Polaris Ranger ETX User Manual

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RA NGER® ETX

RA NGER

RA NGER CREW

Owner's Manual

for Maintenance and Safety

570

570 EPS

570

570 EPS

WARNING

For videos and more information

about a safe riding experience with

your Polaris vehicle, scan this QR

code with your smartphone.

Read, understand, and follow all of the instructions

and safety precautions in this manual and on all product labels.

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

WARNING

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

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

WELCOME

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

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

• Snowmobiles • RZR® sport vehicles

• All-terrain vehicles (ATVs) • GEM® electric vehicles

• Low emission vehicles (LEVs) • VICTORY® motorcycles

• RANGER® utility vehicles • INDIAN® motorcycles

•BRUTUS® work vehicles • POLARIS POWER® generators

• SLINGSHOT® three wheel motorcycles • POLARIS DEFENSE® combat vehicles

We believe POLARIS sets a standard of excellence for all utility and recreational vehicles manufactured in the world today. Many years of experience have gone into the engineering, design, and development of your POLARIS vehicle, making it the finest machine we’ve ever produced.

For safe and enjoyable operation of your vehicle, be sure to follow the instructions and recommendations in this owner’s manual.

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

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

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

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

Printed in U.S.A. 2016 RANGER ETX, RANGER 570/570 EPS, RANGER CREW 570/570 EPS Owner’s Manual P/N 9926455

TABLE OF CONTENTS

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

Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Features and Controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Winch Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

Emission Control Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92

POLARIS Products. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94

Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95

Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98

Maintenance Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103

Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104

INTRODUCTION

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

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

The safety alert symbol indicates a potential personal injury hazard.

DANGER

A DANGER indicates a hazardous situation that, if not avoided, will result in death or serious injury.

WARNING

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

CAUTION

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

NOTICE

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

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

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

INTRODUCTION

WARNING

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

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

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

• Review the safety DVD and take the free online Recreational Off Highway Vehicle Association (ROHVA) training course at www.rohva.org.

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

• No person under the age of 12 may ride as a passenger in this vehicle. All riders must be able to sit with backs against the seat, both feet flat on the floor and both hands on the steering wheel (if driving) or on a passenger hand hold.

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

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

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

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

INTRODUCTION

Vehicle Identification Numbers

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

VIN (stamped into main frame)

####

Vehicle Model Number: ________________________________________________________________________

Frame VIN: _________________________________________________________________________________

Engine Serial Number: ________________________________________________________________________

Key Number: ________________________________________________________________________________

Key

Number

INTRODUCTION

European Vibration and Noise

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

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

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

• Instrument and calibration uncertainty

• Variations in the machine such as wear of components

• Variation of machine operators such as experience or physique

• Ability of the worker to reproduce typical work during measurements

• Environmental factors such as ambient noise or temperature

SAFETY

Safe Riding Gear

The driver and all passengers must wear helmet, eye protection, gloves, long-sleeve shirt, long pants, over-the-ankle boots and seat belt at all times. Protective gear reduces the chance of injury.

Helmet

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

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

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

Helmet

Eye Protection

051039

0006.31

Long

Sleeves

Gloves

Long Pants

Over-the-Ankle

Boots

SAFETY

Safe Riding Gear

Eye Protection

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

Gloves

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

Boots

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

Clothing

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

Rider Comfort

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

SAFETY

Max Payload

Warning

Safety Labels and Locations

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

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

Seat Belt/Drive Responsibly Warning

Shift Caution

Proper Use Warning

Max Payload Warning

WARNING

RANGER Never Exceed If Total Payload

ETX 35 mph (56 kph) 700 lbs. (317 kg)

570/570 EPS 35 mph (56 kph) 850 lbs. (385 kg)

CREW 570/570 EPS 35 mph (56 kph) 1000 lbs. (453 kg)

Exceeds

7181296

Shift Caution

CAUTION

To avoid transmission damage, shift only when vehicle is stationary and at idle. APPL Y BRAKE TO STA RT. When this vehicle is not in operation, or unattended, place shift in the park

position.

7181060

SAFETY

Rollovers have caused

severe injuries and death,

even on flat, open areas.

Proper Use Warning

Safety Labels and Locations

Seat Belt/Drive Responsibly Warning

WARNING

Improper vehicle use can result in SEVERE INJURY or DEATH

Be Prepared

• Fasten seat belts.

• Wear an approved helmet and protective gear.

• ALWAYS use vehicle cab nets and/or doors.

• Each rider must be able to sit with back against seat, feet flat on the

floor, and hands on steering wheel or hand holds. Stay completely inside the vehicle.

Drive Responsibly

Avoid loss of control and rollovers:

• Avoid abrupt maneuvers, sideways sliding, skidding or fishtailing,

and never do donuts.

• Slow down before entering a turn.

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

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

• Avoid sidehilling (riding across slopes).

Be Sure Riders Pay Attention and Plan Ahead

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

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

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

LOCATE AND READ OWNER’S MANUAL. FOLLOW ALL INSTRUCTIONS AND WARNINGS. ALWAYS REVIEW SAFETY VIDEO AND TAKE ROHVA TRAINING (rohva.org).

7181110

Proper Use Warning

Require Proper Use of Your Vehicle

Do your part to prevent injuries:

• Do not allow careless or reckless driving.

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

license.

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

• Do not allow operation on public roads (unless designated

for off-highway vehicle access) - collisions with cars and trucks can occur.

• ETX / 570 / 570 EPS: Do not exceed seating capacity: 2 occupants.

• CREW 570 / 570 EPS: Do not exceed seating capacity: 4 occupants.

SAFETY

Safety Labels and Locations

Passenger/Tire Pressure Warning

WARNING

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

• Never carry passengers in cargo box.

WARNING

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

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

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

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

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

RANGER MIDSIZE RANGER

MIDSIZE

MAXIMUM CARGO BOX LOAD TIRE PRESSURE IN PSI (KPa) MAXIMUM WEIGHT CAPACITY INCLUDES

WEIGHT OF OPERATOR, PASSENGER, CARGO AND ACCESSORIES

Read Operation & Maintenance Manual for more detailed loading information.

500 lbs. (226 kg)

FRONT 10 (69)

REAR 10 (69)

1000 lbs.

(454 kg)

RANGER

MIDSIZE CREW

500 lbs. (226 kg)

FRONT 10 (69)

REAR 14 (96)

1250 lbs.

(547 kg)

Clutch Cover Warning

WARNING

• Moving parts hazard under belt-clutch guard. To

prevent serious injury, do not operate vehicle with guard removed.

• Do not modify engine or clutch. Doing so can cause

part failure, possible imbalance, and excessive engine RPM which can result in serious injury or death.

7175488

Clutch Cover Warning

LSV-EV

500 lbs.

(226 kg)

FRONT 20 (138)

REAR 20 (138)

1000 lbs.

(454 kg)

7181056

SAFETY

WARNING

Operator Safety

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

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

described.

• Never allow anyone under the age of 16 to operate this vehicle and never allow anyone

without a valid driver's license to operate this vehicle.

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

vehicle.

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

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

• The driver and all passengers must wear helmet, eye protection, gloves, long-sleeve shirt,

long pants, over-the-ankle boots and seat belt at all times.

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

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

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

vehicle during operation.

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

product labels.

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

when braking on hills or during turns.

• This vehicle is for off road use only. Never operate on public roads (unless marked for off-

road use). Always avoid paved surfaces.

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

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

visibility and operating conditions, and your experience.

• Never attempt jumps or other stunts.

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

Always follow the inspection procedures described in this manual.

SAFETY

Operator Safety

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

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

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

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

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

• Always follow proper procedures for climbing hills as described in this manual. See page

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

• Always follow the proper procedures outlined in this manual for traveling downhill and for braking on hills. See page 40. Check the terrain carefully before descending a hill. Never travel downhill at high speed. Avoid going downhill at an angle, which would cause the vehicle to lean sharply to one side. Travel straight down the hill where possible.

• Always check for obstacles before operating in a new area. Never attempt to operate over large obstacles such as large rocks or fallen trees. Always follow the proper procedures outlined in this manual when operating over obstacles. See page 39.

• 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. See page 42. W et 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.

SAFETY

Operator Safety

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

proper tire pressure as specified on safety labels.

• Never modify this vehicle through improper installation or use of non-POLARIS

approved accessories.

• Never exceed the stated load capacity for this vehicle. Cargo should be properly

distributed and securely attached. Reduce speed and follow the instructions in this manual for hauling cargo or pulling a trailer. Allow a greater distance for braking.

• Always place the transmission in PARK before getting out of the vehicle.

• Always engage the park brake (if equipped) when leaving the vehicle unattended.

• Always stop the engine before refueling. Remove flammable material containers from the

box before filling them with fuel. Make sure the refueling area is well ventilated and free of any source of flame or sparks. Gasoline is extremely flammable. See page 18 for fuel safety warnings.

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

by someone under the age of 16 or without a driver’s license and proper training, or accidental starting.

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

Equipment Modifications

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

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

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

SAFETY

WARNING

Operator Safety

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

Age Restrictions

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

Never operate with a passenger under the age of 12. All riders must be able to sit with backs against the seat, both feet flat on the floor and both hands on the steering wheel (if driving) or on a passenger hand hold.

Operating Without Instruction

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

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

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

Using Alcohol or Drugs

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

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

Seat Belts

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

All riders must wear seat belts at all times.

Protective Apparel

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

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

SAFETY

Operator Safety

Cab Nets

Riding in this vehicle without using the cab nets (or doors, if equipped) increases the risk of serious injury or death in the event of an accident or rollover. Always use the cab nets (or doors) while riding in this vehicle.

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

Failure to Inspect Before Operating

Failure to inspect and verify that the vehicle is in safe operating condition before operating increases the risk of an accident. Always perform the pre-ride inspection before each use of your RANGER to make sure it's in safe operating condition. See page 36.

Always follow all inspection and maintenance procedures and schedules described in this owner's manual. See page 61.

Operating With a Load on the Vehicle

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

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

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

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

on the vehicle.

Always follow these guidelines:

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

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

2. Verify tire pressure.

3. Use extra caution when operating.

SAFETY

Operator Safety

Handling Gasoline

Gasoline is highly flammable and explosive under certain conditions.

• Always exercise extreme caution whenever handling gasoline.

• Always turn off the engine when refueling.

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

• Always use an approved gasoline container to store fuel and remove the container from the vehicle before filling to avoid fuel ignition due to electrical static discharge.

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

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

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

clothing.

Exposure to Exhaust

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

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

Operating a Damaged Vehicle

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

Operating at Excessive Speeds

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

Operating on Pavement

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

SAFETY

Operator Safety

Operating on Public Roads

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

Turning Improperly

Turning improperly could cause loss of traction, loss of control, accident or rollover. Always follow proper procedures for turning as described in this owner's manual. Never turn abruptly or at sharp angles. Never turn at high speeds. Practice turning at slow speeds before attempting to turn at faster speeds.

Jumps and Stunts

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

Operating in Unfamiliar Terrain

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

Improper Hill Climbing

Climbing hills improperly can cause loss of control or vehicle rollover. Always follow proper procedures for climbing hills as described in this owner's manual. See page 40.

Descending Hills Improperly

Improperly descending a hill could cause loss of control or rollover. Always follow proper procedures for traveling down hills as described in this owner's manual. See page 40.

Stalling While Climbing a Hill

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

If all forward speed is lost:

• Apply the brakes.

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

light brake pressure to control speed.

If you begin rolling downhill:

• Never apply engine power.

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

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

light brake pressure to control speed.

SAFETY

Operator Safety

Improper Tire Maintenance

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

Operating on Slippery Terrain

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

Skidding or sliding due to loss of traction can cause loss of control or rollover (if tires regain traction unexpectedly). Always follow proper procedures for operating on slippery surfaces as described in this owner's manual. See page 39.

Operating on Frozen Bodies of Water

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

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

Unauthorized Use of the Vehicle

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

Hot Exhaust Systems

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

FEATURES AND CONTROLS

ROPS Cab

Frame

Hip Bars

Headlights

Front Bumper/Brush Guard

Radiator

Tailgate

Muffler

(Spark Arrester)

Cargo Box Release Lever

Electrical

Compartment

(CREW)

Electrical

Compartment

(ETX / 570 / 570 EPS)

Seat Belts

Fuel Cap

Cargo Box

Storage

Compartment

(CREW)

Vehicle Components

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

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

92.

FEATURES AND CONTROLS

Console

Cup

Holder

Steering Wheel

Adjustment

Lever

Instrument

Cluster

Ignition/Light

MODE Button

Switch

Gear Selector

(Shifter)

AWD

Switch

Storage

Tray

12V Auxiliary

Storage

Compartment

Outlet

Auxiliary Outlet

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

Mode Button

The yellow button located near the instrument cluster is used to toggle through mode options available. See pages 30-34.

Ignition Switch/Light Switch

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

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

to the LIGHTS ON position after starting the engine.

FEATURES AND CONTROLS

AWD

Differential Lock

Differential Unlock

Console

Adjustable Steering Wheel

The steering wheel can be tilted upward or downward for rider preference. Lift and hold the adjustment lever toward you while moving the steering wheel upward or

downward. Release the lever when the steering wheel is at the desired position.

All Wheel Drive (AWD) Switches

Each model is equipped with an A WD switch that controls the All Wheel Drive System. The type of AWD switch used depends on the type of All Wheel Drive system in your model.

Standard AWD Switch

The standard AWD switch has two positions:

• All Wheel Drive (AWD)

• Two Wheel Drive (2WD) See page 46 for operating instructions.

AWD/Differential Lock Switch

The AW D/Differential Lock Switch has three positions:

• All Wheel Drive (AWD)

• Differential Lock/Two Wheel Drive (2WD)

• Differential Unlock (1WD/Turf Mode) See page 47 for operating instructions.

AWD

2WD

AWD/ADC Drive Mode Switch

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

• All Wheel Drive (AWD/4X4)

• ADC All Wheel Drive (ADC 4X4)

•TURF Mode (1WD)

• Two Wheel Drive (2WD/2X4) See page 49 for operating instructions.

FEATURES AND CONTROLS

Gear Shifter

Console

Gear Selector

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

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

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

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

POLARIS dealer can assist in resolving any shifting problems.

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

Using Low Range

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

• Operating in rough terrain or over obstacles

• Loading the vehicle onto a trailer

• Towing heavy loads

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

FEATURES AND CONTROLS

Throttle

Pedal

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.

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

Park Brake Lever (if equipped)

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

Tip: This feature will not operate properly if

the park brake connector or switch (under the hood) malfunctions or becomes disconnected, or if the switch has moved. Check for disconnection, then see your dealer or other qualified service person promptly if this feature fails to operate properly.

1. To set the park brake, apply the

brakes.

2. Pull the park brake lever upward as

far as possible.

3. T o release the park brake, apply the

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

RELEASE

Park Brake

Release

Park Brake

Lever

SET

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.

Electronic Power Steering (EPS)

Electronic power steering (if equipped) engages when the ignition key is turned to the ON position. EPS remains engaged whether the vehicle is moving or idle.

To conserve battery power, the EPS will shut down 5 minutes after the engine is stopped if the key remains in the ON position. The EPS warning indicator will illuminate to indicate the EPS has shut down. Turn the key off and on to reset the unit.

If the light remains on after starting the engine, the EPS system is inoperative. Your POLARIS dealer can assist.

See page 30 for EPS warning indicator information.

Fuel Cap

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

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

Fuel Cap

FEATURES AND CONTROLS

Seat Belts

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

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

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

To wear the seat belt properly, follow this procedure:

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

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

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

3. Release the strap, it will self tighten.

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

Latch Plate

Buckle

Seat Belt Inspection

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

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

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

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

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

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

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

Do not use bleach, dye or household detergents. Rinse the entire length of the belt webbing. Use a garden hose to flush out the retractor and latch housings regularly.

FEATURES AND CONTROLS

Cab Nets

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

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

Securing a Net

1. After entering the vehicle, insert the lower net rod into the net mount on the floor. Make

sure the ball at the end of the rod is properly secured in the slot at the base of the mount.

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

frame.

Opening a Net

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

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

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

Top Latch

Net Rod

Rod Mount

FEATURES AND CONTROLS

ROPS

Label

ROHVA

Label

Rollover Protective Structure (ROPS)

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

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

operating practices outlined in this manual to avoid vehicle rollover.

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

Storage Compartments

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

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 43-44.

Extreme Use 30 AH Battery (Non-EPS Models Only)

If your factory-installed battery cannot maintain a charge because of operation in extreme cold or with multiple electrical accessories, you may need to purchase a 30 AH battery and a battery strap bracket. Your POLARIS dealer can assist. Your dealer can provide any installation procedures that may differ for an extreme use battery. See page 94 for the part numbers of POLARIS products.

1. Fully charge the new battery before installing it. See page 87.

2. To install the 30 AH battery, remove the existing battery. See page 85.

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

future use.

4. Install the new battery. See page 86.

FEATURES AND CONTROLS

Rider

Information

Center

Speedometer

Indicator

Lamps

MODE Button

Instrument Cluster

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

Speedometer

The speedometer displays vehicle speed in either miles per hour (MPH) or kilometers per hour (km/h). See page 32.

Indicator Lamps

Lamp Indicates Condition

Vehicle Speed

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

Over Temperatur e This lamp illuminates to indicate an overheated engine. If the

EPS Warning This indicator illuminates briefly when the key is turned to the ON

Neutral This lamp illuminates when the transmission is in neutral and the

High Beam This lamp illuminates when the headlamp switch is set to high beam.

Helmet/Seat Belt This lamp is a reminder to the operator to ensure all riders are

Check Engine This indicator appears if an EFI-related fault occurs. Do not operate

indicator flashes, the overheating condition remains, and the system will automatically reduce engine power.

position. If the light remains on, the EPS system is inoperative. Your POLARIS dealer can assist.

ignition key is in the ON position.

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

the vehicle if this warning appears. Serious engine damage could result. Your POLARIS dealer can assist.

FEATURES AND CONTROLS

Instrument Cluster

Rider Information Center

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

The information center is set to display standard units of measurement and a 12-hour clock at the factory. To change to metric and/or a 24-hour clock, see page 32.

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

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

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

2. Fuel Gauge - The segments of the fuel gauge show the level of fuel in the fuel tank.

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

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

POLARIS dealer can assist.

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

and programmable service hour interval.

4. Under / Over V o ltage - This warning usually indicates that the vehicle is operating at an

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

5. Clock - The clock displays time in a 12-hour or 24-hour format. See page 32 for

resetting instructions.

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

interval has been reached. Your POLARIS dealer can provide scheduled maintenance. See page 32 for resetting instructions.

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

on 4X4, AWD or ADC 4X4).

8. Turf Mode Indicator (if equipped) - This indicator illuminates when the operator

unlocks the differential. See page 48.

Trip 1

RPM

FEATURES AND CONTROLS

Instrument Cluster

Rider Information Center

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

Display Units (Standard/Metric)

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

Tip: To exit the set-up mode at any time, wait 10 seconds. The display automatically exits and returns

to the odometer display.

Standard Di splay Metric Display

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

1. Turn the key to the OFF position.

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

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

desired setting.

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

option.

5. Repeat the procedure to change remaining display settings.

Clock Mode

Tip: The clock must be reset any time the battery has been disconnected or discharged.

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

display.

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

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

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

5. Repeat steps 3-4 twice to set the 10-minute and 1-minute segments. After completing the

1-minute segment, step 4 will save the new settings and exit the clock mode.

6. Turn the key to the OFF position.

FEATURES AND CONTROLS

Instrument Cluster

Rider Information Center

Odometer Mode

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

Trip Meter Mode

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

Hour Meter Mode

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

Tachometer Mode

The engine RPM is displayed digitally.

Tip: Small fluctuations in the RPM from day to day may be normal because of changes in humidity,

temperature and elevation.

Programmable Service Interval

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

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

2. Press and hold the MODE button.

3. When the service hours flash, press and release the MODE button to advance the hours

to the desired setting (including OFF). Press and hold the MODE button to set the new service hour interval.

Diagnostic Display Mode

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

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

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

Inactive codes are stored in the history of the unit.

FEATURES AND CONTROLS

Suspect Parameter

Number (SPN)

Error Code

Number (0-9)

Failure Mode Indicator (FMI)

Instrument Cluster

Rider Information Center

Engine Error Codes

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

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

1. If the error codes are not displayed, use the

MODE button to toggle until “Ck ENG” displays on the main line of the display.

2. Press and hold the MODE button to enter

the diagnostics code menu.

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

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

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

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

OPERATION

WARNING

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

Break-In Period

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

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

Engine and Drivetrain Break-in

1. Fill the fuel tank with gasoline. Heed the gasoline warnings on page 18.

2. Check the oil level. See page 64. Add the recommended oil as needed to maintain the oil

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

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

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

6. Pull only light loads.

7. Check fluid levels of transmission and all gearcases after the first 25 hours of operation

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

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

level in the normal (safe) operating range.

vehicle operation and handling.

inspection checklist. See page 36.

and every 100 hours thereafter.

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 breakin period as recommended. Pull only light loads. Avoid aggressive acceleration and high speed operation during the break-in period.

If a belt fails, always clean any debris from the clutch air duct and from the clutch and engine compartments when replacing the belt. See page 73.

OPERATION

Pre-Ride Inspection

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

Item Remarks Page

Brake system/pedal travel Ensure proper operation 25, 78 Brake fluid Ensure proper level 78 Park gear Ensure vehicle does not roll when in PARK. Ensure

Front suspension Inspect, lubricate if necessary 63 Rear suspension Inspect, lubricate if necessary 63 Steering Ensure free operation 79 Tires Inspect condition and pressure 80 Wheels/fasteners Inspect, ensure fastener tightness 80 Frame nuts, bolts, fasteners Inspect, ensure tightness Fuel and oil Ensure proper levels 26, 64 Coolant level Ensure proper level 72 Coolant hoses Inspect for leaks Throttle Ensure proper operation 25 Indicator lights/switches Ensure operation Air filter, pre-filter Inspect, clean 76 Headlamp Check operation, apply POLARIS dielectric grease

Brake light/tail lamp Check operation, apply POLARIS dielectric grease Seat Belts Check length of belt for damage, check latches for Cab Nets Check for wear or damage, ensure proper installation 28

PARK light illuminates.

when lamp is replaced when lamp is replaced proper operation

82 83 27

OPERATION

Starting Engine

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

2. Sit in the driver's seat and fasten the seat belt. Secure the cab nets (or doors).

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

4. Do not press the throttle pedal while starting the engine. Turn the ignition key past the

ON/RUN position to ST ART. 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.

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

Stopping the Engine

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

2. Place the transmission in PARK.

3. Turn the engine off.

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

5. Engage the park brake (if equipped).

WARNING! A rolling vehicle can cause serious injury. Always place the transmission in PARK and engage the park brake (if equipped) when stopping the engine.

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

the vehicle.

Braking

1. Release the throttle pedal completely.

2. Press on the brake pedal evenly and firmly.

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

Tip: When the throttle pedal is released completely and the engine speed drops near an idle, the

vehicle has no engine braking.

OPERATION

Driving Procedure

1. Wear a helmet, eye protection,

gloves, long-sleeve shirt, long pants and over-the-ankle boots.

2. Sit in the driver's seat and fasten the

seat belt.

3. Start the engine and allow it to warm

up.

4. Always use the cab nets (or doors)

while riding in this vehicle.

5. Apply the service brakes and shift

the transmission into gear.

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

7. Release the park brake (if equipped).

8. Keeping both hands on the steering wheel, slowly release the brakes and depress the

throttle with your right foot to begin driving.

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

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

vehicle.

Driving with a Passenger

1. Perform the pre-ride inspection. See page 36.

2. Make sure all passengers are at least 12 years of age and tall enough to comfortably and

safely sit in a passenger seat with the seat belt secured, put both feet on the floor and grasp the hand hold.

3. Make sure all passengers are wearing helmet, eye protection, gloves, long-sleeve shirt,

long pants and over-the-ankle boots.

4. Make sure all passengers secure their seat belt.

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

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

pages 11-11.

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

8. Slow down. Always travel at a speed appropriate for your skills, your passengers’ skills,

and operating conditions. Avoid unexpected or aggressive maneuvers that could cause discomfort or injury to a passenger.

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

and distance for braking.

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

OPERATION

WARNING

Sideways

skid

Turn in

direction of

skid

Driving On Slippery Surfaces

Skidding or sliding can cause loss of control or rollover (if tires regain traction unexpectedly). When operating on slippery surfaces such as ice or loose gravel, reduce speed and use extra caution to reduce the chance of skidding or sliding out of control. Do not operate on excessively slippery surfaces.

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

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

2. Slow down before entering slippery areas.

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

which can cause skids.

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

NOTICE: Severe damage to the drive train may occur if the AWD is engaged while the wheels are

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

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

brakes during a skid.

Driving Over Obstacles

Follow these precautions when operating over obstacles:

1. Always check for obstacles before operating

in a new area.

2. Look ahead and learn to read the terrain. Be

constantly alert for hazards such as logs, rocks and low hanging branches.

3. Travel slowly and use extra caution when

operating on unfamiliar terrain. Not all obstacles are immediately visible.

4. A void operating over large obstacles such as

large rocks and fallen trees. If unavoidable, use extreme caution and operate slowly.

5. Always have all passengers dismount and move away from the vehicle before operating

over an obstacle that could cause a rollover.

OPERATION

Driving Uphill

Whenever traveling uphill, follow these precautions:

1. Avoid excessively steep hills.

2. ADC Models: Always operate in low gear

and engage ADC 4X4 before ascending or descending a hill.

3. Always travel straight uphill.

4. Keep both feet on the floor.

5. Always check the terrain carefully before

ascending any hill. Never climb hills with excessively slippery or loose surfaces.

6. Proceed at a steady rate of speed and

throttle opening. Never open the throttle suddenly.

7. Never go over the crest of a hill at high speed. An obstacle, a sharp drop, or another

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

Driving Downhill

When driving downhill, follow these precautions:

1. Avoid excessively steep hills.

2. ADC Models: Always operate in low gear

and engage ADC 4X4 before ascending or descending a hill.

3. Drive straight downhill. Avoid descending

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

4. Slow down.

5. Apply the brakes slightly to aid in slowing.

OPERATION

Driving on a Sidehill (Sidehilling)

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

If crossing a sidehill is unavoidable, follow these precautions:

1. Slow down.

2. Exercise extreme caution.

3. Avoid crossing the side of a steep hill.

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

descending a hill.

Driving in Reverse

Follow these precautions when operating in reverse:

1. Always check for obstacles or people

behind the vehicle. Always inspect left and right fields of vision before backing.

2. Always avoid backing downhill.

3. Back slowly.

4. Apply the brakes lightly for stopping.

5. Avoid turning at sharp angles.

6. Never open the throttle suddenly.

Parking the Vehicle

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

2. When parking inside a garage or other structure, be sure that the structure is well

ventilated and that the vehicle is not close to any source of flame or sparks, including any appliance with pilot lights.

3. Place the transmission in PARK.

4. Turn the engine off.

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

the vehicle.

6. Engage the park brake (if equipped).

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

OPERATION

Driving Through Water

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

NOTICE: If your vehicle becomes immersed or is operated in water that exceeds the floor level,

Follow these procedures when operating through water:

1. Determine water depths and current before

2. Choose a crossing where both banks have

3. Proceed slowly, avoiding rocks and obstacles.

4. Avoid operating through deep or fast-flowing

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

5. After leaving water, always dry the brakes by applying light pressure to the pedal

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

service is required before starting the engine. Your POLARIS dealer can provide this service. If it's impossible to bring the vehicle in before starting the engine, perform the service outlined on page 75, and take the vehicle in for service at the first opportunity.

entering water.

gradual inclines.

water.

Floorboard

repeatedly until braking action is normal.

Periodic Maintenance Chart beginning on page 61. Give special attention to engine oil, transmission oil, front and rear gearcases (if equipped), and all grease fittings.

Parking on an Incline

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

1. Apply the brakes.

2. Place the transmission in PARK.

3. Turn the engine off.

4. Slowly release the brake pedal and make

sure the transmission is in PARK before exiting the vehicle.

5. Engage the park brake (if equipped).

6. Block the rear wheels on the downhill side.

OPERATION

WARNING

Hauling Cargo

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

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

REDUCE SPEED AND ALLOW GREATER DISTANCES FOR BRAKING WHEN HAULING CARGO. Always load the cargo box with the load as far forward and as low as possible. When operating over rough or hilly terrain, reduce speed and cargo to maintain stable driving

conditions. Always operate the vehicle with extreme care when hauling or towing loads. Always operate in low gear and engage ADC 4X4 (if equipped) when transporting heavy loads and/or

when towing. 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 downhil l.

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

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

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

Model

RANGER ETX

RANGER 570/570 EPS

RANGER CREW 570/570 EPS 1250 lbs. (567 kg) 500 lbs. (227 kg)

WARNING! Driving with passengers in the cargo box can result in severe injury or death. Never allow passengers to ride in the cargo box. Passengers must always ride in the cab with seat belts fastened securely.

Maximum Capacities

(Level Ground)

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

Cargo Box

OPERATION

Towing Loads

Towing improperly can alter vehicle handling and may cause loss of control or brake instability. Always follow these precautions when towing:

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

2. Always operate in low gear and engage ADC 4X4 (if equipped) when transporting heavy

loads and/or when towing.

3. When towing a disabled RANGER vehicle, place the disabled vehicle’s transmission in

neutral. Do not operate the vehicle faster than 10 MPH (16 km/h) when towing.

4. Do not operate the vehicle faster than 10 MPH (16 km/h) when towing. See page 43.

Towing a trailer increases braking distance.

5. Do not tow more than the recommended weight for the vehicle. See the towing capacity

chart below and the specifications charts beginning on page 92.

6. 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.

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

Model Total Towed

RANGER ETX 1500 lbs. (680.4 kg) 850 lbs. (386 kg) 150 lbs. (68.1 kg) 10 MPH (16 km/h)

RANGER 570/570 EPS 1500 lbs. (680.4 kg) 850 lbs. (386 kg) 150 lbs. (68.1 kg) 10 MPH (16 km/h)

RANGER

CREW 570/570 EPS

Load Weight

(Level Ground)

1500 lbs. (680.4 kg) 850 lbs. (386 kg) 150 lbs. (68.1 kg) 10 MPH (16 km/h)

Total Towed

Load Weight

(15° grade)

Total Hitch

Vertical

Weight

Maximum

Towing

Speed

Belt Life

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

OPERATION

Release

Lever

Dumping the Cargo Box

1. Select a level site to dump the cargo box. Do not

attempt to dump or unload the vehicle while parked on an incline.

2. Apply the brakes.

3. Place the transmission in PARK.

4. Engage the park brake (if equipped).

5. Dismount the vehicle.

6. Ensure that the cargo is positioned evenly or

toward the front of the cargo box.

7. Release the tailgate latches.

WARNING! If the weight distribution on the box is located toward the rear of the box when the release lever is pulled forward, the box may dump unexpectedly and cause serious injury to the operator or bystanders. Never operate the dump lever without ensuring that the load is positioned evenly or at the front of the box.

8. Stand clear and pull up on the cargo box release lever. Lift the front of the cargo box to

dump the cargo.

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

10. Close the tailgate and secure both tailgate latches.

WARNING! Operating the vehicle while th e cargo box is raised could result in severe injury. The box could close unexpectedly and cause injury to the driver or passenger. The rear tires will also catch the rear of a raised box, damaging the vehicle and creating hazardous driving conditions. Never operate this vehicle with the cargo box in the raised position.

OPERATION

All Wheel Drive (AWD) System

For models equipped with a lockable rear differential, refer to the All Wheel Drive/Rear Differential section beginning on page 47. For models equipped with Active Descent Contr ol (ADC), refer to the All Wheel Drive/Active Descent Control System section beginning on page 49.

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

When in AWD, the demand drive unit will automatically engage any time the rear wheels lose traction. When the rear wheels regain traction, the demand drive unit will automatically disengage.

There is no limit to the length of time the vehicle may remain in AWD.

Engaging/Disengaging AW D

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

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

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

Initially, the vehicle's electronic system will not enable the AWD until the engine RPM is below 3100. Once enabled, the A WD remains en abled until the AWD switch is turned off. If the switch is turned off while the demand drive unit is movi ng, it will not disengage until the rear wheels regain traction.

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

NOTICE: Switching to AWD while the rear wheels are spinning or slipping may cause severe drive

shaft and gearcase damage. Always switch to AWD while the rear wheels have traction or are at rest.

AWD

2WD

OPERATION

AWD

Differential Lock

Differential Unlock

All Wheel Drive/Rear Differential System

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

For models equipped with Active Descent Control (ADC), r efer to the All Wheel Drive/Active Descent Control System section beginning on page 49. For models that are not equipped with a lockable rear differential or ADC, refer to the All Wheel Drive section beginning on page 46.

Engaging A WD

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

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

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

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

NOTICE: Switching to AWD while the rear wheels are spinning may cause severe drive shaft and

clutch damage. Always switch to AWD while the rear wheels have traction or are at rest.

Disengaging AWD

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

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

1. Stop the vehicle.

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

3. Stop completely.

4. Shift into low gear and drive forward.

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

other qualified service person for service.

OPERATION

All Wheel Drive/Rear Differential System

Locking the Differential

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

Unlocking the Differential (TURF Mode)

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

WARNING! Operating in TURF mode (if equipped) when on sloped, uneven, or loose terrain could cause loss of control and result in serious injury or death. One rear wheel may slip and lose traction or may lift up and grab when it touches the ground again.

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

NOTICE: Damage to the differential can occur if it is engaged while the vehicle is traveling at high

WARNING! Never operate in TURF mode (if equipped) while op erating on a hill or other irregular

terrain. Always move the AWD switch to AWD before ascending or descending a hill.

speeds or while the rear wheels are spinning. Slow the vehicle to nearly stopped before engaging the differential.

OPERATION

All Wheel Drive/Active Descent Control System

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

For models that are not equipped with a lockable rear differential or ADC, refer to the All Wheel Drive section beginning on page 46.

Drive Mode Operation

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

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

when towing.

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

See page 50 for Active Descent Control (ADC) System information.

WARNING! Operate in TURF mode only as needed to protect smooth, level surfaces from tire damage. DO NOT operate in TURF mode when climbing or descending hills, when sidehilling, or when operating on uneven, loose, or slippery terrain such as sand, gravel, ice, snow, obstacles, and water crossings.

Drive Mode Switch

Press and release the top of the switch to toggle through the drive mode options, which display in the information center of the gauge for several seconds.

Press and release the bottom of the switch to toggle to a previous option.

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

NOTICE: Switching to 4X4 or ADC 4X4

while the rear wheels are spinning may cause severe drive shaft and gearcase damage. Always switch to 4X4 or ADC 4X4 while the rear wheels have traction or are at rest.

Rider

Information

Center

Drive Mode

Switch

OPERATION

Active Descent Control (ADC) System (if equipped)

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

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

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

Engaging Active Descent Control

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

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

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

Disengaging Active Descent Control

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

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

• The transmission is shifted to neutral or park

WINCH GUIDE

WARNING

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

Improper winch use can result in SEVERE INJURY or DEATH. Always follow all winch instructions and warnings in this manual.

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

Winch Safety Precautions

1. Read all sections of this manual.

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

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

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

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

when operating winch.

6. Never attempt to “jerk” a load attached to the winch with a moving vehicle. See the

Shock Loading section on page 58.

7. Always keep the area around the vehicle, winch, winch cable and load clear of people

(especially children) and distractions while operating the winch.

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

9. Always be sure that at least five (5) full turns of winch cable are wrapped around the

winch drum at all times. The friction provided by this wrapped cable allows the drum to pull on the winch cable and move the load.

10. Always apply your vehicle’s park brake and/or park mechanism to hold the vehicle in

place during winching. Use wheel chocks if needed.

11. Always align the vehicle and winch with the load directly in front of the vehicle as much

as possible. Avoid winching with the winch cable at an angle to the winching vehicle’s centerline whenever possible.

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

A. Look at the winch drum occasionally. Never let the winch cable “stack” or accumulate at one

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

B. If stacking occurs, stop winching. Follow step 15 on page 56 to feed and rewind the cable

evenly before continuing the winch operation.

WINCH GUIDE

Winch Safety Precautions

13. Never winch up or down at sharp angles. This can destabilize the winching vehicle and

possibly cause it to move without warning.

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

15. The winch motor may become hot during winch use. If you winch for more than 45

seconds, or if the winch stalls during operation, stop winching and permit the winch to cool down for 10 minutes before using it again.

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

winching a load.

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

wearing heavy gloves.

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

under load.

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

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

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

your winch if this occurs.

22. Always inspe ct your winch and winch cable before each use.

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

components.

24. Unplug the remote control from the vehicle when the winch is not in use to prevent

inadvertent activation and use by unauthorized persons.

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

will shorten the life of the cable.

WINCH GUIDE

WARNING

Winch Operation

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

Tip: Consider practicing the operation and use of your winch before you actually need to use it in the

field.

Improper winch use can result in SEVERE INJURY or DEATH. Always follow all winch instructions and warnings in this manual.

Each winching situation is unique.

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

• Proceed slowly and deliberately.

• Never hurry or rush during winching.

• Always pay attention to your surroundings.

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

• Always remember that your winch is very powerful.

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

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

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

damaged cable.

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

3. Always apply your vehicle’s park brake and/or

park mechanism to hold the vehicle in place during winching. Use wheel chocks if needed.

Hook Strap

WINCH GUIDE

NO YES

Winch Operation

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

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

A. Attach the hook itself onto the load or use a tow strap or

chain to secure the load to the winch cable.

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

is designed to stretch.

WARNING! Never use a recovery strap when winching due to the excessive energy that can be released if the winch cable breaks. This can result in SEVERE INJURY or DEATH. See the Shock Loading section on page 58.

B. Never hook the winch cable back onto itself. This will damage the winch cable and may result

in winch cable failure.

WARNING! Replace the winch cable at the first sign of damage to prevent SEVERE INJURY or DEAT H in the event of failure. For your safety , always replace POLARIS winch parts (including the cable) with genuine POLARIS replacement parts available at your authorized POLARIS dealer.

C. If possible, keep the winch cable aligned with the centerline of the winching vehicle. This will

help the spooling of the winch cable and reduce the load on the fairlead.

D. If freeing a stuck vehicle by attaching to a tree, use an item such as a tow strap to avoid

damaging the tree during winch operation. Sharp cables and chains can damage and even kill trees. Please remember to TreadLightly® (treadlightly.org).

E. Before operating the winch , be sure that the safety latch on

the winch cable hook is fully seated when the load is attached.

F. Never operate your winch with a damaged hook or latch.

Always replace damaged parts before using the winch.

5. Never remove the hook strap from the hook.

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

YES

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

WINCH GUIDE

Winch Operation

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

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

“damper” on the winch cable. A damper can be a heavy jacket, tarp, or other soft, dense object. A damper can absorb much of the energy released if a winch cable breaks when

winching. Even a tree limb can help as a damper if no other items are available to you. B. Lay the damper on top of the mid-point of the winch cable length that is spooled out. C. On a long pull, it may be necessary to stop winching so that the damper can be repositioned

to the new mid-point of the winch cable. Always release the tension on the winch cable before

repositioning the damper. D. Avoid being directly in line with the winch cable whenever possible. Also, never permit others

to stand near or in line with the winch cable during winch operation.

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

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

11. The ONLY time a winch-equipped vehicle should be moving when using the winch is when that vehicle itself is stuck. The winch-equipped vehicle should NEVER be in motion to “shock” load the winch cable in an attempt to move a second stuck vehicle. See the Shock Loading section on page 58. For your safety , always follow these guidelines when winching a vehicle free:

A. Release the winch clutch and spool out the necessary length of winch cable. B. Align the winch cable as close as possible to the winching vehicle’s centerline. C. Attach the winch cable hook to the anchor point or the stuck vehicle’s frame following

instructions in this manual. D. Re-engage the clutch on the winch. E. Slowly winch in the slack in the winch cable. F. Select the proper vehicle gear to propel the stuck vehicle in the direction of winching. G. Shift to the lowest gear available on the stuck vehicle. H. Slowly and carefully apply vehicle throttle and winch together to free the vehicle. I. Stop winching as soon as the stuck vehicle is able to propel itself without the help of the

winch. J. Detach the winch cable hook. K. Rewind the winch cable evenly back onto the winch drum following the instructions in this

manual.

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

WINCH GUIDE

Winch Operation

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

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

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

A. Release the clutch on the winch. B. Feed out the winch cable th at is unevenly bunched up in one area. C. Re-engage the winch clutch. D. Have an assistant pull the winch cable tightly with about 100 lbs. (45 kg) of tension using the

hook strap.

E. Slowly winch the cable in while your assistant moves the end of the winch cable back and

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

F. Doing this reduces the chances of the winch cable “wedging” itself between lower layers of

winch cable.

WINCH GUIDE

Winch Cable Care

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

WARNING! Use of worn or damaged cable could lead to sudden failure and SEVERE INJURY.

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

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

cable.

A. A kinked winch cable made of wire rope is shown at

right. Even after being “straightened out,” this cable has already been permanently and severely damaged. Promptly discontinue use of a winch cable in this condition.

B. A kinked winch cable made of wire rope that has been

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

C. A winch cable made of synthetic rope should be

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

D. Also replace the winch cable if there are fused or

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

WINCH GUIDE

Shock Loading

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

Shock loading may tension a winch cable beyond its strength and cause the cable to break. The end of a broken winch cable under such high loading can cause SEVERE INJURY or DEATH to you and other bystanders.

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

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

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

2. Never quickly turn the winch ON and OFF repeatedly (“jogging”). This puts extra load

on the winch, winch cable, and generates excessive heat from the motor. This is a form of shock loading.

3. Never tow a vehicle or other object with your winch. Towing an object with a winch

produces shock loading of the cable even when towing at slow speeds. Towing from a winch also positions the towing force high on the vehicle. This can cause instability of the vehicle and possibly lead to an accident.

4. Never use recovery straps with your winch. Recovery straps are designed to stretch and

can store energy. This stored energy in the recovery strap is released if a winch cable fails making the event even more hazardous. Similarly, never use elastic “bungie” cords for winching.

5. Never use the winch to tie down a vehicle to a trailer or other transportation vehicle. This

type of use also causes shock loading that can cause damage to the winch, winch cable, or vehicles used.

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

WINCH GUIDE

Winch Maintenance and Service Safety

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

DEATH. Always follow all winch instructions and warnings in this manual.

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

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

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

accidental activation of the winch

4. For your safety, always replace POLARIS winch parts (including the cable) with

genuine POLARIS replacement parts available at your authorized POLARIS dealer.

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

designed synthetic rope as the winch cable.

6. Never replace a synthetic-rope winch cable with a consumer-grade polymer rope such as

can be purchased in a hardware store. Although they may look similar, they are NOT alike. A polymer rope not designed for winch use will stretch and store excessive energy when winching.

WARNING! Failure of a stretched rope under winching conditions will release all of the stored energy. This will increase the chances of SEVERE INJURY or DEATH.

EMISSION CONTROL SYSTEMS

Emissions Label (under hood)

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

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

Crankcase Emission Control System

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

Exhaust Emission Control System

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

The emissions label is located under

Electromagnetic Interference

This spark ignition system complies with Canadian ICES-002. This vehicle complies with the EMC requirements of European directives 97/24/EC and

2004/108/EC. Non-ionizing Radiation: This vehicle emits some electromagnetic energy . People with active

or non-active implantable medical devices (such as heart monitoring or controlling devices) should review the limitations of their device and the applicable electromagnetic standards and directives that apply to this vehicle.

MAINTENANCE

Periodic Maintenance Chart

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

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

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

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

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

Record maintenance and service in the Maintenance Log beginning on page 103.

Tip: Service and adjustments are important for proper vehicle operation. If you're not familiar with safe

service and adjustment procedures, a qualified dealer can perform these operations.

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

Severe Use Definition

• Frequent immersion in mud, water or sand

• Frequent or prolonged operation in dusty environments

• 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. Your POLARIS dealer can assist.

Maintenance Chart Key

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

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

WARNING! Improperly performing the procedures marked with a “D” could result in component failure

and lead to serious injury or death. Have an authorized POLARIS dealer or other qualified person perform these services.

MAINTENANCE

Periodic Maintenance Chart

Perform all services at whichever maintenance interval is reached first.

Item Maintenance Interval

Steering Front suspension Rear suspension Tires Brake fluid level Brake pedal travel Brake system Wheels/fasteners Frame fasteners Engine oil level

Ź Air filter, pre-filter - Daily - Inspect; clean often; replace as needed

Coolant - Daily - Check level

Ź Power steering unit (if equipped) - Daily - Inspect daily; clean often

Headlamp/tail lamp - Daily - Check operation; apply dielectric

Ź Air filter - Weekly - Inspect; replace as needed

Brake pad wear 10 H Monthly - Inspect periodically

Battery 20 H Monthly - Check terminals; clean; test Fuel System 20 H Monthly - Inspect; cycle key to pressurize fuel

Ź Engine breather 25 H 1 M - Inspect; replace as needed Ź Demand drive fluid (extreme use) 25 H 1 M - Change fluid every 25 hours if ADC is

Ź Demand drive fluid (front

gearcase) (if equipped)

Ź Middle Gearcase oil (if equipped) 25 H 1 M - Perform a break-in oil level check Ź Rear gearcase oil (if equipped) 25 H 1 M - Perform a break-in oil level check Ź Transmission oil 25 H 1 M - Perform a break-in oil level check Ź Engine oil change (break-in) 25 H 1 M - Perform a break-in oil change at one

Ź General lubrication 50 H 3 M - Lubricate all fittings, pivots, cables, etc.

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

D Steering 50 H 6 M - Lubricate

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

D Throttle cable/Release switch 50 H 6 M 500 (800) Inspect; adjust; lubricate; replace if

Throttle body air intake ducts/ flange

Drive belt 50 H 6 M 500 (800) Inspect; adjust; replace as needed Cooling system (if applicable) 50 H 6 M - Inspect coolant strength seasonally;

Ź Perform these procedures more often for vehicles subjected to severe use. D Have an authorized POLARIS dealer or other qualified person perform these services.

(whichever comes first)

Hours Calendar Miles (Km)

Pre-Ride Make adjustments as needed.

25 H 1 M - Perform a break-in oil level check

50 H 6 M 500 (800) Inspect duct for proper sealing/air leaks

See Pre-Ride Checklist on page 36.

grease to electrical connections if replacing lamps

pump; check lines and fittings for leaks and abrasion

subjected to extreme use. See page 69.

month

necessary

pressure test system yearly

Remarks

Periodic Maintenance Chart

MAINTENANCE

Item Maintenance Interval

Ź Oil lines, fasteners 50 H 6 M - Inspect for leaks and loose fittings Ź Engine oil and filter change 100 H 6 M 1000 (1600) Change oil and filter; (perform a break-

Ź Front Gearcase oil (if equipped) 100 H 6 M - Inspect level; change yearly Ź Middle Gearcase oil (if equipped) 100 H 6 M - Inspect level; change yearly Ź Rear gearcase oil (if equipped) 100 H 6 M - Inspect level; change yearly Ź Transmission oil 100 H 12 M 1000 (1600) Change fluid

D Fuel system 100 H 12 M 1000 (1600) Cycle key to pressurize fuel pump;

Ź Radiator (if applicable) 100 H 12 M - Inspect; clean external surfaces Ź Cooling Hoses 100 H 12 M - Inspect for leaks Ź Engine mounts 100 H 12 M - Inspect

Exhaust muffler/pipe 100 H 12 M - Inspect Drive shafts 100 H 12 M 1000 (1600) Remove and grease

Ź Spark plug 100 H 12 M 1000 (1600) Inspect; replace as needed

D Ignition timing 100 H 12 M - Inspect

Ź Wiring 100 H 12 M - Inspect for wear, routing, security; apply

DŹClutches 100 H 12 M 1000 (1600) Inspect; clean; replace worn parts D Front wheel bearings 100 H 12 M - Inspect; replace as needed

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

Suspension bushings 250 H 24 M 2000 (3200) Inspect; replace if necessary Spark arrester 300 H 36 M - Clean out

Ź Coolant - 60 M - Replace coolant

Valve clearance 500 H - 5000 (8000) Inspect; adjust as needed Idle speed - Adjust as needed

D Toe adjustment - Inspect periodically; adjust when parts DŹAuxiliary brake (if equipped) - Inspect daily; adjust as needed

(whichever comes first)

Hours Calendar Miles (Km)

in oil change at one month)

check for leaks at fill cap, fuel lines/rail and fuel pump; replace lines every two years

dielectric grease to connectors subjected to water, mud, etc.

are replaced

Remarks

Headlight aim - Adjust as needed

Lubrication Recommendations

Check and lubricate all components at the intervals outlined in the Periodic Maintenance Chart beginning on page 61, or more often under severe use, such as wet or dusty conditions. Items not listed in the chart should be lubricated at the general lubrication interval.

Item Lube Method

Engine Oil PS-4 5W-50 4-Cycle Oil See page 64 (570) or page 66 (ETX). Brake Fluid DOT 4 Brake Fluid See page 78. Main Gearcase Oil

(Transmission) Demand Drive (Front

Gearcase) Fluid Front Prop Shaft Yoke U-Joint Grease Locate fittings and grease (3 pumps

AGL Gearcase Lubricant & Transmission Fluid

Demand Drive Fluid See page 69.

See page 68.

maximum).

MAINTENANCE

Full

Add

Oil Fill

Cap

Oil Filter

Drain Plug

Sealing Washer

Engine Oil (570)

Always check and change the oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 61. Always use the recommended engine oil. See page 63.

NOTICE: Allowing dirt or debris to enter the engine

Oil Check

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

1. Position the vehicle on a level surface.

2. Place the transmission in PARK.

3. Always clean away all dirt and debris from

4. Reinstall and tighten the dipstick.

5. Remove the dipstick and check the oil level.

6. Add the recommended fluid as needed.

7. Reinstall and tighten the dipstick.

can result in serious engine damage. Always clean away all dirt and debris from the dipstick area before removing the dipstick.

the dipstick area before removing the dipstick. Remove the dipstick. Wipe it dry with a clean cloth.

Maintain the oil level in the safe range between the FULL and ADD marks. Do not overfill.

Dipstick

Oil and Filter Change

Always check and change the oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 61. Always change the oil filter whenever changing oil.

The engine drain plug is located on the bottom of the crankcase.

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

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

MAINTENANCE

Drain Plug Access

Engine Oil (570)

Oil and Filter Change

3. Clean the area around the drain plug.

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

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

5. Allow the oil to drain completely.

6. Reinstall the sealing washer on the drain plug.

Tip: The sealing surfaces on drain plug and crankcase

should be clean and free of burrs, nicks or scratches.

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

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

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

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

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

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

13. Reinstall and tighten the dipstick.

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

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

16. Stop the engine. Inspect for leaks.

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

18. Dispose of used filter and oil properly.

Oil Filter

MAINTENANCE

Oil Dipstick (Check/Fill)

Upper Oil Fill

Engine Oil (ETX)

Always check and change the oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 61. Always use the recommended engine oil. See page 63.

NOTICE: Allowing dirt or debris to enter the engine can result

Oil Check

The oil dipstick is located on the lower engine, behind the seat. Access the dipstick through the right rear wheel well. Remove the dipstick to check the oil level and to add oil. An additional oil fill hole is located at the top of the engine. Add oil through either the dipstick hole or the upper fill hole. Access the upper fill hole cap through the cargo box access panel.

1. Position the vehicle on a level surface.

2. Place the transmission in PARK.

3. Always clean away all dirt and debris from the

4. Reinstall and tighten the dipstick.

5. Remove the dipstick and check the oil level.

6. Add the recommended fluid as needed.

7. Reinstall and tighten the dipstick.

in serious engine damage. Always clean away all dirt and debris from the dipstick area before removing the dipstick.

dipstick area before removing the dipstick. Remove the dipstick. Wipe it dry with a clean cloth.

Maintain the oil level in the safe range between the FULL and ADD marks. Do not overfill.

Full

Add

Oil and Filter Change

Always check and change the oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 61. Always change the oil filter whenever changing oil.

The engine drain plug is located on the bottom of the crankcase.

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

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

MAINTENANCE

Spring

Filter

Sealing

Washer

Drain

Plug

O-Ring

Filter Cover

Engine Oil (ETX)

Oil and Filter Change

3. Clean the area around the drain plug.

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

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

5. Allow the oil to drain completely.

6. Install a new sealing washer on the drain plug.

Tip: The sealing surfaces on drain plug and crankcase

should be clean and free of burrs, nicks or scratches.

7. Reinstall the drain plug. Torque to 11-13 ft. lbs. (14.5-17.5 Nm).

8. Using a clean dry cloth, clean the oil filter cover on the crankcase.

9. Place shop towels beneath the filter cover to catch oil drips. Remove the cover screws and remove the cover to access the oil filter.

10. Remove the oil filter and spring, retaining the spring for reinstallation.

11. Using a clean dry cloth, clean the surface of the crankcase.

12. Lubricate the o-ring for the new filter with a film of fresh engine oil. Check to make sure the o-ring is in good condition. Install the o-ring to the filter cover.

13. Reinstall the oil filter spring, then install the new filter.

14. Reinstall the oil filter cover and o-ring. Torque the screws to 88 in. lbs. (10 Nm).

15. Fill the sump with 1.75 quarts (1.65 l) of the recommended oil.

16. Reinstall the upper fill cap (if removed) and tighten the dipstick.

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

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

19. Stop the engine. Inspect for leaks.

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

21. Dispose of used filter and oil properly.

MAINTENANCE

Fill Plug

View from

rear of vehicle

View from rear left

side of vehicle

Drain Plug

Gearcases

Gearcase Specification Chart

Gearcase Lubricant Capacity Fill Plug(s)

570 Main Gearcase (Transmission)

ETX Main Gearcase (Transmission)

Demand Drive (Front Gearcase)

AGL Gearcase

Lubricant &

Transmission Fluid

Demand Drive Fluid 9.3 oz.

41 oz.

(1200 ml)

44 oz.

(1300 ml)

(275 ml)

10-14 ft. lbs. 10-14 ft. lbs.

(1 1-13.6 Nm)

Torque

(14-19 Nm) (14-19 Nm)

8-10 ft. lbs.

Drain Plug

Torque

10-14 ft. lbs.

(14-19 Nm)

10-14 ft. lbs.

(14-19 Nm)

11 ft. lbs.

(15 Nm)

Transmission (Main Gearcase)

Always check and change the transmission oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 61. Maintain the oil level even with the bottom thread of the fill plug hole.

Refer to the Gearcase Specifications Chart for recommended lubricants, capacities and torque specifications. See page 94 for the part numbers of POLARIS products.

Fluid Check

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

1. Position the vehicle on a level surface.

2. Remove the fill plug.

3. Check the fluid level.

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

5. Reinstall the fill plug. Torque to specification.

Fluid Change

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

1. Remove the fill plug.

2. Place a drain pan under the drain plug.

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

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

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

6. Reinstall the fill plug. Torque to specification.

7. Check for leaks. Discard used fluid properly.

MAINTENANCE

Drain Plug

Fill Plug

Gearcases

Front Gearcase (Demand Drive)

Always check and change the demand drive fluid at the intervals outlined in the Periodic Maintenance Chart beginning on page 61. Maintain the oil level even with the bottom thread of the fill plug hole.

Refer to the Gearcase Specifications Chart on page 68 for recommended lubricants, capacities and torque specifications. See page 94 for the part numbers of POLARIS products.

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

• operation in ADC mode for prolonged periods

• constant ADC operation on hilly or mountainous terrain

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

Tip: If the front gearcase makes excessive noise during ADC operation, change the demand drive fluid.

If the noise continues, please see your POLARIS dealer or other qualified service person for service.

Oil Check

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

1. Position the vehicle on a level surface.

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

3. Add the recommended oil as needed.

4. Reinstall the fill plug. Torque to specification.

Oil Change

1. Support the vehicle securely with a jackstand.

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

3. Remove the fill plug.

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

5. Remove the drain plug. Drain the oil.

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

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

8. Reinstall the fill plug. Torque to specification.

9. Check for leaks.

10. Discard used oil properly.

MAINTENANCE

Spark Plugs

Spark Plug Recommendations

Refer to the specifications section beginning on page 92 for the recommended spark plug type for your vehicle. Always torque spark plugs to specification.

NOTICE: Using non-recommended spark plugs can result in serious engine damage. Always use

Spark Plug Gap/Torque

RANGER 570/570 EPS .031” (.7-.9 mm) 9 ft. lbs. (12 Nm)

CREW 570/570 EPS

Spark Plug Inspection

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

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

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

2. Remove the spark plug cap. Using the spark plug wrench provided in the tool kit,

3. Reverse the procedure for spark plug installation.

4. Torque to specification.

POLARIS-recommended spark plugs or their equivalent.

Model Electrode Gap New or Used Plug

RANGER ETX .031” (.7-.9 mm) 9 ft. lbs. (12 Nm)

RANGER

.031” (.7-.9 mm) 9 ft. lbs. (12 Nm)

Torque

remove the plug by rotating it counter-clockwise.

Normal Plug

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

The tip should not be white. A white insulator tip indicates overheating, caused by use of an improper spark plug or incorrect throttle body adjustments.

Wet Fouled Plug

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

MAINTENANCE

Cooling System

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

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

Some coolant level drop on new vehicles is normal as the system is purging itself of trapped air. Observe coolant levels and maintain as recommended by adding coolant to the overflow bottle.

Adding or Changing Coolant

POLARIS recommends the use of POLARIS Antifreeze 50/50 Premix. This antifreeze is already premixed and ready to use. Do not dilute with water. See page 94 for the part numbers of POLARIS products.

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

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

Radiator and Cooling Fan

Always check and clean the screen and radiator fins at the intervals outlined in the Periodic Maintenance Chart beginning on page 61. Do not obstruct or deflect air flow through the radiator by installing unauthorized accessories in front of the radiator or behind the cooling fan. Interference with the radiator air flow can lead to overheating and consequent engine damage.

NOTICE: Washing the vehicle with a high-pressure hose could damage the radiator fins and impair

the radiator's effectiveness. Using a high-pressure system is not recommended.

MAINTENANCE

Radiator

Cap

Overflow

Bottle Cap

Cooling System

Overflow Bottle Coolant Level

Always check and change the coolant at the intervals outlined in the Periodic Maintenance Chart beginning on page 61. Maintain the coolant level between the minimum and maximum marks on the bottle (when the fluid is cool).

1. Position the vehicle on a level surface.

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

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

Tip: If coolant must be added often, or if the overflow bottle

runs completely dry, there may be a leak in the system. Your POLARIS dealer can inspect the cooling system.

Radiator Coolant Level

1. Lift the hood.

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

2. Slowly remove the radiator cap.

3. View the coolant level through the opening.

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

Tip: This procedure is required only if the cooling system has been drained for maintenance and/or

repair. But if the overflow bottle has run dry, the level in the radiator should also be inspected.

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

MAINTENANCE

WARNING

Step 3

Step 7

POLARIS Variable Transmission (PVT) System

Failure to comply with the instructions in this warning can result in severe injury or death. Do not modify any component of the PVT system. Doing so may reduce its strength so that a failure

may occur at a high speed. The PVT system has been precision balanced. Any modification will cause the system to be out of balance, creating vibration and additional loads on components.

The PVT system rotates at high speeds, creating large amounts of force on clutch components. As the owner, you have the following responsibilities for your own safety and the safety of others:

• Always follow all recommended maintenance procedures. Always look for and remove debris inside and around the clutch and vent system when replacing the belt.

• See your dealer or other qualified service person 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.

Belt Replacement/Debris Removal

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

WARNING! Failure to remove ALL debris when replacing the belt could result in vehicle damage, loss of control and severe injury or death.

1. Position the vehicle on a level surface. Block the

wheels to prevent vehicle movement. Place the transmission in neutral.

2. Lift the cargo box.

3. Remove the clutch cover screws using a 3/8”

socket with ratcheting wrench and extension.

4. Pull the bottom of the cover outward and over

the suspension to remove it.

5. Make sure the cover gasket does not fall out of the groove when removing the cover.

6. Squeeze the belt together so that it submarines further into the driven clutch, creating

slack in the belt between the clutches.

7. Remove the belt by using the slack to pull part of the belt off the driven clutch.

Step 5 Step 6

MAINTENANCE

Step 8

Step 9

Remove ALL Debris

POLARIS Variable Transmission (PVT) System

Belt Replacement/Debris Removal

8. Rotate the driven clutch by hand until the belt is completely off.

9. Slide the front of the belt out from between the drive clutch and inner clutch cover to completely remove it.

10. Remove all debris wrapped in and around the PVT system.

11. Remove all debris from the entire clutch air duct passage.

12. Check for signs of damage to seals on the transmission and engine. If any seals appear to be damaged, your vehicle requires prompt service. Your POLARIS dealer can assist.

Tip: 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.).

13. To install a belt, place one end of the belt over the driving clutch. Route the belt over the top of the driven clutch and down into the groove of the clutch to allow slack in the belt. Rotate the driven clutch by hand until the belt falls into place.

14. Reinstall the clutch cover in the reverse order of removal, fitting the top of the cover into place, then working the bottom of the cover over the suspension.

15. Ins tall all clutch cover screws. Torque to 4-5 ft. lbs. (5.5-6.5 Nm).

MAINTENANCE

POLARIS Variable Transmission (PVT) System

PVT Drying

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

1. Position the vehicle on a level surface.

2. Remove the red drain plug on the outer clutch cover. Allow the water to drain completely. Reinstall the drain plug.

3. Place the transmission in PARK.

4. Start the engine.

5. 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 five (5) seconds.

6. Allow the engine RPM to settle to idle speed. Apply the brakes. Shift the transmission to the lowest available range.

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

8. Your vehicle requires service as soon as possible. Your POLARIS dealer can assist.

Vehicle Immersion

NOTICE: If your vehicle becomes immersed, major engine damage can result if the machine is not

thoroughly inspected. Take the vehicle in for service before starting the engine. Your POLARIS dealer can provide this service.

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

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

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

3. Remove the spark plugs. Turn the engine over several times using the electric start.

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

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

6. Take the vehicle in for service as soon as possible, whether you succeed in starting it or not. Your POLARIS dealer can provide the required service.

7. If water has been ingested into the PVT follow the procedure on page 75 for drying.

Drain Plug

MAINTENANCE

Cover Clips

View of Under-Box Area

Filter Systems

Air Filter

Always change the air filter at the intervals outlined in the Periodic Maintenance Chart beginning on page 61.

1. Lift the cargo box.

2. Clean all dirt and debris from the air box area.

3. Unlatch the two (2) cover clips and carefully remove the air box cover. Inspect the seal between the cover and air box to ensure the seal is not torn and has been maintaining a proper seal.

4. Inspect the air filter and air box for dirt, debris, oil or water. If the filter needs to be replaced, remove the worm gear clamp from the filter neck with a flat-blade screwdriver or 6mm socket. Slide the filter rearward to remove it from the boot, then lift it straight upward and out of the air box.

5. With the filter removed, clean the intake boot and air box thoroughly and wipe well with a clean, dry cloth.

NOTICE: Dirt or debris in the intake boot could result in severe engine damage. Always clean all dirt

6. Reinstall the air filter (if clean) or install a new air filter (if soiled). Do not attempt to

NOTICE: Use of a non-POLARIS-approved air filter may cause engine damage. Always use a

7. Make sure the filter is fully seated on the intake boot and that there is no gap between the

8. Reinstall the air box cover. Make sure both hinges are fully inserted. Secure the cover

and debris from the intake boot before installing the filter.

clean the air filter.

POLARIS-approved replacement filter. See page 94 for the part numbers of POLARIS products.

filter and boot after installation. Tighten the worm gear clamp to 24 in. lbs. (2.7 Nm).

clips.

MAINTENANCE

WARNING

Spark Arrester

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

• Do not perform service on the spark arrester while the system is hot. Exhaust system temperatures can reach 1000° F. Allo w 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 operate without the spark arrestor.

• 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 arrester clean-out plug located on the bottom of the muffler.

2. Place the transmission in PARK.

3. Start the engine.

4. Purge accumulated carbon from the system by momentarily revving the engine several

times.

5. If carbon is expelled, cover or plug the exhaust outlet and rap on the pipe around the

clean-out plug while revving the engine several more times.

6. If particles are still suspected to be in the muffler , elevate the rear of the vehicle one foot

higher than the front. Block the wheels.

7. Repeat steps 4 and 5 until no more particles are expelled when the engine is revved.

8. Stop the engine. Allow the arrester to cool.

9. Reinstall the arrester plug and remove the outlet cover or plug.

MAINTENANCE

Brakes

The front and rear brakes are hydraulic disc type brakes. Press down on the brake pedal to engage the brakes. See page 25.

Brake Fluid

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

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

Change the brake fluid every two years and any time the fluid becomes contaminated, the fluid level is below the minimum, or if the type and brand of the fluid in the reservoir are unknown. See page 63 for fluid recommendations.

1. Position the vehicle on a level surface.

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

3. If the fluid level is lower than the upper level line, open the hood and 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.

Brake Fluid

Reservoir

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. Check brake discs for signs of cracks, excessive corrosion, warping or other damage. Clean any grease using an approved brake cleaner or alcohol.

WARNING! Do not apply WD-40 or any petroleum product to brake discs. These types of products are flammable and may also reduce the friction between the brake pad and caliper.

5. Inspect the brake disc spline and pad wear surface for excessive wear . Change pads when worn to .030” (0.762 mm).

.030” (0.762 mm)

MAINTENANCE

Cam

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 61.

1. Position the vehicle on a level surface.

2. Lightly turn the steering wheel left and right.

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

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

Spring Adjustment

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

MAINTENANCE

WARNING

Tires

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

Tire Tread Depth

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

Axle and Wheel Nut Torque Specifications

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

Do not lubricate the stud or the lug nut.

Nut Type Location Nut Torque

1/8” (3 mm)

Lug Nut (Aluminum Wheels)

Nut and Washer (Steel Wheels)

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

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

+90° (1/4 Turn)

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

Front 80 ft. lbs. (108.5 Nm)

MAINTENANCE

Tires

Wheel Removal

1. Apply the brakes.

2. Place the transmission in PARK.

3. Stop the engine.

4. Loosen the wheel nuts slightly.

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

6. Remove the wheel nuts and washers. Remove the wheel.

Wheel Installation

1. Place the transmission in PARK.

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

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

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

4. Carefully lower the vehicle to the ground.

5. Torque the wheel nuts to specification. See page 80.

Power Steering Unit

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

MAINTENANCE

Fuses

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

The fuse box is located in the electrical compartment under the left rearmost seat. Spare fuses are provided in the fuse box.

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

Fuse Size Feature Supported

5A Brake Light 10A Drive System, Fuel Pump 20A EFI, Power Steering (if equipped),

20A Circuit

Breaker

Lights

Poor lighting can result in reduced visibility when driving. Headlight and taillight lenses become dirty during normal operation. Clean lights frequently and replace burned out lamps promptly . Do not operate this vehicle at night or in low light conditi ons until the headlight is replaced. Always make sure lights are adjusted properly for best visibility.

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

Lights, Accessories

Fan

Headlight Lamp Replacement

1. Access the headlamp wiring harnesses through the front wheel wells.

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

2. Unplug the headlamp from the wiring

harness. Be sure to pull on the connector, not on the wiring.

3. Turn the lamp counter-clockwise to remove

it.

4. Install the new lamp.

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

the housing.

5. Reinstall the harness assembly into the

headlight assembly.

Connector

MAINTENANCE

25 ft.

(7.6 m)

8” (20 cm)

Lights

Headlight Beam Adjustment

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

2. Measure the distance from the floor to the center of the headlight and make a mark on

the wall at the same height.

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

headlights.

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

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

5. If a headlight needs adjustment, locate the adjustment

screw at the back of the headlight.

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

screw.

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

Adjustment

Screw

Brake Lights

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

1. Turn the ignition switch to the ON position.

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

pedal travel. If the light doesn't come on, check the bulb.

MAINTENANCE

WARNING

Lower

Mark

Upper

Mark

Battery

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

Antidote:

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

oil. Call physician immediately. Eyes: Flush with water for 15 minutes and get prompt medical attention. Batteries produce explosive gases. Keep sparks, flame, cigarettes, etc. away. V entilate when charging

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

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

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

Battery Fluid (Conventional Battery)

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

Add only distilled water . T ap water cont ains minerals that are harmful to a battery.

MAINTENANCE

WARNING

Battery

Battery Removal

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

1. Remove the seat (rear seat on CREW 570) to access the battery compartment.

2. On conventional batteries, remove the battery vent

tube.

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

Disconnect the red (+) battery cable last.

4. Remove the battery hold-down strap.

5. Lift the battery out of the vehicle. Be careful not to tip

a conventional battery sideways, which could spill electrolyte.

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

and one cup water to prevent damage to the vehicle.

MAINTENANCE

Battery

Battery Installation

Using a new battery that has not been fully charged can damage the battery and result in a shorter life. It can also hinder vehicle performance. Follow the battery charging instructions on page 87 before installing the battery.

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

Before installing the 30 AH battery, remove the plastic spacer at the bottom of the battery compartment. Save the spacer for future use.

1. Ensure that the battery is fully charged.

2. Place the fully charged battery in the battery holder.

3. With conventional batteries, install the battery vent tube (sealed batteries do not have a vent tube). The vent tube must be free of obstructions and securely installed. Route the tube away from the frame and vehicle body to prevent contact with electrolyte.

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

4. Coat the terminals with dielectric grease or petroleum jelly.

5. Connect and tighten the red (+) cable first. Connect and tighten the black (-) cable last.

6. Verify that cables are properly routed. Cables should be safely tucked away at the front and rear of the battery.

7. Install the battery hold-down strap.

Battery Storage

Whenever the vehicle is not used for a period of three months or more, remove the battery from the vehicle, ensure that it's fully charged, an d store it out of the sun in a cool, dry place. Check battery voltage each month during storage and recharge as needed to maintain a full charge. See page 87.

POLARIS recommends maintaining battery charge by using a POLARIS Battery Tender charger or by charging about once a month to make up for normal self-discharge. Battery Tender can be left connected during the storage period, and will automatically charge the battery if the voltage drops below a pre-determined point. See page 94 for the part numbers of POLARIS products.

MAINTENANCE

Battery

Battery Charging (Conventional Battery)

1. Remove the battery from the vehicle to prevent damage from leaking or spilled electrolyte during charging. See page 85.

2. Charge the battery with a charging output no larger than 1/10 of the battery’s amp/hr

rating. Charge as needed to raise the specific gravity to 1.270 or greater.

3. Reinstall the battery . See page 86. Make sure the positive terminal is toward the driver’s

side of the vehicle.

Battery Charging (Sealed Battery)

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

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

The single most important thing about maintaining a sealed battery is to keep it fully charged. Since the battery is sealed and the sealing strip cannot be removed, you must use a voltmeter or multimeter to measure DC voltage.

WARNING! An overheated battery may explode, causing severe injury or death. Always watch charging times carefully. Stop charg ing if the battery becomes very warm to the touch. Allow it to cool before resuming charging.

For a refresh charge, follow all instructions carefully.

1. Check the battery voltage with a voltmeter or multimeter. A fully charged battery will register 12.8 V or higher. If the voltage is less than 12.8 volts, recharge the battery at 1.2 amps or less until battery voltage is 12.8 or greater.

2. When using an automatic charger, refer to the charger manufacturer's instructions for

recharging. When using a constant current charger, use the guidelines below for recharging.

Always verify battery condition before and 1-2 hours after the end of charging.

State of

Charge

100% 12.8-13.0 volts None, check at 3 mos. from date of

75%-100% 12.5-12.8 volts May need slight charge, if no charge

50%-75% 12.0-12.5 volts Needs charge 5-11 hours 25%-50% 11.5-12.0 volts Needs charge At least 13 hours,

0%-25% 11.5 volts or less Needs charge with desulfating charger At least 20 hours

Voltage Action

manufacture

given, check in 3 months

Charge Time

(Using constant current charger @ standard amps specified on top of battery)

None required

3-6 hours

verify state of charge

MAINTENANCE

Cleaning and Storage

Washing the Vehicle

Keeping your POLARIS vehicle clean will not only improve its appearance but it can also extend the life of various components.

NOTICE: High water pressure may damage components. POLARIS recommends washing the vehicle NOTICE: Certain products, including insect repellents and chemicals, will damage plastic surfaces.

The best and safest way to clean your POLARIS vehicle is with a garden hose and a pail of mild soap and water.

1. Use a professional-type washing cloth, cleaning the upper body first and the lower parts

2. Rinse with clean water frequently.

3. Dry surfaces with a chamois to prevent water spots.

Washing Tips

• Avoid the use of harsh cleaners, which can scratch the finish.

• Do not use a power washer to clean the vehicle.

• Do not use medium to heavy duty compounds on the finish.

• Always use clean cloths and pads for cleaning and polishing. Old or reused cloths and pads may contain dirt particles that will scratch the finish.

• Grease all zerk fittings immediately after washing. Allow the engine to run for a while to evaporate any water that may have entered the engine or exhaust system.

If a high pressure water system is used for cleaning (not recommended), exercise extreme caution. The water may damage components and could remove paint and labels. Avoid directing the water stream at the following items:

• Wheel bearings • Brakes • Switches and controls

• Radiator • Cab and body panels • Electrical components and wiring

• Transmission seals • Labels and decals

by hand or with a garden hose, using mild soap. Do not allow these types of products to contact the vehicle.

last.

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

Polishing the Vehicle

POLARIS recommends the use of common household aerosol furniture polish for polishing the finish on your POLARIS vehicle. Follow the instructions on the container.

• Avoid the use of automotive products, some of which can scratch the finish of your vehicle.

• Always use clean cloths and pads for cleaning and polishing. Old or reused cloths and pads may contain dirt particles that will scratch the finish.

MAINTENANCE

Cleaning and Storage

Chrome Wheel Care (if equipped)

Proper maintenance will protect chrome wheels from corrosion, preserve wheel life and ensure a “like new” appearance for many years. Chrome wheels exposed to road salt (or salt in the air in coastal areas) are more susceptible to corrosion if not properly cleaned. Clean chrome wheels more often if they're exposed to salt or other corrosive elements.

1. Wash chrome wheels frequently. Use a mild detergent. Never use abrasive cleaners on

plated or painted surfaces.

2. Rinse well with clear water. Soap, detergents, salt, dirt, mud and other elements can

cause corrosion.

3. Polish the clean chrome wheels periodically. Use an automotive grade chrome polish.

4. Routinely and liberally apply a weather resistant wax to each polished chrome wheel.

Choose a product suitable for chrome finishes. Read and follow the product labels and instructions.

Removing Corrosion

If light rust is found on the chrome finish, use steel wool (#0000-OTT grade) to remove it. Gently rub the affected areas with the steel wool until the corrosion has been removed. Clean and polish the wheel as outlined above.

Storage Tips

NOTICE: Starting the engine during the storage period will disturb the protective film created by

fogging and damage could occur. Never start the engine during the storage period.

Clean the Exterior

Make any necessary repairs and clean the vehicle as recommended. See page 88.

Stabilize the Fuel

1. Fill the fuel tank.

2. Add POLARIS Carbon Clean Fuel Treatment or POLARIS Fuel Stabilizer or equivalent

fuel treatments or stabilizers. Follow the instructions on the container for the recommended amount. Carbon Clean removes water from fuel systems, stabilizes fuel and removes carbon deposits from pistons, rings, valves and exhaust systems.

3. Allow the engine to run for 15-20 minutes to allow the stabilizer to disperse through the

entire fuel delivery system.

Oil and Filter

Change the oil and filter. See page 64.

Air Filter / Air Box

1. Inspect and clean or replace the pre-cleaner and air filter. See page 76.

2. Clean the air box.

MAINTENANCE

Cleaning and Storage

Storage Tips

Inspect and Lubricate

Inspect all cables and lubricate all areas of the vehicle as recommended in the Periodic Maintenance Chart beginning on page 61.

Battery Maintenance

See pages 86-87 for storage and charging procedures.

Fluid Levels

Inspect the fluid levels. Add or change fluids as recommended in the Periodic Maintenance Chart beginning on page 61.

• Front and rear gearcase fluid (if equipped)

• Transmission fluid

• Brake fluid (change every two years and any time the fluid looks dark or contaminated)

• Coolant (test strength/fill)

Fog the Engine

1. Treat the fuel system with POLARIS Carbon Clean or other equivalent fuel treatment.

Follow the instructions on the container. Start the engine. Allow it to idle for several minutes so the Carbon Clean reaches the injectors. Stop the engine.

2. Remove the spark plugs and add 2-3 tablespoons of engine oil. T o access the plug holes,

use a section of clear 1/4” hose and a small plastic squeeze bottle filled with the premeasured amount of oil. Do this carefully! If you miss the plug holes, oil will drain from the spark plug cavities into the hole at the front of the cylinder head, and appear to be an oil leak.

3. Reinstall the spark plugs. Torque to specification. See page 70.

4. Apply dielectric grease to the inside of each spark plug cap and reinstall the caps onto

the plugs.

5. Turn the engine over several times. Oil will be forced in and around the piston rings and

ring lands, coating the cylinder with a protective film of fresh oil.

6. If POLARIS fuel system additive is not used, fuel tank, fuel lines, and injectors should

be completely drained of gasoline.

Storage Area/Covers

Be sure the storage area is well ventilated. Cover the vehicle with a genuine POLARIS cover. Do not use plastic or coated materials. They do not allow enough ventilation to prevent condensation, and may promote corrosion and oxidation.

MAINTENANCE

Removal from Storage

1. Check the battery electrolyte level and charge the battery if necessary. Install it in the

vehicle. Make sure the battery vent hose is routed properly and that it's not pinched or restricted in any way.

2. Make sure the spark plug is tight.

3. Fill the fuel tank with fuel.

4. Check all the points listed in the Daily Pre-Ride Inspection section on page 36. Tightness

of the bolts, nuts and other fasteners should be checked by an authorized POLARIS dealer or other qualified service facility.

5. Lubricate at the intervals outlined in the Periodic Maintenance Chart beginning on page

61.

Transporting the RANGER

Follow these procedures when transporting the vehicle.

1. Apply the brakes.

2. Place the transmission in PARK.

3. Turn the engine off.

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

the vehicle.

5. Engage the park brake (if equipped).

6. Secure the fuel cap, hood and cargo box. Ensure that the seats are attached correctly and

are not loose.

WARNING! Cargo and other loose vehicle parts may fly off while transporting this vehicle. Secure or remove all cargo, and inspect the unit for loose parts prior to transport.

7. Always tie the frame of the RANGER to the transporting unit securely with suitable

straps or rope. Do not attach tie straps to the front A-arm bolt pockets.

8. Remove the key to prevent loss during transporting.

SPECIFICATIONS

RANGER ETX

RANGER 570/570 EPS

Maximum Weight Capacity (includes weight of operator, passenger, cargo, accessories)

Dry Weight 1045 lbs. (474 kg) (ETX)

Test GVW - Rollover Protection System (ROPS)

Fuel Capacity 8.8 gal. (33.3 l) 8.8 gal. (33.3 l) Engine Oil Capacity 2 qts. (1.9 l) (570)

Coolant Capacity 120 oz. (3.5 l) 170 oz. (5 l) Overall Length 110 in. (279.4 cm) 142 in. (360.7 cm) Overall Width 58 in. (147.3 cm) 60 in. (152.4 cm) Overall Height 73 in. (185 cm) 73 in. (185 cm) Wheelbase 73 in. (185 cm) 105 in. (266.7 cm) Cargo Box Dimensions (Inside) 32x42x11.5 in. (81x107x29 cm) 32x42x11.5 in. (81x107x 9 cm) Ground Clearance 10 in. (25.4 cm) 10 in. (25.4 cm) Min. Turning Radius 150 in. (381 cm) 237 in. (602 cm) Towing Capacity 1500 lbs. (680.4 kg) 1500 lbs. (680.4 kg) Hitch Tongue Capacity 150 lbs. (68 kg) 150 lbs. (68 kg) Max. Cargo Box Load 500 lbs. (227 kg) 500 lbs. (227 kg) Engine Dual overhead cam, 4 valve 4 stroke single cylinder. Displacement 567 cc (570) / 325 cc (ETX) Bore x Stroke (mm) 99mm x 73.6mm (570) / 78mm x 68mm (ETX) Alternator Output 560 W @ 3000 RPM Compression Ratio 10:1 (570) / 11.5:1 (ETX) Starting System Electric Fuel System Electronic Fuel Injection Ignition Timing ECU Controlled

Spark Plug NGK MR7F / .031” (0.7-0.9 mm) Lubrication System Wet Sump Cooling Liquid Front Suspension McPherson Strut w/8 in. (20.3 cm) of travel (570)

Rear Suspension Independent w/9 in. (23 cm) of travel (570)

Throttle Body Size 42 mm (570) / 36 mm (ETX) Ignition System Digital CDI

1000 lbs. (454 kg) 1250 lbs. (567 kg)

1075 lbs. (488 kg) (570) 1100 lbs. (499 kg) (570 EPS) 1140 lbs. (517 kg) (570 w/park brake)

2750 lbs. (1247 kg) per OSHA 29 CFR 1928.53

1.75 qts. (1.6 l) (ETX)

32° +/- 2° @ 5000 RPM

McPherson Strut w/9 in. (22.7 cm) of travel (ETX)

Dual A-arm, Anti-Sway Bar w/10 in. (25.4 cm) of travel (ETX)

RANGER CREW 570/570 EPS

1323 lbs. (600 kg) (570) 1352 lbs. (613 kg) (570 EPS)

2650 lbs. (1202 kg) per OSHA 29 CFR 1928.53

2 qts. (1.9 l)

SPECIFICATIONS

RANGER ETX

RANGER 570/570 EPS

Driving System Type PVT PVT Shift Type Single Lever (console) Single Lever (console) Gear Reduction - Low 28.84:1 28.84:1 Gear Reduction - Reverse 25.83:1 25.83:1 Gear Reduction - High 13.58:1 (570) / 9.65:1 (ETX) 13.58:1 Drive Ratio - Front 3.818:1 3.818:1 Tire Size - Front 25 x 8 - 12 25 x 10 - 12 Tire Size - Rear 25 x 11 - 12 25 x 10 - 12 Tire Pressure - Front 10 psi (69 kPa) 10 psi (69 kPa) Tire Pressure - Rear 10 psi (69 kPa) 14 psi (96 kPa) Brakes, Front/Rear Foot Activated, 4 wheel hydraulic

disc Hood Headlights 2 single beam, 50W, quartz/halogen 2 single beam, 50W, quartz/halogen Taillights 10 L.E.D. (.28W) 10 L.E.D. (.28W) Brake Light 10 L.E.D. (3.1W) 10 L.E.D. (3.1W) Indicator Light 1.0 W 1.0 W

RANGER CREW 570/570 EPS

Foot Activated, 4 wheel hydraulic disc

Clutching

See your POLARIS dealer for clutching specifications.

POLARIS PRODUCTS

Part Number Description

Engine Lubricant

2870791 Fogging Oil (12 oz./355 ml Aerosol) 2876244 PS-4 Full Synthetic 5W-50 4-Cycle Oil (qt./.95 l) 2876245 PS-4 Full Synthetic 5W-50 4-Cycle Oil (gal./3.8 l) 2878920 PS-4 Extreme Duty Synthetic 10W-50 4-Cycle Oil (qt./.95 l) 2878919 PS-4 Extreme Duty Synthetic 10W-50 4-Cycle Oil (gal./3.8 l)

Gearcase / Transmission Lubricants

2878068 AGL Full Synthetic Gearcase Lubricant & Transmission Fluid (qt./.95 l) 2878069 AGL Full Synthetic Gearcase Lubricant & Transmission Fluid (gal./3.8 l) 2877922 Demand Drive Fluid (qt./.95 l) 2877923 Demand Drive Fluid (gal./3.8 l) 2870465 Pump for Gallon (3.8 l) Jug

Coolant

2880514 Antifreeze 50/50 Premix (qt./.95 l) 2880513 Antifreeze 50/50 Premix (gal./3.8 l)

Grease / Specialized Lubricants

2871312 Grease Gun Kit, All Season Grease 2871322 All Season Grease (3 oz./89 ml cartridge) 2871423 All Season Grease (14 oz./414 ml cartridge) 2876160 ATV Angle Drive Fluid (qt./.95 l) 2872276 ATV Angle Drive Fluid (2.5 gal./9.5 l) 2871460 Premium Starter Grease 2871515 U-Joint Grease (3 oz./89 ml cartridge) 2871551 U-Joint Grease (14 oz./414 ml cartridge) 2871329 Dielectric Grease (Nyogel™)

Additives / Miscellaneous

2871326 Carbon Clean 2870652 Fuel Stabilizer 2872189 DOT 4 Brake Fluid 2871956 Loctite™ 565 Thread Sealant 2859044 POLARIS Battery Tender™ Charger 5253552 POLARIS Battery Strap Bracket for 30 AH Battery 4010630 POLARIS 30 AH Battery 2521372 POLARIS Air Filter

TROUBLESHOOTING

Drive Belt Wear/Burn

Possible Cause Solution

Driving onto a pickup or tall trailer in high range

Starting out going up a steep incline

Driving at low RPM or ground speed (3-7 MPH)

Insufficient warm-up at low ambient temperatures

Slow/easy clutch engagement Use the throttle quickly and effectively. Towing/pu shing at low RPM/low

ground speed Utility use/plowing Use low range only . Stuck in mud or snow Shift the transmission to low range and carefully use fast, aggressive throt-

Climbing over large objects from a stopped position

Belt slippage from water or snow ingestion into the PVT system

Clutch malfunction Your POLARIS dealer can assist. Poor engine performance Check for fouled plugs or foreign material in fuel tank or fuel lines. Your

Slippage from failure to warm up belt

Wrong or missing belt Install the recommended belt. Improper break-in Always break in a new belt and/or clutch. See pages 35 and 73.

Use low range during loading.

Use low range. See warnings on page 40.

Drive at a higher speed or use low range more frequently. See page 73.

Warm the engine at least 5 minutes. With the transmission in neutral, advance the throttle to about 1/8 throttle in short bursts, 5 to 7 times. The belt will become more flexible and prevent belt burning.

Use low range only.

tle application to engage clutch. WARNING: Excessive throttle may cause loss of control and vehicle roll-

over. Shift the transmission to low range and carefully use fast, brief, aggressive

throttle application to engage clutch. WARNING: Excessive throttle may cause loss of control and vehicle roll-

over. Dry out the PVT. See pag e 75. Inspect clutch seals for damage if repeated

leaking occurs.

POLARIS dealer can assist. Always warm up the belt by operating below 30 MPH for one mile (5

miles or more when temperature is below freezing).

TROUBLESHOOTING

Engine Doesn't Turn Over

Possible Cause Solution

Low battery voltage Recharge the battery to 12.8 VDC Loose battery connections Check all connections and tighten Loose solenoid connections Check all connections and tighten Loose electronic control box connections Inspect, clean, reinstall connectors

Engine Turns Over, Fails to Start

Possible Cause Solution

Out of fuel Refuel Clogged fuel filter Your POLARIS dealer can assist. W a ter is present in fuel Drain the fuel system and refuel Old or non-recommended fuel Replace with fresh recommended fuel Fouled or defective spark plug Inspect plug and replace if necessary No spark to spark plug Inspect plug and replace if necessary Water or fuel in crankcase Your POLARIS dealer can assist. Low battery voltage Recharge the battery to 12.8 VDC Mechanical failure Your POLARIS dealer can assist.

Engine Backfires

Possible Cause Solution

Weak spark from spark plug Inspect, clean and/or replace spark plug Incorrect spark plug gap or heat range Set gap to specs or replace plug Old or non-recommended fuel Replace with fresh recommended fuel Incorrectly installed spark plug wires Your POLARIS dealer can assist. Incorrect ignition timing Your POLARIS dealer can assist. Mechanical failure Your POLARIS dealer can assist. Loose ignition connections Check all connections and tighten Water present in fuel Replace with fresh recommended fuel

Engine Pings or Knocks

Possible Cause Solution

Poor quality or low octane fuel Replace with recommended fuel Incorrect ignition timing Your POLARIS dealer can assist. Incorrect spark plug gap or heat range Set gap to specs or replace plug

TROUBLESHOOTING

Engine Runs Irregularly, Stalls or Misfires

Possible Cause Solution

Fouled or defective spark plug Inspect, clean and/or replace spark plug Worn or defective spark plug wires Your POLARIS dealer can assist. Incorrect spark plug gap or heat range Set gap to specs or replace plug Loose ignition connections Check all connections and tighten Water present in fuel Replace with new fuel Low battery voltage Recharge battery to 12.8 VDC Kinked or plugged fuel tank vent line Inspect and replace Incorrect fuel Replace with recommended fuel Clogged air filter Inspect and clean or replace Low fuel pressure Your POLARIS dealer can assist. Other mechanical failure Your POLARIS dealer can assist.

Possible Lean Fuel Cause Solution

Low or contaminated fuel Add or change fuel, clean the fuel system Low octane fuel Replace with recommended fuel Clogged fuel filter Your POLARIS dealer can assist.

Possible Rich Fuel Cause Solution

Fuel is very high octane R eplace with lower octane fuel

Engine Stops or Loses Power

Possible Cause Solution

Out of fuel Refuel Kinked or plugged fuel vent line Inspect and replace W ater is present in fuel Replace with new fuel Fouled or defective spark plug Inspect, clean and/or replace spark plug Worn or defective spark plug wires Your POLARIS dealer can assist. Incorrect spark plug gap or heat range Set gap to specs or replace plug Loose ignition connections Check all connections and tighten Low battery voltage Recharge the battery to 12.8 VDC Incorrect fuel Replace with fresh recommended fuel Clogged air filter Inspect and clean or replace Other mechanical failure Your POLARIS dealer can assist. Overheated engine Clean radiator screen and core, clean engine exterior.

Your POLARIS dealer can assist.

WARRANTY

Limited Warranty

POLARIS Industries Inc., 2100 Highway 55, Medina, MN 55340 (POLARIS) gives a SIX MONTH LIMITED WARRANTY on all components of your POLARIS vehicle against defects in material or workmanship. POLARIS further warrants that the spark arrester in this product will meet the efficiency requirements of USFS standard 5100-1C for at least 1000 hours when subjected to normal use and when maintenance and installation are in accordance with POLARIS recommendations.

This warranty covers parts and labor charges for repair or replacement of defective parts and begins on the date of purchase by the original retail purchaser. This warranty is transferable to another owner during the warranty period through a POLARIS dealer, but any such transfer will not extend the original term of the warranty. The duration of this warranty may vary by international region based upon local laws and regulations.

Registration

At the time of sale, the Warranty Registration Form must be completed by your dealer and submitted to POLARIS within ten days of purchase. Upon receipt of this registration, POLARIS will record the registration for warranty. No verification of registration will be sent to the purchaser as the copy of the Warranty Registration Form will be your proof of warranty coverage. If you have not signed the original registration and received the customer copy, please contact your dealer immediately. NO WARRANTY COVERAGE WILL BE ALLOWED UNLESS YOUR VEHICLE IS REGISTERED WITH POLARIS. Initial dealer preparation and set-up of your vehicle is very important in ensuring trouble-free operation. Purchasing a machine in the crate or without proper dealer set-up will void your warranty coverage.

Warranty Coverage And Exclusions:

Limitations Of Warranties And Remedies

This POLARIS limited warranty excludes any failures that are not caused by a defect in material or workmanship. THIS WARRANTY DOES NOT COVER CLAIMS OF DEFECTIVE DESIGN. This warranty also does not cover acts of God, accidental damage, normal wear and tear, abuse or improper handling. This warranty also does not cover any vehicle, component, or part that has been altered structurally, modified, neglected, improperly maintained or used for racing, competition or purposes other than for which it was designed.

This warranty excludes damages or failures resulting from improper lubrication; improper engine timing; improper fuel; surface imperfections caused by external stress, heat, cold or contamination; operator error or abuse; improper component alignment, tension, adjustment or altitude compensation; snow, water, dirt or other foreign substance ingestion/contamination; improper maintenance; modified components; use of aftermarket or unapproved components, accessories, or attachments; unauthorized repairs; or repairs made after the warranty period expires or by an unauthorized repair center.

Polaris Ranger ETX User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual