E Emission-related service (Failure to conduct this maintenance will
not void the emissions warranty but may affect emissions.)

n Have an authorized POLARIS dealer perform these services.

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

Perform all services at whichever maintenance interval is reached first.

Item Maintenance Interval

(whichever comes first)

Remarks

Hours Calendar Miles

(Km)

n

Steering - Pre-Ride - Make adjustments as need

ed. See Pre-Ride Checklist
on page 41.

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

Tires - Pre-Ride -

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

Brake system - Pre-Ride ­Wheels/fasteners - Pre-Ride ­Frame fasteners - Pre-Ride -

X Engine oil level - Pre-Ride -

X

E

Air filter, pre-filter - Daily - Inspect; clean often; replace

as needed

X

E

Air box sediment
tube

- Daily - Drain deposits when visible

Coolant
(if applicable)

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

X Power steering unit

(if equipped)

- Daily - Inspect daily; clean often

Headlamp/tail
lamp

- Daily - Check operation; apply
dielectric grease if replacing

X

E

Air filter,
main element

- Weekly - Inspect; replace as needed

59

MAINTENANCE

Periodic Maintenance Chart

Perform all services at whichever maintenance interval is reached first.

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

E Emission-Related Service

n Have an authorized POLARIS dealer perform these services.

Item Maintenance Interval

(whichever comes first)

Remarks

Hours Calendar Miles

(Km)

X

n

Brake pad wear 10 H Monthly - Inspect periodically
Battery 20 H Monthly - Check terminals; clean; test

X Front Gearcase Oil

(if equipped)

25 H Monthly - Inspect level; change yearly

X Middle Gearcase

Oil (if equipped)

25 H Monthly - Inspect level; change yearly

X Rear gearcase oil

(if equipped)

25 H Monthly - Inspect level; change yearly

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

X

E

Engine breather
filter (if equipped)

25 H Monthly - Inspect; replace if necessary

X Engine oil change

(break-in)

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

at one month

Park brake cable
tension

25 H 1 M - Check tension, adjust

X General

lubrication

50 H 3 M - Lubricate all fittings, pivots,

cables, etc.

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

n

Steering 50H 6 M - Lubricate

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

nE Throttle cable/

ETC switch

50 H 6 M - Inspect; adjust; lubricate;

replace if necessary

E Throttle body air

intake ducts/flange

50 H 6 M - Inspect duct for proper seal-

ing/air leaks

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

needed

Cooling system
(if applicable)

50 H 6 M - Inspect coolant strength

seasonally; pressure test
system yearly

Park brake cable
tension

100 H 6 M - Check tension, adjust

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

at one month

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

60

MAINTENANCE

Periodic Maintenance Chart

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

E Emission-Related Service

n Have an authorized POLARIS dealer perform these services.

Item Maintenance Interval

(whichever comes first)

Remarks

Hours Calendar Miles

(Km)

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

lines, fuel valve, filter, pump,
throttle body; replace lines
every two years

n

Fuel filter 100 H 12 M - Replace yearly

X Radiator

(in applicable)

100 H 12 M - Inspect; clean external

surfaces

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

Exhaust muffler/
pipe

100 H 12 M - Inspect

X

E

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

n

Ignition timing 100 H 12 M - Inspect

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

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

n

Clutches (drive
and driven)

100 H 12 M - Inspect; clean; replace worn

parts

n

Front wheel
bearings

100 H 12 M - Inspect; replace as needed

n

Brake fluid 200 H 24 M - Change every two years
Spark arrestor 300 H 36 M - Clean out
Idle speed - Adjust as needed

n

Toe adjustment - Inspect periodically; adjust

when parts are replaced

n

X

Auxiliary brake (if
equipped)

- Inspect daily; adjust as
needed

Headlight aim - Adjust as needed

61

MAINTENANCE

Lubrication Recommendations

Check and lubricate all components at the intervals outlined in the Peri­odic Maintenance Chart beginning on page 57, 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 PLUS 2W-50 Add to proper level on dipstick.

See page 63.

Brake Fluid DOT 4 Maintain level between fill lines.

See page 84.

Main Gearcase Oil
(Transmission)

AGL PLUS Transmission
Fluid

See page 68 (6X6).
See page 67 (4X4/CREW).

Front Gearcase Oil Demand Drive Plus Fluid See page 69.
Middle Gearcase Oil (6X6) Premium ATV Angle Drive

Fluid

See page 70.

Rear Gearcase Oil (6X6) Premium ATV Angle Drive

Fluid

See page 71.

Prop Shaft U-joints (6X6) POLARIS Premium U-

Joint Lube

Locate fittings and grease.

Front Prop Shaft Yoke POLARIS Premium U-

Joint Lube

Locate fittings and grease
(3 pumps maximum).

6X6 Prop Shaft U-Joints

62

MAINTENANCE

Engine Intake Restrictor Plate

Some RANGER 800 models are equipped with an intake restrictor plate
in order to meet vehicle class regulations. This plate MUST NOT be
removed for any reason. Removal of the intake restrictor plate will void

the warranty on the vehicle.

Engine Oil

Always check and change the engine oil at the intervals outlined in the
Periodic Maintenance Chart beginning on page 57. 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 PLUS Performance
Synthetic 2W-50 4-cycle oil or a similar oil. See page 110 for the part
numbers of POLARIS products.

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.

63

MAINTENANCE

Engine Oil

Always check and change the oil at the intervals outlined in the Periodic
Maintenance Chart beginning on page 57. Always use the recommended
engine oil.

Oil Check

The oil dipstick and fill tube is
located on the engine.

1. Position the vehicle on a level
surface.

2. Lift the lever lock to remove the

dipstick. W ipe it dry with a clean
cloth.

3. Reinstall the dipstick completely ,

but do not lock it. The dipstick
must be screwed completely in
to keep the angle and depth of
the stick consistent.

4. Remove the dipstick and check

the oil level. Maintain the oil
level in the safe range. Do not
overfill.

Tip: Due to the dipstick entry angle into

the crankcase, the oil level will read
higher on the bottom side of the dip­stick. Always read the level on the
upper surface of the dipstick.

5. After reinstalling the dipstick, be

sure to seat the lever lock.

Safe

{

Safe

Range

Check Level

on Top Side

Dipstick

64

MAINTENANCE

Engine Oil

Oil and Filter Change

Always change the oil and filter at the intervals outlined in the Periodic
Maintenance Chart beginning on page 57. Always change the oil filter
whenever changing oil.

1. Position the vehicle on a level surface.

2. Run the engine for two to three minutes until warm. Stop the engine.

3. Clean the area around the drain plug.

4. Place a drain pan beneath engine crankcase.

CAUTION! Hot oil can cause burns to skin. Do not allow hot oil to contact skin.

5. Remove the drain plug.

6. Allow the oil to drain completely.

7. Reinstall the sealing washer on the drain plug. The sealing surfaces
on drain plug and crankcase should be clean and free of burrs, nicks
or scratches.

8. Reinstall the drain plug. Torque to 20 ft. lbs. (27 Nm).

9. Place shop towels beneath the oil filter. Using an oil filter wrench,
turn the filter counter-clockwise to remove it.

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

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

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

65

MAINTENANCE

Engine Oil

Oil and Filter Change

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

14. Shift the transmission to neutral.

15. Apply the brakes. Engage the park brake.

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

17. Stop the engine. Inspect for leaks.

18. Check the oil level on the dipstick and add oil as necessary to bring
the level to the upper mark on the dipstick.

19. Dispose of used filter and oil properly.

66

MAINTENANCE

Gearcases

Gearcase Specification Chart

RANGER 4X4 Gearcase Specifications

Gearcase Lubricant Capacity Fill Plug

Torque

Drain Plug

Torque

Main Gearcase
(Transmission)

AGL PLUS

Transmission Fluid

34 oz.

(1000 ml)

12 ft. lbs.

(16.3 Nm)

12 ft. lbs.

(16.3 Nm)

Front Gearcase Demand Drive

Plus Fluid

9.3 oz.

(275 ml)

8-10 ft. lbs.

(11-13.6 Nm

11 ft. lbs.

(15 Nm)

RANGER 6x6 Gearcase Specifications

Gearcase Lubricant Capacity Fill Plug

Torque

Drain Plug

Torque

Main Gearcase
(Transmission)

AGL PLUS

Transmission Fluid

43.6 oz.

(1290 ml)

12 ft. lbs.

(16.3 Nm)

12 ft. lbs.

(16.3 Nm)

Front Gearcase Demand Drive

Plus Fluid

9.3 oz.

(275 ml)

8-10 ft. lbs.

(11-13.6 Nm

11 ft. lbs.

(15 Nm)

Middle Gearcase Premium ATV

Angle Drive Fluid

6.75 oz.
(200 ml)

14 ft. lbs.

(19.4 Nm)

14 ft. lbs.

(19.4 Nm)

Rear Gearcase Premium ATV

Angle Drive Fluid

18 oz.

(532 ml)

14 ft. lbs.

(19.4 Nm)

14 ft. lbs.

(19.4 Nm)

RANGER CREW Gearcase Specifications

Gearcase Lubricant Capacity Fill Plug

Torque

Drain Plug

Torque

Main Gearcase
(Transmission)

AGL PLUS

Transmission Fluid

34 oz.

(1000 ml)

12 ft. lbs.

(16.3 Nm)

12 ft. lbs.

(16.3 Nm)

Front Gearcase Demand Drive

Plus Fluid

9.3 oz.

(275 ml)

8-10 ft. lbs.

(11-13.6 Nm

11 ft. lbs.

(15 Nm)

67

MAINTENANCE

Gearcases

Transmission (Main Gearcase) (4X4/CREW)

Always check and change the transmission oil at the intervals outlined
in the Periodic Maintenance Chart beginning on page 57. Maintain the
oil level even with the bottom of the fill plug hole threads.

Refer to the Gearcase Specifications Chart on page 66 for recommended
lubricants, capacities and torque specifications. See page 110 for the
part numbers of POLARIS products.

Oil Check

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

1. Position the vehicle on a level surface.

2. Remove the fill plug.

3. Check the oil level. Add the recommended oil as needed.

4. Reinstall the fill plug. Torque to specification.

Oil Change

The drain plug is located near the bottom of the gearcase.

1. Remove the fill plug.

2. Place a drain pan under the gearcase.

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

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

5. Add the recommended oil.

6. Reinstall the fill plug. Torque to specification.

7. Check for leaks. Dispose of used oil properly.

Drain Plug

Fill Plug

68

MAINTENANCE

Gearcases

Transmission (Main Gearcase) (6X6)

Always check and change the transmission oil at the intervals outlined
in the Periodic Maintenance Chart beginning on page 57. Maintain the
oil level even with the bottom of the fill plug hole.

Refer to the Gearcase Specifications Chart on page 66 for recommended
lubricants, capacities and torque specifications. See page 110 for the
part numbers of POLARIS products.

Oil Check

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

1. Position the vehicle on a level
surface.

2. Remove the fill plug.

3. Check the oil level.

4. Add the recommended oil as

needed.

5. Reinstall the fill plug. Torque to

specification.

Oil Change

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

1. Remove the fill plug.

2. Place a drain pan under the drain plug. Remove the drain plug.

Allow the oil to drain completely.

3. Wipe the magnetic end of the drain plug clean to remove accumu-

lated metallic filings. Install a new sealing washer.

4. Reinstall the drain plug. Torque to specification.

5. Add the recommended oil. Do not overfill.

6. Reinstall the fill plug. Torque to specification.

7. Check for leaks. Dispose of used oil properly.

Drain Plug

Fill

Plug

69

MAINTENANCE

Gearcases

Front Gearcase

Always check and change the front gearcase oil at the intervals outlined
in the Periodic Maintenance Chart beginning on page 57. Maintain the
oil level even with the bottom thread of the fill plug hole.

Refer to the Gearcase Specifications Chart on page 66 for recommended
lubricants, capacities and torque specifications. See page 110 for the
part numbers of POLARIS products.

Oil Check

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

1. Position the vehicle on a level
surface.

2. Remove the fill plug. Check the

oil level.

3. Add the recommended oil as

needed.

4. Reinstall the fill plug. Torque to

specification.

Oil Change

1. Support the vehicle securely with a jackstand.

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

3. Remove the fill plug.

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

side.

5. Remove the drain plug. Allow the oil to drain completely.

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

7. Add the recommended oil.

8. Reinstall the fill plug. Torque to specification.

9. Check for leaks. Dispose of used oil properly.

Drain

Plug

Fill

Plug

70

MAINTENANCE

Gearcases

Middle Gearcase (6X6)

Always check and change the middle gearcase oil at the intervals out­lined in the Periodic Maintenance Chart beginning on page 57. Maintain
the oil level even with the bottom thread of the fill plug hole.

Refer to the Gearcase Specifications Chart on page 66 for recommended
lubricants, capacities and torque specifications. See page 110 for the
part numbers of POLARIS products.

The middle gearcase fill plug is located on the side of the gearcase.

Oil Check

1. Position the vehicle on a
level surface.

2. Remove the fill plug. Check

the oil level.

3. Add the recommended oil as

needed.

4. Reinstall the fill plug. T orque

to specification.

Oil Change

1. Remove the fill plug.

2. Place a drain pan under the

drain plug.

3. Remove the drain plug.

Allow the oil to drain completely.

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

5. Add the recommended fluid.

6. Reinstall the fill plug. Torque to specification.

7. Check for leaks. Discard used oil properly.

Drain Plug

Fill Plug

71

MAINTENANCE

Gearcases

Rear Gearcase (6X6)

Always check and change the rear gearcase oil at the intervals outlined
in the Periodic Maintenance Chart beginning on page 57.

Refer to the Gearcase Specifications Chart on page 66 for recommended
lubricants, capacities and torque specifications. See page 110 for the
part numbers of POLARIS products.

The rear gearcase fill plug is on the driver's side of the rear gearcase.

Oil Check

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

1. Position the vehicle on a level
surface.

2. Remove the fill plug. Check the

oil level.

3. Add the recommended oil as

needed.

4. Reinstall the fill plug. Torque to

specification.

Oil Change

1. Remove the fill plug.

2. Place a drain pan under the drain plug.

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

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

5. Add the recommended oil.

6. Reinstall the fill plug. Torque to specification.

7. Check for leaks. Dispose of used oil properly.

Fill

Plug

Drain Plug

72

MAINTENANCE

Spark P lugs

Spark Plug Recommendations

Refer to the specifications section beginning on p a ge 1 04 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.

Spark Plug Gap/Torque

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.

1. Remove the seat. Remove the spark plug cap.

2. Using the spark plug wrench provided in the tool kit, remove the
plug by rotating it counterclockwise.

3. Reverse the procedure for spark plug installation. Torque to specifi­cation.

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 incorrect throttle body adjustments.

Model Electrode Gap New Plug Torque Used Plug Torque

All .035" (.9 mm) 18 ft. lbs.

(24 Nm)

18 ft. lbs.

(24 Nm)

73

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

To ensure that the coolant maintains its ability to protect the engine, we
recommend that the system be completely drained every two years and a
fresh mixture of antifreeze and water added. POLARIS recommends the
use of POLARIS Premium 60/40 anti-freeze/coolant or a 50/50 mixture
of high quality aluminum compatible anti-freeze/coolant and distilled
water. POLARIS Premium 60/40 is already premixed and ready to use.
Do not dilute with water. See page 110 for the part numbers of
POLARIS products.

Always follow the manufacturer's mixing recommendations for the
freeze protection required in your area.

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

74

MAINTENANCE

Cooling System

Radiator and Cooling Fan

Always check and clean the screen and radiator fins at the intervals out­lined in the Periodic Maintenance Chart beginning on page 57. 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 high­pressure system is not recommended.

Overflow Bottle Coolant Level

Always check and change the coolant at the intervals outlined in the
Periodic Maintenance Chart beginning on page 57. Maintain the coolant
level between the minimum and maximum marks on the bottle (when
the fluid is cool).

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

1. Position the vehicle on a level surface.

2. View the coolant level in the overflow bottle.

3. If the coolant level is below the
safe operating range, lift the
hood and locate the overflow
bottle lid. Remove the 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. Have the cooling system
inspected by your POLARIS dealer.

75

MAINTENANCE

Cooling System

Radiator Coolant Level

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.

5. Reinstall the pressure cap. Use of a non-standard pressure cap will
not allow the recovery system to function properly. See your dealer
for the correct replacement part.

Power Steering Unit

If your model is equipped with
power steering, frequently clean
the areas around and on the power
steering unit to allow proper cool­ing. Clean these areas thoroughly.

Clean Often

76

MAINTENANCE

POLARIS Variable Transmission (PVT) System

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

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

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

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

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

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

When To Use Low Range and High Range

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

Condition Range to Use

Operating at speeds less than 7 MPH (11 km/h) Low
Towing heavy loads Low
Operating in rough terrain (swamps, mountains, etc.) Low
Operating at speeds greater than 7 MPH (11 km/h) High

WARNING

77

MAINTENANCE

PVT System

PVT Drying

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

1. Position the vehicle on a level surface.

2. Remove the drain plug. Allow the water to drain completely. Rein­stall the drain plug.

3. Apply the brakes. Start the engine.

4. Engage the park brake.

5. Shift the transmission to neutral.

6. Apply varying throttle for 10-15 seconds to expel the moisture and
air-dry the belt and clutches. Do not hold the throttle wide open for
more than 10 seconds.

7. Allow the engine RPM to settle to idle speed. Apply the service
brakes. Release the park brake and shift the transmission to the low­est available range.

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

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

78

MAINTENANCE

Vehicle Immersion

NOTICE: If your vehicle becomes immersed, major engine damage can result

if the machine is not thoroughly inspected. Take the vehicle to your
dealer before starting the engine.

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

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

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

if water is present.

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

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

the electric start.

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

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

dure.

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

whether you succeed in starting it or not.

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

page 77 for drying.

79

MAINTENANCE

Filter Systems

Air Filter

Always change the air filter at the intervals outlined in the Periodic
Maintenance Chart beginning on page 57. Service the air filter more fre­quently if the vehicle is operated in wet conditions or at high throttle
openings for extended periods.

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

2. Remove the air

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

Tip: Grasp the filter end

to prevent damage
to the filter paper.

3. Remove the air filter.

4. Do not attempt to clean the main element. Install a new air filter.

Tip: Apply a small amount of general purpose grease to the sealing edges of the

filter before installing.

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

suitable container.

Fuel Filter

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

Air Filter

80

MAINTENANCE

Spark Arrestor

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

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

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

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

Never go under the vehicle while it's inclined.

WARNING

81

MAINTENANCE

Spark Arrestor

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

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

2. Place the transmission in neutral.

3. Engage the park brake.

4. Start the engine.

5. Purge accumulated carbon from

the system by momentarily rev­ving the engine several times.

6. If carbon is expelled, cover or

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

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

the vehicle one foot higher than the front. Block the wheels.

8. Repeat steps 5 and 6 until no more particles are expelled when the

engine is revved.

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

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

Clean-Out

Plugs

Exhaust

Outlet

82

MAINTENANCE

Throttle System

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

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

Throttle Freeplay

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

Check the throttle pedal freeplay
at the intervals outlined in the
Periodic Maintenance Chart
beginning on page 57. Adjust the
freeplay if necessary.

Throttle Freeplay Inspection

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

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

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

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

3.2 mm).

WARNING

Throttle

Pedal

83

MAINTENANCE

Throttle System

Throttle Body/Idle RPM

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

Throttle Freeplay Adjustment

1. Remove the seat.

2. Locate the throttle cable adjuster.

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

4. Loosen the adjuster lock nut.

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

Tip: While adjusting, lightly flip the throttle

pedal up and down.

6. T ighten the lock nut.

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

Boot

Adjuster

Lock Nut

84

MAINTENANCE

Brakes

The front and rear brakes are hydraulic disc type brakes activated by the
brake pedal. See page 26.

Brake Fluid

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

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

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

1. Position the vehicle on a level
surface.

2. View the brake fluid level at the

reservoir in the driver’s side
wheel well.

3. The level should be between the

upper (MAX) and lower (MIN)
level lines.

4. If the fluid level is lower than

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

5. Apply the brake forcefully for a

few seconds and check for fluid
leakage around the fittings.

Maximum

Minimum

85

MAINTENANCE

Brakes

Brake Inspection

1. Check the brake system for
fluid leaks.

2. Check the brake pedal for

excessive travel or a spongy
feel.

3. Check the friction pads for

wear, damage and looseness.

4. Inspect the brake disc spline

and pad wear surface for
excessive wear.

5. Change pads when worn to

3/64" (1 mm).

Park Brake Inspection

1. Apply the brakes.

2. Pull the park brake lever

downward as far as possible.

3. Check the vehicle for

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

3/64" (1mm)

Park Brake Release

86

MAINTENANCE

Brakes

Park Brake Adjustment

Inspect and adjust park brake cable tension after the first 25 hours of
operation and every 100 hours thereafter to ensure proper cable tension.
Loss of tension in the park brake cable may cause “BRAKE” to display
in the rider information center, along with activation of the limiting fea­ture. If this occurs, move the park brake lever to the forward-most posi­tion, then inspect and adjust park brake cable tension.

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

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

1. Position the vehicle on a level surface.

2. Shift the transmission to neutral.

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

Steering Wheel Inspection

Check the steering wheel for specified freeplay and smooth operation at
the intervals outlined in the Periodic Maintenance Chart beginning on
page 57.

1. Position the vehicle on level ground.

2. Lightly turn the steering wheel left and right.

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

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

87

MAINTENANCE

Suspension Adjustments

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

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

2. Reposition the shocks to the outside mounting holes.

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

Spring Adjustment

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

Outside Mounting Holes

Inside Mounting Holes

Cam

Rear Suspension Shown

Adjustment is similar for Front Suspension

88

MAINTENANCE

Tires

Operating your vehicle with worn tires, improperly inflated tires, non-standard
tires or improperly installed tires will affect vehicle handling and could cause an
accident resulting in serious injury or death. Always follow all tire maintenance
procedures as outlined in this manual and on the labels on the vehicle. Always
use original equipment size and type when replacing tires.

Tire Tread Depth

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

Axle and Wheel Nut Torque Specifications

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

Do not lubricate the stud or the lug nut.

Nut Type Location Nut Torque

Lug Nut
(Aluminum
Wheels)

Front and Rear 30 ft. lbs. (41 Nm)

PLUS 1/4 TURN

Nut and
Washer (Steel
Wheels)

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

Spindle Nut Front 70 ft. lbs. (95 Nm)
Hub Retaining Nuts Center and Rear 110 ft. lbs. (150 Nm)

WARNING

1/8" (3 mm)

89

MAINTENANCE

Tires

Wheel Removal

1. Apply the brakes. Engage the park brake.

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

3. Loosen the wheel nuts slightly.

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

frame.

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

Wheel Installation

1. Apply the brakes.

2. Place the transmission

in gear.

3. Engage the park brake.

4. Place the wheel in the

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

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

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

6. Carefully lower the vehicle to the ground.

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

90

MAINTENANCE

Lights

Poor lighting can result in reduced visibility when driving. Headlight
and taillight lenses become dirty during normal operation. Clean lights
frequently and replace burned out lamps promptly. Always make sure
lights are adjusted properly for best visibility.

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

Headlight Lamp Replacement

1. Open the hood.

CAUTION! Hot components
can cause burns to skin. Allow
lamps to cool before servicing.

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

3. Turn the lamp counter­clockwise to remove it.

4. Install the new lamp.

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

5. Reinstall the harness assembly into the headlight assembly.

Brake Lights

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

1. Turn the ignition switch to the ON position.

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

Wiring Harness

91

MAINTENANCE

Lights

Headlight Beam Adjustment

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

2. Place the transmission in gear. Engage the park brake.

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

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

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

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

beam should be aimed 8" (20 cm) below the mark placed on the
wall. Include the weight of a rider on the seat while performing this
step.

6. If a headlight needs adjustment, locate the adjustment screw at the

back of the headlight.

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

8. Repeat steps 5-7 until the lamp is properly adjusted.

25 ft.

(7.6 m)

8" (20 cm)

XX

92

MAINTENANCE

Fuses

If the engine stops or will
not start, or if you experi­ence other electrical fail­ures, a fuse may need
replacement. Locate and
correct any short circuits
that may have caused the
blown fuse, then replace
the fuse. Spare fuses are
provided in the fuse box.

If you suspect that a fuse
or relay may not be work­ing properly, please see
your POLARIS dealer.

Tip: The 120 ohm resistor (if

equipped) is used by
your POLARIS dealer for
power steering diagnos­tics.

Fuse Feature Supported

20A Accessories, 12V Power Receptacle
10A Electronic Fuel Injection
20A Engine Control Module
20A Lights
20A Main Fuse - Ignition, Instrument Cluster
30A Power Steering (if equipped)

93

MAINTENANCE

Battery

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

Antidote:

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

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

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

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

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

Battery Fluid (Conventional Battery)

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

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

WARNING

Lower

Mark

Upper

Mark

94

MAINTENANCE

Battery

Battery Removal

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

1. Open the hood.

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

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

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

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

NOTICE: If electrolyte spills, immediately wash it off with a solution of one

tablespoon baking soda and one cup water to prevent damage to the
vehicle.

WARNING

95

MAINTENANCE

Battery

Battery Installation

Using a new battery that has not been fully charged can damage the bat­tery and result in a shorter life. It can also hinder vehicle performance.
Follow the battery charging instructions on page 96 before installing the
battery.

1. Ensure that the battery is fully
charged.

2. Place the fully charged battery in

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

3. With conventional batteries, install

the battery vent tube and route it
down in front of the shift cable,
into the left front wheel well.

4. Route the vent tube through the

hole in the frame support from the
back side and place it behind the
wheel well panel.

NOTICE: Route vent tube as shown to

prevent electrolyte from
damaging critical components
(such as wire harness, brake
lines, throttle cable).

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

5. On conventional batteries, coat the

terminals with dielectric grease or petroleum jelly.

6. Connect and tighten the red (+) cable first. Connect and tighten the

black (-) cable last.

7. Verify that cables are properly routed and install the hold-down

strap.

Vent

Tube

Route through
hole in frame

Shift

Cable

Route

behind

panel

96

MAINTENANCE

Battery

Battery Storage

Whenever the vehicle is not used for a period of three months or more,
remove the battery from the vehicle, ensure that it's fully charged, and
store it out of the sun in a cool, dry place. Check battery voltage each
month during storage and recharge as needed to maintain a full charge.
See page 96.

POLARIS recommends maintaining battery charge by using a
POLARIS Battery Tender charger or by char ging about once a month to
make up for normal self-discharge. Battery T ender can be left connected
during the storage period, and will automatically charge the battery if
the voltage drops below a pre-determined point. See page 110 for the
part numbers of POLARIS products.

Battery Charging (Conventional Battery)

1. Remove the battery from the vehicle to prevent damage from leak­ing or spilled electrolyte during charging. See page 94.

2. Charge the battery with a charging output no lar ger than 1/10 of the

battery’s amp/hr rating. Charge as needed to raise the specific grav­ity to 1.270 or greater.

3. Reinstall the battery . See page 95. Make sure the posi tive terminal is

toward the front of the vehicle.

Battery Charging (Sealed Battery)

The following battery charging instructions apply only to the installa­tion of a sealed battery. Read all instructions before proceeding with the
installation of this battery.

The sealed battery is already filled with electrolyte and has been sealed
and fully charged at the factory. Never pry the sealing strip off or add
any other fluid to this battery.