Polaris Ranger Crew User Manual

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WARNING

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

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

WARNING

The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects or other reproductive harm.

WELCOME

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

• Snowmobiles

• All-terrain vehicles (ATVs)

• RANGER utility vehicles

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

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

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

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

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

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

Copyright 2007 Polaris Sales Inc. All information contained within this publication is based on the latest product information at the time of publication. Due to constant improvements in the design and quality of production components, some minor discrepancies may result between the actual vehicle and the information presented in this publication. Depictions and/or procedures in this publication are intended for reference use only. No liability can be accepted for omissions or inaccuracies. Any reprinting or reuse of the depictions and/or procedures contained within, whether whole or in part, is expressly prohibited.

Printed in U.S.A. 2008 RANGER Crew Owner’s Manual P/N 9921279

TABLE OF CONTENTS

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

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

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

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

Emission Control Systems . . . . . . . . . . . . . . . 59

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

Specifications. . . . . . . . . . . . . . . . . . . . . . . . . 108

Polaris Products. . . . . . . . . . . . . . . . . . . . . . . 110

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

Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115

Maintenance Log . . . . . . . . . . . . . . . . . . . . . . 124

Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126

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.

VIN

Key

Number

####

Vehicle Model Number: ___________________________________________________

Frame VIN: ____________________________________________________________

Engine Serial Number: ___________________________________________________ (side of engine cylinder head)

Key Number ____________________________________________________________

SAFETY

Safety Decals and Locations

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

If any decal becomes illegible or comes off, contact your Polaris dealer to purchase a replacement. Replacement safety decals are provided by Polaris at no charge.

Container/Passenger/Tire Pressure Warning

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

SAFETY

Safety Decals and Locations

Clutch Cover Warning

WARNING

NO STEP

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

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

7172563

Cab Frame/Seat Belt Warning

WARNING

• VEHICLE ROLLOVER could cause severe injury or death. The cab frame is not designed or intended to provide rollover protection.

• ALWAYS WEAR YOUR SEAT BELT for maximum protection.

• ALWAYS WEAR EYE PROTECTION and keep hands and feet in vehicle at all times.

Cab Frame/Seat Belt

Warning

Clutch Cover

Warning

7173778

Age Warning

Discretionary

Warning

Cab Frame/Seat Belt

Warning

Shift

Caution

SAFETY

Safety Decals and Locations

Age Warning

WARNING Operating this vehicle if you are under the age of 16 increases your chance of

severe injury or death. NEVER operate this vehicle if you are under age 16 or without a valid driver’s

license.

7175101

Shift Caution

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

7172674

Discretionary Warning

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

• Operate on public roads. A collision can occur with a another vehicle.

• Carry more than five passengers, or passengers under age five.

• Use ALCOHOL or DRUGS before or while operating this vehicle.

• Operate at speeds too fast for your skills or the conditions.

• Operate this vehicle on HILLS steeper than 15 degrees 15°. To prevent flipover on hilly terrain, use throttle and brakes gradually.

ALWAYS:

• Avoid paved surfaces which may adversely affect handling and control.

• Use proper RIDING TECHNIQUES to avoid vehicle overturns on hills and rough terrain and in turns.

• Wear eye protection.

REVERSE operation can be dangerous even at low speeds. Steering becomes difficult. To prevent flipover, avoid sharp turns.

The park/emergency brake lever will supply increased braking, but should be used as an emergency or parking brake only.

READ OWNER’S MANUAL. FOLLOW ALL INSTRUCTIONS AND WARNINGS. IF OWNER’S MANUAL IS MISSING, CONTACT A POLARIS DEALER FOR A

REPLACEMENT. THIS GENERAL PURPOSE OFF-ROAD UTILITY VEHICLE DOES NOT MEET

FEDERAL MOTOR VEHICLE SAFETY STANDARDS FOR ON-ROAD VEHICLES.

7175215

SAFETY

Operator Safety

WARNING

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

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

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

Age Restrictions

This vehicle is an ADULT VEHICLE ONLY. Operation is prohibited for anyone under 16 years of age or anyone without a valid driver’s license. No person under the age of 5 may ride as a passenger in this vehicle.

Know Your Vehicle

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

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

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

SAFETY

Operator Safety

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

The safety alert symbol, on your vehicle or in this manual, alerts you to the potential for injury.

WARNING

The safety alert warning indicates a potential hazard that may result in serious injury or death.

CAUTION

The safety alert caution indicates a potential hazard that may result in minor injury or damage to the vehicle.

CAUTION

A caution indicates a situation that may result in damage to the vehicle.

NOTE

A note will alert you to important information or instructions.

SAFETY

Operator Safety

WARNING

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

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

• Operation is prohibited for anyone under 16 years of age or anyone without a valid driver’s license.

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

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

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

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

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

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

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

• Never attempt jumps or other stunts.

• Always inspect your vehicle each time you use it to make sure it's in safe operating condition. Always follow the inspection and maintenance procedures and schedules described in this manual.

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

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

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

SAFETY

Operator Safety

• Always follow proper procedures for turning as described in this

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

• Always have this vehicle checked by an authorized Polaris dealer if it

has been involved in an accident.

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

abilities. Practice on smaller hills before attempting larger hills.

• Always follow proper procedures for climbing hills as described in

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

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

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

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

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

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

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

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

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

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

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

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

Always maintain proper tire pressure as specified on page 5.

SAFETY

Operator Safety

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

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

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

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

• Always engage the park brake before getting out of the vehicle. See page 37.

• Always apply the service brakes before releasing the park brake.

• Always turn off the engine before refueling. Make sure the refueling area is well ventilated and free of any source of flame or sparks. Gasoline is extremely flammable. See page 21 for fuel safety warnings.

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

FOR MORE INFORMATION ABOUT SAFETY, call Polaris at 1-800342-3764.

SAFETY

Operator Safety

WARNING

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

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

Do not make any modifications to your RANGER.

Equipment Modifications

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

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

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

ers, blades, tires, sprayers, or large racks, may change the handling characteristics of the vehicle. Use only Polaris-approved accessories, and familiarize yourself with their function and effect on the vehicle.

SAFETY

Operator Safety

WARNING

POTENTIAL HAZARD Stalling, rolling backwards while climbing a hill WHAT CAN HAPPEN Loss of control or overturn resulting in serious injury or death HOW TO AVOID THE HAZARD Maintain a steady speed when climbing a hill.

If you lose all forward speed:

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

WARNING

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

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

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

SAFETY

Operator Safety

WARNING

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

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

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

WARNING

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

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

roads and highways.

SAFETY

Operator Safety

WARNING

POTENTIAL HAZARD Operating this vehicle after consuming alcohol

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

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

WARNING

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

and your experience.

SAFETY

Operator Safety

WARNING

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

WARNING

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

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

SAFETY

Operator Safety

WARNING

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

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

described in the Owner's Manual.

WARNING

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

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

SAFETY

Operator Safety

WARNING

POTENTIAL HAZARD Failure to follow the minimum age recommendations for this vehicle WHAT CAN HAPPEN Serious injury or death (the child or others) HOW TO AVOID THE HAZARD Operation is prohibited for anyone under 16 years of age or anyone without a

valid driver’s license. Even though a child may be within the age group for which some vehicles are recommended, he or she may not have the skills, abilities, or judgment needed to operate the vehicle safely and may be involved in a serious accident.

Never operate with a passenger under the age of 5.

WARNING

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

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

vehicle. See page 5. Always maintain proper tire pressure as described on the decal and in the

Owner's Manual. See page 5.

SAFETY

Operator Safety

WARNING

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

WARNING

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

WARNING

Exhaust system components are very hot during and after use of the vehicle. Hot components can cause serious 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.

SAFETY

Fuel Safety

WARNING

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

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

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

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

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

FEATURES AND CONTROLS

Component Locations

Some Polaris vehicles are equipped with special features such as the cab frame. Not all models come with all features. Refer to the specifications section beginning on page 108.

Cab Frame

Hip Bar

Console

Steering

Wheel

Storage Box (under seat)

12-Volt

Receptacle

Storage

Compartment

Cargo Box

Fuel Tank

Cap

Seat Belts

Battery

(under hood)

FEATURES AND CONTROLS

Component Locations

Headlights

Hood

Hold-Down

Strap

Radiator

Front Bumper/Brush Guard

FEATURES AND CONTROLS

Component Locations

Tailgate

Latch Release

Taillights

Tailgate

Air Box

Receiver Hitch

Taillights

CV Boot/Rear Caliper

Muffler

(Spark Arrestor)

Trailer Hitch Bracket

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

To avoid injury and property damage, always heed the warnings and towing capacities outlined on pages 52-55.

FEATURES AND CONTROLS

Component Locations

Instrument Cluster

Yo ur RANGER is equipped with an instrument cluster that senses vehicle speed from the right front wheel. The instrument cluster measures distance in miles as well as time, hours of operation and engine RPM.

Refer to page 34 for the location of the instrument cluster.

Park Brake

Indicator

Speedometer

Needle

Speedometer

Rider

Information

Center

NOTE: In addition to showing vehicle speed, the speedometer needle flashes

when a low fuel condition exists.

FEATURES AND CONTROLS

Instrument Cluster

Rider Information Center

The rider information center is located in the instrument cluster. All segments will light up for 2.5 seconds at start-up.

NOTE: If the instrument cluster fails to illuminate, a battery over-voltage may

1. Gear Indicator - This

2. AWD Indicator - This

3. Engine Hour Display Indicator

4. Service Interval/Diagnostic Mode Indicator

5. Low Battery and Over Voltage - This warning usually indicates

6. Odometer/Tachometer/Tripmeter/ Hour Meter/Clock

7. Fuel Gauge - The segments of the fuel gauge show the level of fuel

8. Check Engine Warning Indicator - This indicator serves two pur-

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.

indicator displays gear

345

shifter position. H = High Gear

L = Low Gear N = Neutral R = Reverse Gear

indicator illuminates when the AWD switch is in the AWD position.

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.

in the fuel tank. When the last segment clears, a low fuel warning is activated. All segments will flash, FUEL will display in the LCD, and the speedometer needle will blink. Refuel immediately.

poses. The word HOT displays if the engine overheats. It also appears if an EFI-related fault occurs. Do not operate the vehicle if this warning appears. Serious engine damage could result.

FEATURES AND CONTROLS

Instrument Cluster

Rider Information Center

Standard Modes

Use the yellow mode button located under the speedometer to toggle through the mode options. See page 34.

Odometer Mode

The odometer records the miles traveled by the vehicle.

Trip Meter Mode

The trip meter records the miles traveled by the vehicle on each trip if it's reset before each trip. To reset the trip meter, select the trip meter mode. Press and hold the mode button (override button) until the total changes to 0.

NOTE: In the Rider Information Center, the trip meter display contains a deci-

Hour Meter Mode

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

Tachometer Mode

The engine RPM is displayed digitally.

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

Clock Mode

The clock displays time in a 12-hour format. To reset the clock, see page

28.

mal point, but the odometer displays without a decimal point.

of changes in humidity, temperature and elevation.

FEATURES AND CONTROLS

Instrument Cluster

Rider Information Center

Diagnostic Mode

The wrench icon will display when the gauge is in the diagnostic mode. To exit the diagnostic mode, turn the key switch off and on. Any movement of the tires will also cause the gauge to exit the diagnostic mode.

To enter the diagnostics mode:

1. Turn the key switch off and wait 10 seconds.

2. Lock the parking brake.

3. Place the transmission in neutral.

4. Hold the mode/reverse override button and turn the key switch on.

Release the switch as soon as the display is activated.

5. Use the mode button to toggle through the diagnostic screens.

Clock Screen

To reset the clock:

1. Enter the diagnostic mode.

2. Toggle to the clock screen.

3. Press and hold the mode button until the hour display flashes.

Release the button.

4. Press and release the mode button once to advance the setting by

one hour. Press and hold the mode button to advance the hours quickly.

5. When the desired hour is displayed, wait approximately four sec-

onds, until the minute display flashes.

6. When the display stops flashing, the mode has been set.

7. Use the same procedure to reset the minutes.

FEATURES AND CONTROLS

Instrument Cluster

Rider Information Center

Diagnostic Mode

Battery Voltage Screen

View this screen to check battery voltage level.

Tachometer Screen

View the tachometer to check engine speed.

AWD Diagnostic Screen

The gauge indicates whether or not current is flowing through the AWD coil (only on models with switchable AWD). This screen is for informational purposes only. Please see your dealer for all major repairs.

Gear Circuit Diagnostic Screen

This screen displays the resistance value (in ohms) being read at the gear switch input of the gauge. This screen is for informational purposes only. Please see your dealer for all major repairs.

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. See page 30.

NOTE: The service interval is programmed at 50 hours at the factory.

FEATURES AND CONTROLS

Instrument Cluster

Rider Information Center

Diagnostic Mode

Programmable service interval

To enable or disable the service interval:

1. Enter the diagnostic mode.

2. Toggle to the service interval screen.

3. Press and hold the mode button for about seven (7) seconds, until

either ON or OFF appears in the Rider Information Center, depending on your preference.

To reset the service interval:

1. Enter the diagnostic mode.

2. Toggle to the service interval screen.

3. Press and hold the mode button for 2-3 seconds, until the wrench

icon flashes. Release the button.

4. Press and release the mode button once to advance the setting by

one hour. Press and hold the mode button to advance the hours quickly.

NOTE: If you scroll past the intended number, press and hold the button until

5. When the desired setting is displayed, wait until the wrench icon

Miles/Kilometers toggle

The display in the tripmeter and odometer can be changed to display either standard or metric units of measurement.

1. Enter the diagnostic mode.

2. Toggle to the screen that displays either kilometers (KM) or miles

3. Press and hold the mode button until the letters flash, then press and

the hours cycle back to zero.

stops flashing. The new service interval is now programmed.

(MP).

release the button once. When the display stops flashing, the mode has been set

FEATURES AND CONTROLS

Instrument Cluster

Rider Information Center

Downloading Codes

The EFI diagnostic mode is for informational purposes only. Please see your Polaris dealer for all major repairs.

See page 32 for Blink Codes and Failure Descriptions. Use the following procedure to download blink codes (failure codes) from the EFI module.

1. Apply the brakes. Engage the parking brake.

2. Stop the engine.

3. Turn the key switch to the ON position.

4. Turn the key switch off and on three times in less than five seconds,

then leave the switch on. Any blink code numbers stored in the EFI module will display, one at a time, on the screen. The number “61” and the word “END” displays after all codes have been transmitted.

FEATURES AND CONTROLS

Instrument Cluster

Rider Information Center

Downloading Codes

Blink

Failure Description

Code

-- No RPM Signal 21 Loss of Synchronization 45 Barometric Pressure Sensor: Circuit Low Input 46 Barometric Pressure Sensor: Circuit High Input 22 TPS: Open or Short Circuit to Ground 22 TPS: Short Circuit to Battery 23 RAM Error: Defective ECU 42 Engine Temp Sensor Circuit: Short to Ground 42 Engine Temp Sensor Circuit: Open or Short to Battery 51 Injector 1: Open Load 51 Injector 1: Short Circuit to Ground 51 Injector 1: Short Circuit to Battery 52 Injector 2: Open Load 52 Injector 2: Short Circuit to Ground 52 Injector 2: Short Circuit to Battery 53 Rear Differential: Open Load 53 Rear Differential: Short Circuit to Ground 53 Rear Differential: Short Circuit to Battery 54 Engine Temp Lamp: Open Load 54 Engine Temp Lamp: Short Circuit to Ground 54 Engine Temp Lamp: Short Circuit to Battery 55 Diag Lamp: Open Load 55 Diag Lamp: Short Circuit to Ground 55 Diag Lamp: Short Circuit to Battery 56 Pump Relay: Open Load 56 Pump Relay: Short Circuit to Ground 56 Pump Relay: Short Circuit to Battery 57 Reverse Beeper: Open Load 57 Reverse Beeper: Short Circuit to Ground 57 Reverse Beeper: Short Circuit to Battery 58 Cooling Fan: Open Load 58 Cooling Fan: Short Circuit to Ground 58 Cooling Fan: Short Circuit to Battery 41 Intake Air Temp Sensor: Open or Short Circuit to +Sensor Voltage 41 Intake Air Temp Sensor: Short Circuit to Ground 61 END

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 rear passenger seat. When refueling, always use either leaded or unleaded gasoline with a minimum pump octane number of 87 R+M/2 octane. Do not use E-85 fuel.

Seat Belts

The RANGER is equipped with lap-style seat belts for the operator and passengers

Seat Belt

Fuel Cap

WARNING

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

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

To wear the seat belt properly, follow this procedure:

1. Place the belt across your lap as low on your hips as possible. Make sure that the belt is not twisted.

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

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

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

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

center.

FEATURES AND CONTROLS

Console

Instrument

Gauge

12V

Accessory

Outlet

Mode

Button

Cup

Holder

Storage

Compartment

Cup

Holder

Storage

Box

Park Brake

Lever

Gear Selector

(Shifter)

Storage

Tra y

Auxiliary Outlets

Each 12-volt accessory plug receptacle has spade connections on the back that may be used to power an auxiliary light or other optional accessories or lights. One outlet is located on the console. The connections are behind the console, under the hood. An additional outlet is located on the panel below the left rear passenger seat.

Mode Button

The yellow button located directly under the speedometer is used to toggle through mode options available such as odometer, trip meter, hour meter, tachometer and clock. See page 27 for operation of the modes.

FEATURES AND CONTROLS

Gear Selector

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

NOTE: Low gear is the primary

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

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

NOTE: Maintaining shift linkage adjustment is important to assure proper

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

CAUTION

Do not attempt to shift the transmission while the vehicle is moving or damage to the transmission could result. Always shift when the vehicle is stationary and the engine is at idle.

Gear

Selector

FEATURES AND CONTROLS

Brake Pedal

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

Throttle Pedal

Push the pedal down to increase engine speed. Spring pressure returns the pedal to the rest position when released. Always check that the throttle pedal returns normally before starting the engine. Make sure there's adequate throttle pedal freeplay. See page 86 for throttle pedal adjustment procedures.

Brake Pedal

Throttle

Pedal

FEATURES AND CONTROLS

Park Brake Lever

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

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

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

1. Apply the brakes.

2. Pull the park brake lever

3. To release the park brake,

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.

Park Brake

Release

downward as far as possible.

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

WARNING

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

FEATURES AND CONTROLS Switches

Light Switch

Ignition

Switch

AWD/Differential Lock Switch

Ignition Switch

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

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

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

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

The key returns to the ON position when released.

WARNING

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

FEATURES AND CONTROLS

Switches

Light Switch

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

AWD/Differential Lock Switch

The AWD/Differential Switch has three positions:

• All Wheel Drive (AWD)

• Differential Lock (2WD)

• Differential Unlock (1WD)

Press the top of the rocker switch to engage All Wheel Drive (AWD). See page 58 for AWD operating instructions.

Move the rocker switch to the center position to lock the differential and operate in two wheel drive (2WD). See page 57 for Differential Lock operating instructions.

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

All Wheel Drive

Differential Lock

Differential Unlock

OFF

2WD

OPERATION

Break-In Period

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

CAUTION

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 gasoline. Heed the gasoline warnings on page

21.

2. Check the oil level. See page 68. 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 familiarize 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.

6. Pull only light loads.

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

8. Inspect and adjust park brake cable tension after the first 25 hours of operation and every 100 hours thereafter to ensure proper cable tension. See page 88.

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.

OPERATION

Pre-Ride Inspection

WARNING

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

Item Remarks Page

Brake system/pedal travel Ensure proper operation 36

Brake fluid Ensure proper level 87

Front suspension Inspect, lubricate if necessary 65

Rear suspension Inspect, lubricate if necessary 65

Steering Ensure free operation 89

Tires Inspect condition and pressure 5

Wheels/fasteners Inspect, ensure fastener tightness 91

Frame nuts, bolts, fasteners Inspect, ensure tightness -

Fuel and oil Ensure proper levels

Coolant level Ensure proper level 78

Coolant hoses Inspect for leaks -

Throttle Ensure proper operation 85

Indicator lights/switches Ensure operation 38

Air filter, pre-filter Inspect, clean 83

Air box sediment tube Drain deposits whenever visible 83

Headlamp Check operation, apply Polaris dielec-

tric grease when lamp is replaced

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

tric grease when lamp is replaced

26 68

OPERATION

Starting the Engine

WARNING

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

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

2. Apply the brakes. Engage the park brake.

3. Shift the transmission to neutral.

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

4. 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.

5. If the engine does not start within five seconds, release the ignition switch and wait five seconds. Repeat steps 4 and 5 until the engine starts.

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

CAUTION

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

OPERATION

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 property damage and 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.

NOTE: Practice starting and stopping (using the brakes) until you're familiar

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

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

with the controls.

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

WARNING

OPERATION

Driving Safely

Driving Procedure

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

2. After starting the engine and allowing it to warm up, apply the service brakes, and shift the transmission into gear.

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

4. Release the park brake.

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

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

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

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

OPERATION

Driving Safely

Driving on Slippery Surfaces

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

1. Slow down when entering slippery areas.

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

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

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

CAUTION

Severe damage to the drive train may occur if the AWD is engaged while the wheels are spinning. Always allow the wheels to stop spinning before engaging AWD.

WARNING

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

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

surfaces

OPERATION

Driving Safely

Driving Uphill

Whenever traveling uphill, follow these precautions:

1. Always travel straight uphill.

2. Avoid steep hills

(15° maximum).

3. Keep both feet on

the floor.

4. Proceed at a

steady rate of speed and throttle opening.

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

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

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

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

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

15° maximum

WARNING

OPERATION

Driving Safely

Driving on a Sidehill (Sidehilling)

WARNING

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

Driving Downhill

Whenever descending a hill, follow these precautions:

1. Proceed directly downhill.

2. Slow down.

3. Apply the brakes slightly to aid in slowing.

WARNING

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

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

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

OPERATION

Driving Safely

Driving Through 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.

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

1. Always determine water depths and current before entering.

2. Choose a crossing

where both banks have gradual inclines.

3. Proceed slowly, avoiding rocks and obstacles.

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

sure to the pedal repeatedly until braking action is normal.

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

vices outlined in the Periodic Maintenance Chart beginning on page

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

Floorboard

CAUTION

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 95, and take the vehicle to your dealer at the first opportunity.

OPERATION

Driving Safely

Driving Over Obstacles

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

WARNING

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

OPERATION

Driving Safely

Driving in Reverse

Follow these guidelines when operating in reverse:

1. Back slowly.

2. Apply the brakes lightly for stopping.

3. Avoid turning at sharp angles.

4. Never open the throttle suddenly while backing.

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

WARNING

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

OPERATION

Driving Safely

Parking on an Incline

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

1. Place the transmission in gear.

2. Apply the brakes. Engage the park brake.

3. Turn the engine off.

4. Block the rear wheels on the downhill side.

WARNING

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

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

OPERATION

Driving Safely

Hauling Cargo

WARNING

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

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

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

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

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

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

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

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

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

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

OPERATION

Driving Safely

Hauling Cargo

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

Model Maximum Total

RANGER Crew 1750 lbs. (795 kg) 1000 lbs. (454 kg)

Weight Capacity

(Level Ground)

Maximum Cargo Box

Weight Capacity

WARNING

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

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

OPERATION

Driving Safely

Dumping the Cargo Box

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 a passenger. The rear tires will also catch the rear of a raised box, damaging the vehicle and creating hazardous driving conditions. Never operate this vehicle with the cargo box in the raised position.

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. Engage

the park brake.

3. Dismount the vehicle.

4. Ensure that the cargo is

positioned evenly or toward the front of the cargo box.

5. Release the tailgate by

pulling up on the tailgate latch.

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

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

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

Release Lever

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.

OPERATION

Driving Safely

Towing Loads

WARNING

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

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

page 52. Towing a trailer increases braking distance. Do not tow more than the recommended weight for the vehicle. See the

towing capacity chart below and the specifications charts beginning on page

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

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

Model Total Towed

RANGER

Crew

Load Weight

(Level Ground)

2000 lbs.

(907 kg)

Total Towed

Load Weight

(15° grade)

850 lbs. (386 kg)

To t al Hi t c h

Vertical

Weight

150 lbs.

(68.1 kg)

Maximum

To w in g

Speed

10 mph

(16 kph)

Belt Life

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

OPERATION

Driving Safely

Parking the Vehicle

WARNING

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

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

2. Turn the engine off.

3. Engage the park brake.

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

WARNING

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

Differential Lock

Locking the Differential

The rear axle is equipped with a lockable differential that allows the operator to choose between an open differential or a closed differential. Locking the differential in slippery or low traction conditions helps improve traction.

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

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

CAUTION

OPERATION

2WD

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.

OPERATION

All Wheel Drive (AWD)

The illuminated amber AWD switch indicates that the vehicle is in AWD.

When the AWD switch is on, the front 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.

When the AWD switch is in the center position the differential is locked and the vehicle is in two-wheel drive. See page 57.

When the AWD switch is in the off position, the differential is open and the vehicle is in one-wheel drive for operation on turf or when active traction is not needed.

The AWD switch may be turned on or off while the vehicle is moving. If the switch is turned off while the front hubs are driving, they will not release until the rear wheels regain traction.

CAUTION

AWD Switch

2WD

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

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

1. Stop the vehicle.

2. Operate in reverse for at least 10 feet.

3. Stop completely.

4. Shift into low gear and drive forward.

EMISSION CONTROL SYSTEMS

Noise Emission Control System

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

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

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

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

Crankcase Emission Control System

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

Exhaust Emission Control System

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

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

Electromagnetic Interference

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

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

MAINTENANCE

Periodic Maintenance Chart

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

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

Record maintenance and service in the Maintenance Log beginning on page 124.

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

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.

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

MAINTENANCE

Periodic Maintenance Chart

Maintenance Chart Key

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

E Emission Control System Service - 4 Cycle (California)

Q Have an authorized Polaris dealer perform these services.

WARNING

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

MAINTENANCE

Periodic Maintenance Chart

Perform all services at whichever maintenance interval is reached first.

Item Maintenance Interval

Q Steering - Pre-Ride - Make adjustments as need

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

Tires - Pre-Ride -

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

Brake system - Pre-Ride -

Wheels/fasteners - Pre-Ride -

Frame fasteners - Pre-Ride -

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

XEAir box sediment

tube

Coolant (if applicable)

Headlamp/tail lamp

XEAir filter,

main element

Brake pad wear 10 H Monthly - Inspect periodically

Battery 20 H Monthly - Check terminals; clean; test

X Front Gearcase Oil

(if equipped)

X Middle Gearcase

Oil (if equipped)

X Rear gearcase oil

(if equipped)

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

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

E Emission Control System Service - 4 Cycle (California)

Q Have an authorized Polaris dealer perform these services.

(whichever comes first)

Hours Calendar Miles

- Daily - Drain deposits when visible

- Daily - Check level daily, change

- Daily - Check operation; apply

- Weekly - Inspect; replace as needed

25 H Monthly - Inspect level; change yearly

(Km)

ed. See Pre-Ride Checklist on page 41.

as needed

coolant every 2 years

dielectric grease if replacing

Remarks

Periodic Maintenance Chart

MAINTENANCE

Item Maintenance Interval

XEEngine breather

filter (if equipped)

X Engine oil change

(break-in)

Park brake cable tension

X General

lubrication

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

Steering 50 H 6 M - Lubricate

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

Throttle cable/

ETC switch

Q Park brake cable 50 H 6 M - Inspect; adjust; lubricate;

E Throttle body air

intake ducts/flange

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

Cooling system (if applicable)

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

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

Park brake cable tension

X Perform these procedures more often for vehicles subjected to severe use. E Emission Control System Service - 4 Cycle (California)

Q Have an authorized Polaris dealer perform these services.

(whichever comes first)

Hours Calendar Miles

25 H Monthly - Inspect; replace if necessary

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

25 H 1 M - Check tension, adjust

50 H 3 M - Lubricate all fittings, pivots,

50 H 6 M - Inspect; adjust; lubricate;

50 H 6 M - Inspect duct for proper seal-

50 H 6 M - Inspect coolant strength

100 H 6 M - Check tension, adjust

(Km)

at one month

cables, etc.

replace if necessary

ing/air leaks

needed

seasonally; pressure test system yearly

at one month

Remarks

MAINTENANCE

Periodic Maintenance Chart

Item Maintenance Interval

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

Fuel filter (if external to tank)

X Radiator

(in applicable)

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

Exhaust muffler/ pipe

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

Q Ignition timing 100 H 12 M - Inspect

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

Q Clutches (drive

and driven)

Q Front wheel

bearings

Q Brake fluid 200 H 24 M - Change every two years

Spark arrestor 300 H 36 M - Clean out

Idle speed - Adjust as needed

Q Toe adjustment - Inspect periodically; adjust

Auxiliary brake (if

equipped)

Headlight aim - Adjust as needed

X Perform these procedures more often for vehicles subjected to severe use. E Emission Control System Service - 4 Cycle (California).

Q Have an authorized Polaris dealer perform these services

(whichever comes first)

Hours Calendar Miles

100 H 12 M - Replace yearly

100 H 12 M - Inspect; clean external

100 H 12 M - Inspect

100 H 12 M - Inspect; clean; replace worn

100 H 12 M - Inspect; replace as needed

(Km)

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

surfaces

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

parts

when parts are replaced

- Inspect daily; adjust as needed

Remarks

MAINTENANCE

Lubrication Recommendations

Check and lubricate all components at the intervals outlined in the Periodic Maintenance Chart beginning on page 60, 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.

Brake Fluid DOT 4 Maintain level between fill lines.

Main Gearcase Oil (Transmission)

Front Gearcase Oil Premium Demand Drive Hub

Rear Gearcase Oil Premium ATV Angle Drive

Prop Shaft U-joint Polaris Premium U-Joint

Front Prop Shaft Yoke Polaris Premium U-Joint

Ball Joint (if equipped) Polaris Premium all Season

Premium AGL Synthetic Gearcase Lube

Fluid

Lube

Grease or grease conforming to NLGI No. 2

See page 68.

See page 87.

See page 71.

See page 73.

See page 74.

Locate fittings and grease. See page 66.

Locate fittings and grease (3 pumps maximum).

Locate fitting (back side of struts), grease with grease gun. See page 66.

MAINTENANCE

Lubrication Recommendations

Ball Joint (if equipped)

Prop Shaft

U-Joint

MAINTENANCE

Engine Oil

Always check and change the engine oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 60. Always change the oil filter whenever changing oil.

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.

CAUTION

Mixing brands or using a non-recommended oil may cause serious engine damage. Always use the recommended oil. Never mix oil brands.

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.

MAINTENANCE

Engine Oil

Always check and change the oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 60. 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. Apply the brakes. Start the

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

3. Lift the lever lock to remove the

dipstick. Wipe it dry with a clean cloth.

4. 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.

5. Remove the dipstick and check

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

NOTE: 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.

6. After reinstalling the dipstick, be

sure to seat the lever lock.

Dipstick

{

Safe

Range

Check Level

on Top Side

Safe

MAINTENANCE

Engine Oil

Oil and Filter Change

CAUTION

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

Always change the oil and filter at the intervals outlined in the Periodic Maintenance Chart beginning on page 60. 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 and remove the drain plug.

5. Allow the oil to drain completely.

6. Reinstall the sealing washer on the drain plug.

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

7. Reinstall the drain plug. Torque to 16 +/- 2 ft. lbs. (19-24 Nm).

8. Place shop towels beneath the oil filter. Using an oil filter wrench,

9. Using a clean dry cloth, clean the filter sealing surface on the crank-

10. Lubricate the o-ring on the new filter with a film of fresh engine oil.

11. Install the new filter and turn by hand until the filter gasket contacts

free of burrs, nicks or scratches.

turn the filter counter-clockwise to remove it.

case.

Check to make sure the o-ring is in good condition.

the sealing surface, then turn and additional 1/2 turn.

MAINTENANCE

Engine Oil

Oil and Filter Change

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

13. Shift the transmission to neutral.

14. Apply the brakes. Engage the park brake.

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

16. Stop the engine. Inspect for leaks.

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

18. Dispose of used filter and oil properly.

Gearcases

Gearcase Specification Chart

Gearcase Lubricant Capacity Fill Plug

Main Gearcase

(Transmission)

Front Gearcase Premium Demand

Rear Gearcase Premium ATV

Premium AGL

Synthetic

Gearcase Lube

Drive Hub Fluid

Angle Drive Fluid

15.2 oz. (450 ml)

5 oz.

(150 ml)

18 oz.

(532 ml)

To r q u e

14 ft. lbs.

(19.4 Nm)

8-10 ft. lbs.

(11-13.6 Nm

40-50 ft. lbs.

(54-68 Nm

Drain Plug

To r q u e

14 ft. lbs.

(19.4 Nm)

11 ft. lbs.

(15 Nm)

30-45 in. lbs.

(3-5 Nm)

MAINTENANCE

Gearcases

Transmission (Main Gearcase)

Always check and change the transmission oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 60. Maintain the oil level even with the bottom of the fill plug hole.

Refer to the Gearcase Specifications Chart on page 70 for recommended lubricants, capacities and torque specifications. See page 110 for the part numbers of Polaris products.

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

Oil Check

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.

Fill Plug

MAINTENANCE

Gearcases

Transmission (Main Gearcase)

Oil Change

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

1. Remove the fill plug.

2. Place a drain pan under the drain plug. Remove the drain plug. Drain the oil. Dispose of used oil properly.

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

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

5. Reinstall the drain plug. Torque to specification.

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

7. Reinstall the fill plug. Torque to specification.

8. Check for leaks.

Drain Plug

MAINTENANCE

Gearcases

Front Gearcase

Always check and change the front gearcase oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 60. Maintain the oil level even with the bottom thread of the fill plug hole.

Refer to the Gearcase Specifications Chart on page 70 for recommended lubricants, capacities and torque specifications. See page 110 for the part numbers of Polaris products.

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

Oil Change

1. Support the vehicle securely with a

jackstand.

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

3. Remove the fill plug.

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

5. Remove the drain plug. Drain the oil. Discard used oil properly.

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

7. Add the recommended oil.

8. Reinstall the fill plug. Torque to specification.

9. Check for leaks.

Drain Plug

Fill Plug

MAINTENANCE

Gearcases

Rear Gearcase

Always check and change the rear gearcase oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 60.

Refer to the Gearcase Specifications Chart on page 70 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. Remove the drain plug.

3. Drain the oil. Dispose of used oil properly.

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

tion.

5. Add the recommended oil.

6. Reinstall the fill plug. Torque to specification.

7. Check for leaks.

Fill Plug

Drain Plug

MAINTENANCE

Spark Plugs

CAUTION

Using non-recommended spark plugs can result in serious engine damage. Always use Polaris-recommended spark plugs. Refer to the specifications section beginning on page 108.

Spark Plug Gap/ Torque

Model Electrode Gap New Plug Torque Used Plug Torque

RANGER

Crew

Spark plug condition is indicative of engine operation. The spark plug firing end condition should be read after the engine is warmed up and the vehicle is driven at higher speeds. Immediately check the spark plug for correct color. See page 76.

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

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

(24 Nm)

WARNING

18 ft. lbs.

(24 Nm)

MAINTENANCE

Spark Plugs

Spark Plug Condition

Normal Plug

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

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

Wet Fouled Plug

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

Spark Plug Removal and Replacement

1. Remove the seat to access the engine compartment.

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

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

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

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

cation. See page 75.

MAINTENANCE

Cooling System

Operation

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

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

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

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.

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

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.

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

freeze protection required in your area.

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 60. 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.

CAUTION

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

Coolant Level

Always check and change the coolant at the intervals outlined in the Periodic Maintenance Chart beginning on page 60. Maintain the coolant level between the minimum and maximum marks on the bottle (when the fluid is cool).

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

1. Position the vehicle on a level surface.

2. View the coolant level in

the overflow bottle.

3. If the coolant level is

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

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

dry, there may be a leak in the system. Have the cooling system inspected by your Polaris dealer.

Overflow

Bottle

Radiator Cap

Overflow

Bottle

MAINTENANCE

Cooling System

Radiator Coolant Level

WARNING

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

1. Lift the hood.

2. Slowly remove the radiator cap.

3. View the coolant level through the opening.

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

NOTE: This procedure is required only if the

NOTE: Use of a non-standard pressure cap will

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.

not allow the recovery system to function properly. See your dealer for the correct replacement part.

Radiator Cap

MAINTENANCE

Polaris Variable Transmission (PVT) System

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.).

When To Use Low Range and High Range

Condition Range to Use

Operating at speeds less than 15 MPH (24 km/h) Low

Towing heavy loads Low

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

Operating at speeds greater than 15 MPH (24 km/h) High

MAINTENANCE

PVT System

WARNING

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

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

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

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

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

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

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. Loosen the bottom screws that secure the clutch cover.

2. Allow the water to drain.

3. Tighten the screws.

4. Apply the brakes. Start the engine.

5. Engage the park brake.

6. Shift the transmission to neutral.

7. 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.

8. 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.

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

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

MAINTENANCE

Filter Systems

Air Filter

Always change the air filter at the intervals outlined in the Periodic Maintenance Chart beginning on page 60.

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

2. Remove the air box

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

3. Remove the air filter.

4. Do not attempt to clean

the main element. Install a new air filter.

NOTE: Apply a small amount

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

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

into a suitable container.

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

conditions or at high throttle openings for extended periods.

Air Filter

MAINTENANCE

Spark Arrestor

WARNING

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

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

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

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

Never go under the vehicle while it's inclined.

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

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

2. Shift the transmission to neutral.

Apply the brakes. Start the engine.

3. Purge accumulated carbon from

the system by momentarily revving the engine several times.

4. If carbon is expelled, cover or

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

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

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

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

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

Exhaust

Outlet

Clean-Out

Plugs

MAINTENANCE

Throttle System

WARNING

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

Never start or operate this vehicle if it has a sticking or improperly operating throttle pedal.

Immediately contact your dealer for service if throttle problems arise. Always check the pedal for free movement and return before starting the

engine and occasionally during operation.

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 60. Adjust the freeplay if necessary.

Throttle

Pedal

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).

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 85.

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

6. Tighten the lock nut.

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

Boot

Lock Nut

Adjuster

MAINTENANCE

Brakes

The front and rear brakes are hydraulic disc type brakes activated by the brake pedal. See page 36.

Brake Fluid

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

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

1. Position the vehicle on a level surface.

2. View the brake fluid level at

the reservoir under the hood. The level should be between the upper (MAX) and lower (MIN) level lines.

3. If the fluid level is lower than the upper level line, add brake fluid to

the upper (MAX) line.

4. Apply the brake forcefully for a few seconds and check for fluid

leakage around the fittings.

WARNING

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

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 move-

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

3/64" (1mm)

Park Brake

Release

Park Brake Cable Tension

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

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

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

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.

as needed.

MAINTENANCE

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 60.

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.

Suspension Adjustment

The rear suspension may 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).

Outside Mounting Holes

Inside Mounting Holes

Cam

Rear Spring Adjustment

The rear shock absorber springs are adjusted by rotating the adjustment cam either clockwise or counterclockwise to increase or decrease spring tension.

MAINTENANCE

Seat Belts

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

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

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

releases freely.

3. Check the belt webbing

for wear, cuts or damage. If any irregularities are found, have the seat belt system checked and/or replaced by an authorized Polaris dealer.

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

1. To adjust, loosen the bolts.

2. Reposition both the buckle and retractor. Tighten the bolts.

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

secure the belt on the lap of the center passenger.

Bolts

WARNING

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

MAINTENANCE

Tires

WARNING

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

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

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.

Nut Type Location Nut Torque

1/8" (3 mm)

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

2-Piece Flange Nut

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

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

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

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

MAINTENANCE

Tires

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.

Wheel Removal

1. Apply the brakes. Stop the engine. Place the transmission in gear. Engage the park brake.

2. Loosen the wheel nuts slightly.

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

frame.

4. Remove the wheel nuts and washers. Remove the wheel.

Wheel Installation

1. Apply the brakes.

2. Place the transmis-

sion 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.

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 91.

MAINTENANCE

Lights

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

WARNING

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

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

Headlight Lamp Replacement

1. Open the hood.

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

3. Turn the lamp counterclockwise to remove it.

4. Install the new lamp.

NOTE: Make sure the tab on the

5. Reinstall the harness

lamp locates properly in the housing.

assembly into the headlight assembly.

Wiring

Harness

MAINTENANCE

Lights

Headlight Beam Adjustment

25 ft.

(7.6 m)

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

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

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

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

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

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

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

5. If the headlight needs

adjustment, open the hood.

NOTE: The lights are part of the

6. Turn the adjustment screw

7. Close the hood. Repeat

hood assembly.

to adjust the beam.

Adjustment

Screw

View of driver’s headlight with hood lifted.

steps 4-6 until the beam is properly adjusted.

8" (20 cm)

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.

MAINTENANCE

Vehicle Immersion

CAUTION

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.

3. Filter replacement is required if water is present.

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

5. Remove the spark plugs.

6. Turn the engine over several times using the electric start.

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

NOTE: Attempt to start the engine. If necessary, repeat the drying procedure.

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

whether you succeed in starting it or not.

NOTE: If water has been ingested into the PVT follow the procedure on page

82 for drying.

MAINTENANCE

Battery

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

Conventional 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.

WARNING

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

Antidote:

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

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

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

MAINTENANCE

Battery

WARNING

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

Battery Removal

1. Open the hood.

2. On conventional batteries,

remove the battery vent tube.

3. Disconnect the black (nega-

tive) battery cable first.

4. Disconnect the red (positive)

battery cable last.

5. Lift the battery out of the

vehicle. Be careful not to tip a conventional battery sideways, which could spill electrolyte.

CAUTION

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.

Polaris Ranger Crew User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual