Polaris Ranger EV User Manual

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Page 1

PMS 419

RANGER EV

Owner's Manual

for Maintenance and Safety

Page 2

WARNING

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

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

Page 3

WELCOME

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

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

• Snowmobiles

• All-terrain vehicles (ATVs)

• Low emission vehicles (LEVs)

• RANGER® utility vehicles

• RZR® sport vehicles

• VICTORY® motorcycles

• GEM® electric 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 should be performed only by a factory certified Master Service Dealer® (MSD) technician.

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

Page 4

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. 2014 RANGER EV Owner’s Manual P/N 9924304

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TABLE OF CONTENTS

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

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

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

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Winch Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

POLARIS Products. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

Maintenance Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

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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.

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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 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.

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INTRODUCTION

Vehicle Identification Numbers

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

Key

Number

####

Frame VIN

Vehicle Model Number: ________________________________________________________________________

Frame VIN: _________________________________________________________________________________

Motor Serial Number (on side of motor): ___________________________________________________________

Key Number: ________________________________________________________________________________

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INTRODUCTION

European Vibration and Noise

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

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SAFETY

Helmet

Eye

Protection

Gloves Over-the-Ankle Boots

Long

Pants

Long

Sleeves

Safe Riding Gear

The driver and all passengers must wear helmet, eye protection, gloves, longsleeve 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.

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.

051039

0006.31

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.

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SAFETY

Proper Use

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.

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.

• Do not exceed seating capacity: 2 occupants.

7179978

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SAFETY

Discretionary

Warning

Safety Labels and Locations

Discretionary Warning

WARNING

Improper vehicle use can result in Severe Injury or Death.

NEVER Operate:

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

• After or while using Alcohol or Drugs.

• On hills steeper than 15 degrees 15°.

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

• With more than one passenger, or a passenger under age twelve or who cannot comfortably reach the floor and hand holds.

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

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

ALWAYS:

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

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

• Reduce speed and use extra caution when carrying a passenger.

• Avoid sharp turns or turns while applying heavy throttle.

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

• Make sure passenger reads and understands all safety labels.

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

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

7176169

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SAFETY

Battery

Caution

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 RESULTING IN SERIOUS INJURY OR DEATH.

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

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

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

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

RANGER MID-SIZE LSV-EV

MAXIMUM CARGO BOX LOAD 500 lbs.

TIRE PRESSURE IN PSI (KPa) FRONT 20 (138)

MAXIMUM WEIGHT CAPACITY INCLUDES WEIGHT OF

OPERATOR, PASSENGER, CARGO AND ACCESSORIES Read Operation & Maintenance Manual for more detailed loading information.

Battery Caution

CAUTION

• Do not drive through water above the floor of the vehicle.

Battery damage will occur.

• Batteries require regular maintenance.

• Failure to maintain batteries in accordance with the owners

manual can result in battery damage, vehicle malfunction, fire and/or severe injury or death.

• Max towing speed 10 MPH (16 km/h) - drivetrain damage

will occur if towed faster than 10 MPH (16 km/h).

• Set parking brake before leaving vehicle.

• Turn Power On key to “Off” position and remove when not

in use.

• When towing vehicle, turn Power On key to “Off” position.

7176204

(226 kg)

REAR 20 (138)

1000 lbs.

(454 kg)

7179550

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SAFETY

Battery Charging

Warning

Battery Compartment

Warning

Safety Labels and Locations

Battery Charging Warning

WARNING

• Explosive gases are released when batteries are charged. Keep sparks, flames and cigarettes away. Shield eyes when working near batteries.

• Do not charge batteries in a non-ventilated enclosed area or near flammable materials.

• Do not attempt to charge frozen, leaking, or damaged batte ries.

• Connect battery charger to properly rated electrical receptacle with GFCI.

• Do not charge with storage or weather cover on vehicle or with the cab enclosure doors closed, as fire and explosion are possible.

• Refer to Owner’s Manual or contact your local POLARIS dealer with any questions.

TO MAXIMIZE BATTERY LIFE

• Always check and maintain water level monthly. Use only distilled water. Water level should be kept 1/4” (6 mm) below fill well. Do not overfill the battery.

• Always keep batteries fully charged. For maximum life, charge your vehicle at every opportunity. Use only the charger supplied with the vehicle. Inspect battery connections regularly.

• Failure to properly maintain your batteries will void warranty coverage.

7176414

Battery Compartment Warning

WARNING

• SULFURIC ACID in batteries will burn skin, eyes, and clothing. Do not tip batteries. Keep vent caps tight and level. In event of injury, flush with water and call physician immediately.

• HIGH VOLTAGE CABLES and terminals are contained within this compartment. Improper contact between battery terminals can result in electrical shorts. ELECTRICAL SHORTS can result in burns.

• Do not use high pressure water to wash the battery compartment. Damage to the vented batteries will result.

• Tampering with or unauthorized modification of this unit could result in serious personal injury, will void the warranty, and can result in permanent damage to the vehicle.

• Refer to your Owner’s Manual or contact your local POLARIS dealer with any questions.

7176206

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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 oper ate 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.

• 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 keep hands and feet inside the vehicle at al l 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 con dition. Always follow the inspection procedures described in this manual.

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

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

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

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

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

Page 16

SAFETY

Operator Safety

• Always follow proper procedures for climbing hills as described in this manual. See page 36. Check the terrain carefully before attempting to climb a hill. Never climb hills with excessively slippery or loose surfaces. 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 36. 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 37.

• 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 37. Wet brakes may have reduced stopping ability. Test your brakes after leaving water. If necessary, apply them lightly several times to let friction dry out the pads.

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

• Always use the proper size and type of tires specifie d 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 set the park brake and remove the key when leaving the vehicle unattended.

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

Equipment Modifications

Never install any accessory that grounds to the vehicle chassis. The chassis is a floating ground to protect against electrical short circuits and hazards.

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

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

Page 17

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

Page 18

SAFETY

Operator Safety

Ventilation When Charging Batteries

Failure to provide adequate ventilation while charging batteries can result in an explosion. Volatile hydrogen gas is emitted during charging and may accumulate in pockets at the ceiling.

• Always ensure a minimum of 5 air changes per hour in the charging area.

• Always remove any storage covers from the vehicle and open any cab doors (if equipped) before

charging.

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 33.

Always follow all inspection and maintenance procedures and schedules described in this owner's manual. See page 52.

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.

Operating a Damaged Vehicle

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

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.

Page 19

SAFETY

Operator Safety

Operating on Pavement

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

Operating on Public Roads

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

Turning Improperly

Turning improperly could cause loss of traction, loss of control, accident or rollover. Always follow proper procedures for turning as described in this owner’s manual. Never turn abru ptly 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.

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 35.

Page 20

SAFETY

Operator Safety

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 36.

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 the owner's manual. See page 36.

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.

• Switch to reverse and slowly allow the vehicle to roll straight downhill while applying light brake pressure to control speed.

If you begin rolling downhill:

• Never press the accelerator.

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

• Switch to reverse and slowly allow the vehicle to roll straight downhill while applying light brake pressure to control speed.

Improper Tire Maintenance

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

Operating on Frozen Bodies of Water

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

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

Page 21

SAFETY

Operator Safety

Unauthorized Use of the Vehicle

Leaving the keys in the vehicle 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 key when the vehicle is not in use.

Hot Drive Systems

The motor and controller are very hot during and after use of the vehicle. Hot components can cause burns and fire. Do not touch hot drive system components. Always keep combustible materials away from the drive system. Use caution when traveling through tall grass, especially dry grass. Always inspect areas near the drive system after driving through tall grass, weeds, brush and other tall ground cover. Promptly remove any grass or debris clinging to the vehicle.

Precautions During Maintenance

WARNING! Do not work in or near the battery compartment or on any other electrical component of

the vehicle while charging the batteries. Always disconnect the main power connector before servicing or unplugging any electrical components. See page 30.

Always follow all safety instructions in the maintenance portion of this owner’s manual, as well as the following:

• Make sure the vehicle is properly immobilized be fore beginning any maintenance.

• Always block the chassis securely before working under the vehicle.

• Turn the key off and remove it from the vehicle.

• Insulate any tools used within the battery ar ea to prevent sparks or battery explosion caused by shorting the battery terminals or wiring. Remove the batteries, or cover the exposed terminals with an insulating material.

FOR MORE INFORMATION ABOUT SAFETY

call POLARIS at 1-800-342-3764.

Page 22

FEATURES AND CONTROLS

ROPS

Cab

Frame

Console

Hip Bar

Cargo

Box

Headlights

Front Bumper/Brush Guard

Tailgate

Latch

Releases

Receiver Hitch

CV Boot/Rear Caliper

Tailgate

Taillight

Reflector

Component Locations

Page 23

Console

1. Park Brake Lever

2. Headlight Switch

3. Charge Status Indicator

4. AWD Switch

5. Battery Discharge Indicator

6. Hour Meter

7. Charge Plug Holder

8. 12V Auxiliary Outlet

9. Drive Mode Switch

10. Direction Selector

11. Key Switch

12. Indicator Lights

FEATURES AND CONTROLS

Page 24

FEATURES AND CONTROLS

100% Remains (Full Charge)

50% Remains

70% Discharged

Recharge the batteries

50% Discharged

30%

Charging Cord

Console

Battery Discharge Indicator

The battery discharge indicator displays the amount of charge removed (used) from fully charged batteries. When the batteries are fully charged, the right-most bar illuminates, indicating 0% has been used. The charge status indicator will be solid green (see page 23). As the batteries discharge, the bar moves leftward.

Tip: If batteries are not allowed to recharge fully (solid

green light), the battery discharge indicator may be inaccurate.

When the second bar from the left flashes, battery discharge is at 70%. The batteries should be recharged as soon as possible. A void dischar ging

the batteries more than 80%.

NOTICE: If the two left-most bars begin to flash, battery damage may occur with continued operation.

Hour Meter

The hour meter records and displays the hours of actual vehicle movement since manufacture.

Auxiliary 12-Volt Terminal Board

The 12-volt terminal board is located under the hood. It contains constant 12-volt, switched 12-volt and ground terminals that can be used to power auxiliary lights and accessories. The terminals are limited to 10 amps.

Stop the vehicle and recharge the batteries.

Auxiliary Outlets

The 12-volt receptacle can be used to power accessories, but is limited to 10 amps (the terminal board and 12-volt outlet are fused together at 10 amps.

Charging Cord

The charging cord is located inside the charge plug holder on the console. See page 62 for charging instructions.

Page 25

FEATURES AND CONTROLS

Console

Park Brake Lever

To help prevent the vehicle from rolling, set the park brake when parking the vehicle. When the park brake is set and the park brake indicator is illuminated, motor 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 promptly if this feature fails to operate properly.

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

1. Apply the brakes.

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

3. To release the park brake, apply the brakes. Press the park brake release inward and

move the lever upward as far as possible.

Charge Status Indicator

When charging the batteries, the charge status indicator light flashes and changes color to indicate the status of the charge. Refer to the table below.

Color Indication Code Definition

Green Solid Charge is complete, charger is in maintenance mode. Green Fast Flash Less than 80% of charge is completed. Green Slow Flash More than 80% of charge is completed.

Amber Flashing Power mode is reduced, low AC voltage or high internal

Red Flashing Charger error exists; reset charger power and refer to Trou-

charger temperature exists; open hood to improve air flow.

bleshooting Guide on page 27.

Key Switch

Move the direction selector switch to neutral, then turn the key to the ON position to activate the electrical circuits.

Tip: The accelerator will not start the motor if the direction selector

switch is in forward or reverse when the key is turned on. Switch to neutral, then choose forward or reverse.

Turn the key to the OFF position to disable all electrical circuits. The key can be removed from the switch when it is in the OFF position.

Page 26

FEATURES AND CONTROLS

Console

Drive Mode Switch

CAUTION! Changing the drive mode switch position while driving

could result in an automatic increase or decrease in speed without a change to accelerator pedal pressure.

Press the top of the switch to select high mode. Use high mode for most trail-riding conditions. The vehicle will operate at speeds up to 25 MPH (40 km/h).

Press the bottom of the switch to select low mode. Low mode is recommended for short-term operation in extreme load conditions. Use low mode when towing, hauling loads or maneuvering over obstacles. Speed will be limited to a maximum of 10 MPH (16 km/h) and regenerative braking increases to improve control in aggressive terrain. Return the mode switch to high mode for normal operation.

Move the switch to the center position to select the maximum range mode. Use this mode to operate the vehicle a greater distance or for a longer time period. This mode limits both speed and torque to obtain the maximum driving range.

High

Maximum

Range

Low

Mode Maximum

High 25 MPH

Max

Range

Low 10 MPH

Speed

(40 km/h)

15 MPH

(24 km/h) (16 km/h)

Torque

(percent of

maximum

torque)

70% Minimum Trail riding 50% Minimum Whenever possible, to maximum driv-

100% Maximum Towing, hauling loads, driving on steep

Deceleration

(regenerative

braking)

Application

ing range of battery pack hills or aggressive terrain

Page 27

FEATURES AND CONTROLS

Console

Direction Selector Switch

When the direction selector is in the center position, the vehicle is in neutral. The vehicle will not move if the accelerator is depressed. Place the switch in neutral before turning the key on.

Push the top of the switch to choose forward operation. Push the bottom of the switch to choose reverse operation. Always come to a complete stop before reversing direction.

Tip: The malfunction light will illuminate after reversing direction if

you press the accelerator pedal before coming to a complete stop.

AWD Switch

The AW D switch has three positions: All Wheel Drive (AWD), Differential Lock/Two Wheel Drive (2WD) and Off (1WD/Turf Mode).

Press the top of the switch to engage All Wheel Drive (AWD). See page 42 for operating instructions.

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

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

See page 42 for Differential Lock operating instructions.

Forward

Neutral

Reverse

AWD

2WD

1WD/TURF

Headlight Switch

Press the top of the switch to turn the headlights on. Press the bottom of the switch to turn the headlights off.

Off

Page 28

FEATURES AND CONTROLS

Indicator Panel

Console

Indicator Panel Lights

The indicator lights activate when the key is in the ON position.

Indicator Status Indicates

Malfunction

Steady

Park Brake Steady Engaged park brake

Gear Position Steady Selected gear (forward/neutral/reverse)

Motor/Controller High

Temperature

Flashing Reduced performance due to elevated temperature

Steady Power delivery terminated to protect against overheating

If either occurs, stop the vehicle and turn the key off. Allow the motor and controller to cool adequately before operating.

Electrical malfunction (flash sequence on controller indicates type; see troubleshooting guide on page 27)

Key was turned on in forward or reverse (switch to neutral, then to forward or reverse)

Malfunction

Motor/Controller

High Temperature

Park Brake

Neutral Gear

Reverse

Gear

Forward

Gear

Page 29

FEATURES AND CONTROLS

Malfunction Indicator Troubleshooting Guide

The malfunction codes will blink on the controller. The code definitions provided here are for informational purposes only.

Tip: If the indicator illuminates due to a minor issue such as a low voltage condition or a sequence fault

(reversing direction without releasing the accelerator, turning the key on while in forward or reverse), select neutral and turn the key off and on to clear the error. If the error does not clear, please see your POLARIS dealer for diagnosis and repair.

# of Blinks Code Definition

Steady Key was turned on in forward or reve rse (switch to neutral, then to forward or

1 Data or configuration error 2 Sequence fault 3 Power fault 4 Contactor issue 6 Throttle input error 7 Voltage protection 8 Controller or motor out of temperature range

13 Software fault

Charge Status Indicator Troubleshooting Guide

The code definitions provided are for informational purposes only. Please see your POLARIS dealer for diagnosis and repair.

reverse)

# of

Blinks

1 Battery high voltage Check battery size and condition; reset 2 Battery low voltage 3 Charge time-out, battery pack not reaching

required voltage, charger output reduced due to high temperatures

4 Battery could not be trickle-charged to

minimum voltage

5 Charger shut down due to overheating Ensure sufficient cooling air flow (open the

6 Charger internal fault Reset charger (interrupt AC power for 15

Code Definition Solution

charger (interrupt AC power for 15 seconds) Check connections; operate charger at

lower ambient temperature Check battery for shorted or damaged cells

hood) and reset the charger (interrupt AC power for 15 seconds)

seconds); return to qualified service provider if fault persists

Page 30

FEATURES AND CONTROLS

Batteries

This vehicle is equipped with eight 12-volt batteries that supply the power needed to operate the vehicle. The batteries are located under the seat. See page 63 for battery access instructions.

Always observe all battery safety warnings and safe handling procedures as outlined on vehicle safety labels and in this manual. Refer to the battery maintenance section beginning on page 61.

Battery Handling Precautions

• Always make sure that all electrical accessories are grounded directly to the negative (-) post on the terminal board. Never use the chassis or body as a ground connection.

• Always keep battery terminals and connections clean and free of corrosion at all times. See page 63.

• Always maintain a full charge on the batteries. For best battery life, avoid discharging the batteries more than 80%. See page 22.

• Make sure new batteries are fully charged before using.

• New deep cycle batteries need to be cycled several times before reaching full capacity (50125 cycles, depending on type). Capacity will be limited during this time.

• Make sure vent caps are installed properly and securely during vehicle operation and battery charging.

• Recharge batteries fully at the end of each day the vehicle is operated, allowing adequate time for the charger to complete its charge cycle. The batteries in this vehicle do not have a “memory effect”. Frequent charging will extend their life.

• Avoid charging at temperatures above 120° F. (49° C.) ambient air temperature. Closed, unvented storage buildings often exceed this temperature when exposed to direct sunlight.

• Never connect an auxiliary battery to the factory-installed DC-to-DC converter. If more than 10 amps are needed for accessories, always install the POLARIS-approved auxiliary accessory battery kit.

• Never connect a 12-volt accessory directly to the batteries. Always connect any powered accessory to a 12-volt auxiliary outlet or terminal board. See page 22.

• Never connect jumper cables to any of the batteries of this vehicle.

• Use only insulated tools when working in the battery compartment.

Page 31

FEATURES AND CONTROLS

Batteries

Battery Conditioning

New batteries cannot initially hold all of their capacity. The approximate capacity of the battery pack increases as the number of charge cycles increases.

# of Charge Cycles: New153045 Percent of Full Capacity: 80% 90% 95% 100%

Ambient Temperature Implications on Batteries

1. Battery range decreases as ambient temperature decreases. This can affect the range by

up to 30%.

2. Batteries discharge when left uncharged. They can discharge up to 13% per month

(higher rates in warmer climates) with the key off and much faster if the key is left on.

3. Batteries can freeze if left uncharged at low ambient temperatures.

Percent Charged: 100% 50% 0% Approximate Freezing Point: -60° F

(-51° C)

Charger Operation

Open the hood and any door enclosures or zippers. This will decrease charger temperature, which allows it to operate more efficiently, and shorten charge times. See pages 61-62 for charging procedures.

1. Always use extension cords with the appropriate ratings for the country in which it is

used. In North America this is a UL rating. The cords must also be rated for the conditions in which they are used, such as being rated for protection from oil in a garage or workshop environment.

2. Use the proper cord wire gauges for the cord length used:

Length: <25 ft (7.5 m) <50 ft (15 m) <100 ft (30 m) Gauge: 16AWG (1.5mm2) 14AWG (2.5mm2) 10AWG (6.0mm2)

0° F

(-18° C)

25° F

(-4° C)

Battery Operation Range

Range is significantly affected by tire pressure, alignment, terrain and driving style. Always maintain proper tire pressure as specified on safety labels.

Page 32

FEATURES AND CONTROLS

Battery Installation

and Wire Lead

Connection

to contactor +

Front of vehicle

to controller -

Main Power Connector

B+ wire

Main Power Connector

NOTICE: Damage to electrical connections and components will occur if they are unplugged before

When disconnected, the main power connector disconnects the battery pack from all electrical components, with the exception of the contactor. After servicing the vehicle, the main power connector should be the last connection to be made.

The main power connector is located under the seat on the driver’s side of the controller tray, adjacent to the main line contactor. To disconnect, unplug the connector.

To disconnect the battery pack from the vehicle completely, disconnect the main power connector, then remove the B+ wire from the battery terminal.

WARNING! Insulate any tools used within the battery area to prevent sparks or battery explosion caused by shorting the battery terminals or wiring. Remove the batteries, or cover the exposed terminals with an insulating material.

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 39-40.

the main power connector is disconnected. Always disconnect the main power connector before servicing or unplugging any electrical components.

Page 33

FEATURES AND CONTROLS

Accelerator

Pedal

Brake

Pedal

ROPS Cab

Frame

Brake Pedal

Push the brake pedal toward the floor to slow or stop the vehicle. Apply the brakes before turning the key on.

Accelerator Pedal

The accelerator pedal will function only when the key is ON and the direction selector switch is set to either forward or reverse. To begin moving or to increase vehicle speed, gradually push the accelerator pedal toward the floor. Holding the accelerator pedal down continuously will accelerate the vehicle to the maximum speed.

To slow the vehicle, release the accelerator pedal. Electric motor braking provides braking when the pedal is released. For additional speed control or to stop the vehicle, apply the service brakes.

Roll-Over Protection System (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.

Seat Removal

Pull up on the front of the seat to disengage the front latches. Slide the seat forward and lift it away from the seat base.

To reinstall the seat, align the rear seat tabs with the slots on the rear of the seat base. Slide the seat fully rearward, then push down firmly along the front edge of the seat to secure the latches.

Page 34

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 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 coul d 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.

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.

Latch Plate

Buckle

Page 35

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.

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 31 Brake fluid Ensure proper level 56

Front suspension Inspect, lubricate if necessary 53 Rear suspension Inspect, lubricate if necessary 53 Steering Ensure free operation 57 Tires Inspect condition and pressure 11

Wheels/fasteners Inspect, ensure fastener tightness 58 Frame nuts, bolts, fasteners Inspect, ensure tightness Accelerator Ensure proper operation 31 Indicator lights/switches Ensure operation 26 Headlamp Check operation, apply POLARIS dielectric grease when

Brake light/tail lamp Check operation, apply POLARIS dielectric grease when Seat belts Check length of belt for damage, check latches for proper Latches (hood/tailgate/seat) Ensure all latches are secure -

Batteries Ensure full charges, proper water levels, clean terminals 61-63 Battery cables Inspect for proper cable routing and secure connections 63

lamp is replaced lamp is replaced operation

59 60 32

Page 36

OPERATION

Driving Procedure

1. Disconnect the charging cable

(if connected).

2. Wear a helmet, eye protection,

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

3. Sit in the driver's seat and fasten

the seat belt.

4. Apply the brakes. Place the

direction selector in neutral (N).

5. Turn the key to the ON position.

Wait about a second for the contactor to close before continuing.

6. Move the direction selector to

forward or reverse.

7. Move the drive mode switch to the desired setting. See page 24.

8. Release the park brake.

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

10. Keeping both hands on the steering wheel, release the brake pedal and gradually push

the accelerator toward the floor to begin driving.

11. Drive slowly. Practice maneuvering and using the accelerator and brakes on level

surfaces.

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

vehicle. Never carry more than one passenger in this vehicle. Never allow a passenger to ride in the cargo box.

13. To stop the vehicle, release the accelerator pedal completely and brake to a complete

stop.

Tip: Always come to a complete stop before reversing direction.

14. Set the park brake.

15. Place the direction selector in neutral.

16. Turn the key off.

WARNING! A rolling vehicle can cause serious injury. Always set the park brake when leaving the vehicle unattended.

Page 37

OPERATION

WARNING

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.

Sideways

skid

Turn in

direction of

skid

Page 38

OPERATION

Driving Uphill

Whenever traveling uphill, follow these precautions:

1. Always travel straight uphill.

2. Avoid excessively steep hills.

3. Keep both feet on the floor.

4. Always check the terrain carefully before

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

5. Proceed at a steady rate of speed.

6. 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.

7. If the vehicle stalls while climbing a hill,

apply the brakes. Place the direction selector in neutral, turn the key off and on, then select low range. Place the direction selector switch in reverse and slowly allow the vehicle to roll straight downhill while applying light brake pressure to control speed.

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.

Driving Downhill

When driving downhill, follow these precautions:

1. Avoid excessively steep hills.

2. Always descend a hill with the direction

selector switch on forward. Never descend a hill with the switch on neutral.

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.

Page 39

OPERATION

Driving Through Water

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

NOTICE: Serious damage can occur to the

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

4. Avoid operating through deep or fast-

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

Driving Over Obstacles

Follow these precautions when operating over obstacles:

1. Always check for obstacles before

2. Look ahead and learn to read the

3. Travel slowly and use extra caution

4. Move the drive mode switch to low

5. A void operating over lar ge obstacles such as lar ge rocks and fallen trees. If unavoidable,

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

electrical system and batteries if the vehicle is operated in water deeper than the floorboards.

entering water.

gradual inclines.

Floorboard

obstacles.

flowing water.

repeatedly until braking action is normal.

operating in a new area.

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

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

mode if needed. See page 24.

use extreme caution and operate slowly.

over an obstacle that could cause a rollover.

Page 40

OPERATION

Driving in Reverse

Follow these precautions when operating in reverse:

1. Always check for obstacles or people

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

2. Always avoid backing downhill.

3. Back slowly.

4. Apply the brakes lightly for stopping.

5. Avoid turning at sharp angles.

6. Never accelerate suddenly.

Parking on an Incline

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

1. Apply the brakes.

2. Set the park brake.

3. Place the direction selector in neutral.

4. Turn the key off.

5. Block the rear wheels on the downhill

side.

Parking the RANGER

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 direction selector in neutral.

4. Set the park brake.

5. Turn the key off. Remove the key to prevent unauthorized use.

Page 41

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. Slow down and drive in the lowest gear available. SECURE ALL LOADS BEFORE OPERATING. Unsecured loads can create unstable operating

conditions, which could result in loss of control of the vehicle. OPERATE ONLY WITH STABLE AND SAFELY ARRANGED LOADS. When handling off-centered

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

HEAVY LOADS CAN CAUSE BRAKING AND CONTROL PROBLEMS. Use extreme caution when applying brakes with a loaded vehicle. Avoid terrain or situations that may require backing 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. Move the drive mode switch to low mode if needed. See page 24.

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 Maximum Capacities

RANGER EV 1000 lbs. (455 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. A passengers must always ride in the cab with seat belt fastened securely.

(Level Ground)

Cargo Box

Page 42

OPERATION

Towing Loads

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

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

2. Do not operate the vehicle faster than 10 MPH (16 km/h) when towing. See page 39.

Towing a trailer increases braking distance.

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

chart below and the specifications charts beginning on page 68.

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

location or you may lose control of the vehicle.

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

Model Total Towed

RANGER EV 1250 lbs.

Load Weight

(Level Ground)

(567 kg)

Total Tow ed

Load Weight

(15° grade)

850 lbs. (386 kg)

Total Hi tch

Vertical

Weight

150 lbs.

(68.1 kg)

Maximum

Towin g

Speed

10 MPH (16 kph)

Towing the RANGER

NOTICE: When towing the vehicle, the key MUST be in the OFF position or severe motor damage will

Follow these procedures when towing the vehicle:

1. Place the direction selector in neutral.

2. Turn the key off.

3. Always follow these precautions when towing this vehicle:

occur.

• Do not operate faster than 10 MPH (16 km/h).

• Do not tow on public streets.

• Do not allow passengers in the towed vehicle.

• Avoid abrupt starts and stops.

• Avoid sharp turns and abrupt steering maneuvers.

• Avoid towing on a hill.

Page 43

OPERATION

Dumping the Cargo Box

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

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

2. Apply the brakes.

3. Set the park brake.

4. Place the direction selector in neutral.

5. Turn the key off.

6. Dismount the vehicle.

7. Ensure that the cargo is positioned evenly or toward

the front of the cargo box.

8. 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.

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

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

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

12. 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.

Release

Lever

Transporting the RANGER

When transporting the RANGER for a long distance or on public streets, always use a trailer with an approved load rating greater than the RANGER’s curb vehicle weight of 1700 lbs. (771 kg) plus any installed accessories or cargo.

Follow these guidelines when transporting the RANGER.

1. Place the direction selector in neutral. Set the park brake.

2. Remove the key to prevent loss.

3. Secure the seat, hood and tailgate latches. 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.

4. Always tie the frame of the RANGER to the transporting unit securely with suitable

straps.

5. If using an open trailer, remove the windshield (if equipped).

6. Never allow passengers on a trailer or in a trailered vehicle.

7. Reduce speed and drive with caution.

Page 44

OPERATION

All Wheel Drive (AWD)

Press the top of the rocker switch to engage All Wheel Drive (AWD). Once enabled, the AWD remains enabled until the switch is turned off.

The AW D switch may be turned on or off while the vehicle is moving. When the A WD 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.

Tip: AWD will not engage initially until speed is less than 5 MPH

(8 km/h).

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

NOTICE: Switching to AWD while the rear wheels are spinning

may cause severe drive train damage. Always switch to AWD while the rear wheels have traction or are at rest.

Locking the Differential

NOTICE: Damage to the differential can occur if it is engaged

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

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

Press the bottom of the switch to unlock the differential and allow the rear drive wheels to operate independently. This mode of operation is well suited to turf driving or whenever aggressive traction is not required.

AWD

2WD

1WD/TURF

Disengaging AWD

Move the AWD switch to the center or bottom position to disengage AWD. If the switch is turned off while the front gearcase is moving, it will not disengage 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. Move the direction selector to reverse. Operate in reverse for at least 10 feet (3 m).

3. Stop completely.

4. Move the direction selector to forward and drive forward.

5. If the front gearcase remains locked after following these instructions, return the vehicle

to your dealer for service.

Page 45

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 50.

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 48 to feed and rewind the cable

evenly before continuing the winch operation.

Page 46

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. Take your winch to your dealer for

service 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.

Page 47

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 hu rry 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

Page 48

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 50.

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 dama ged 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.

Page 49

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 50. 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-e ng a ge th e clut ch on th e win ch . E. Slowly winch in the slack in the winch cable. F. Select the proper veh icle gear to propel the stuck vehicle in the direction of winching. G. Shift to the lowest gear availab le 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.

Page 50

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 that is unevenly bunched up in one area. C. Re-engage the winch clutch. D. Have an assistant pull the winch cable tightly with about 100 lbs. (45 kg) of tension using the

hook strap.

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

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

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

winch cable.

Page 51

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.

Page 52

WINCH GUIDE

Shock Loading

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Page 53

WINCH GUIDE

Winch Maintenance and Service Safety

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

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

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

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

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

accidental activation of the winch

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

genuine POLARIS replacement parts available at your authorized POLARIS dealer.

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

designed synthetic rope as the winch cable.

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

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

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

Page 54

MAINTENANCE

Periodic Maintenance Chart

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

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

Record maintenance and service in the Maintenance Log beginning on page 75.

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

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

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

• Racing or race-style high RPM use

• Prolonged low speed, heavy load operation

Maintenance Chart Key

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

D Have an authorized POLARIS dealer 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 perform these services.

Page 55

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

Brake pad wear 10 H Monthly - Inspect periodically

Battery terminals 25 H Monthly - Inspect and clean (page 63) Battery fluid levels 25 H Monthly - Add as needed (page 63) Battery terminals 25 H Monthly - Inspect; torque to specification

Ź Front gearcase oil 25 H 1 M - Perform a break-in oil level check Ź Main gearcase oil (Transaxle) 25 H 1 M - Perform a break-in oil level check Ź General lubrication 50 H 3 M - Lubricate all fittings, pivots, cables, etc.

D Steering 50 H 6 M - Lubricate

Ź Front Suspension 50 H 6 M - Lubricate Ź Rear Suspension 50 H 6 M - Lubricate Ź Front gearcase oil 100 H 12 M - Perform a break-in oil level check Ź Main gearcase oil (Transaxle) 100 H 12 M - Perform a break-in oil level check Ź Wiring 100 H 12 M - Inspect for wear, routing, security; apply

D Front wheel bearings 100 H 12 M - Inspect; replace as needed D Brake fluid 200 H 24 M - Change every two years D Toe adjustment - Inspect periodically; adjust when parts

D Headlight aim - Adjust as needed

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

D Have an authorized POLARIS dealer perform these services.

(whichever comes first)

Hours Calendar Miles (Km)

Pre-Ride

Inspect and make adjustments as

needed. See Pre-Ride Checklist on

grease if replacing

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

are replaced

Remarks

page 33.

Lubrication Recommendations

Check and lubricate all components at the intervals outlined in the Periodic Maintenance Chart beginning on page 52, 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

Brake Fluid DOT 4 Brake Fluid See page 56. Main Gearcase Oil (Transaxle) ATV Angle Drive Fluid See page 54. Front Gearcase Oil Demand Drive Fluid See page 55.

Page 56

MAINTENANCE

Gearcases

Gearcase Specification Chart

Gearcase Lubricant Capacity Fill Plug Torque Drain Plug Torque

Main Gearcase (Transaxle)

Front Gearcase Demand Drive Fluid 5.1 oz.

Main Gearcase (Transaxle)

Always check and change the main gearcase oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 52. 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 70 for the part numbers of POLARIS products.

Oil Check

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

1. Position the vehicle on a level surface.

2. Remove the fill plug.

3. Check the oil level.

4. Add the recommended oil as needed.

5. Reinstall the fill plug. Torque to specification.

ATV Angle Drive Fluid 20.3 oz.

(600 ml)

(150 ml)

14 ft. lbs.

(19.4 Nm)

8-10 ft. lbs.

(11-13.6 Nm

Fill Plug

14 ft. lbs.

(19.4 Nm)

11 ft. lbs.

(15 Nm)

Drain Plug

Oil Change

The drain plug is located on the lower right side of the main gearcase, near the fill plug. Refer to the Gearcase Specifications Chart for recommended

Fill Plug

Drain Plug

lubricants, capacities and torque specifications.

1. Remove the fill plug.

2. Place a drain pan under the drain plug. Remove the drain plug. Allow the oil to drain completely.

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

4. Reinstall the drain plug. Torque to specification.

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

6. Reinstall the fill plug. Torque to specification.

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

Page 57

MAINTENANCE

Gearcases

Front Gearcase

Always check and change the front gearcase oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 52. Maintain the oil level even with the bottom thread of the fill plug hole.

Refer to the Gearcase Specifications Chart on page 54 for recommended lubricants, capacities and torque specifications. See page 70 for the part numbers of POLARIS products.

Oil Check

The front gearcase fill plug is located on the left 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.

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

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

7. Add the recommended oil.

8. Reinstall the fill plug. Torque to specification.

9. Check for leaks.

10. Discard used oil properly.

Fill Plug

Drain Plug

Page 58

MAINTENANCE

Maximum

Minimum

Brakes

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

Brake Fluid

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

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 53 for fluid recommendations.

1. Position the vehicle on a level surface.

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

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

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

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 3/64" (1 mm).

3/64" (1mm)

Page 59

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 52.

1. Position the vehicle on a level surface.

2. Lightly turn the steering wheel left and right. There should be 0.8"-1.0" (20-25 mm) of freeplay at the outer rim of the steering wheel.

3. 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 rear shock absorber springs by rotating the adjustment cams either clockwise or counter-clockwise to increase or decrease spring tension.

Page 60

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

Nut and Washer (Steel Wheels) Front and Rear 35 ft. lbs. (47 Nm)

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

PLUS 1/4 TURN

(90 degrees)

Wheel Removal

1. Apply the brakes. Set the park brake. Turn the key off.

2. Loosen the wheel nuts slightly.

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

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

Wheel Installation

1. Set the park brake. Place the wheel in the correct position on the wheel hub. Be sure the valve stem is toward the outside and rotation arrows on the tire point toward forward rotation.

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

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

3. Carefully lower the vehicle to the ground.

4. Torque the wheel nuts to specification. See page 58.

Page 61

MAINTENANCE

25 ft.

(7.6 m)

8" (20 cm)

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 i n low light conditions 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.

Headlight Lamp Replacement

1. Open the hood.

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

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

3. Turn the lamp 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.

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. Turn the key on. Turn the headlights on.

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, access the adjustment screw under the hood or through the wheel well.

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

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

Wiring Harness

Page 62

MAINTENANCE

Tab

Release

Lights

Brake Lights

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

1. Turn the key to the ON position.

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

Indicator Lamp Replacement

1. Lift the hood.

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

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

4. Locate the expired lamp. Using a screwdriver, rotate the lamp 1/4 turn counter-clockwise.

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

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

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

8. Close the hood.

Page 63

MAINTENANCE

WARNING

Batteries

Battery posts, terminals and related components contain lead and lead compounds, chemicals known to cause cancer and reproductive harm. Always wash your hands after touching or handling the batteries.

Charging a damaged battery can result in serious injury. Never attempt to charge a frozen or bulging battery. Discard the battery appropriately and install a new battery.

Improperly connecting or disconnecting battery cables can result in an explosion and cause serious injury or death.

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.

Page 64

MAINTENANCE

Charging Cord

Batteries

Battery Charging

When not in use, park the vehicle and connect the battery charger. The vehicle’s charging cord is located inside the charge plug holder on the console.

WARNING! Failure to provide adequate ventilation while charging batteries can result in an explosion. Hydrogen gas is emitted during charging and will rise and accumulate at the ceiling. Always ensure a minimum of five (5) air changes per hour in the charging area. Never charge the batteries in an area subject to a flame or spark, including areas containing gas or propane water heaters and furnaces. Do not smoke in the charging area.

Always follow these precautions when charging the batteries:

1. Position the vehicle on a level surface.

2. Make sure the charging area is well ventilated.

3. Make sure the key is off.

4. Open the hood and any door enclosures or zippers.

5. Always use a extension cord with a minimum rating of 20 amps.

6. Inspect the charging cord and extension cord for cracks, loose connections and frayed wiring. Replace any damaged components promptly.

7. Always connect the vehicle charger to the extension cord first, then plug the cord into a wall receptacle.

8. Make sure the charger uses a dedicated circuit to prevent overloading. If charging multiple vehicles, each vehicle should use a dedicated circuit.

Tip: After the batteries have fully recharged, the battery charger will automatically cycle in and out of

the trickle charge mode to maintain the charge.

9. When disconnecting the charger, always disconnect the extension cord from the wall receptacle first, then disconnect the cord from the vehicle’s charging cord.

Page 65

MAINTENANCE

Batteries

Battery Access

To access the batteries, remove the seat. See page 31. Remove the storage tray (if equipped).

NOTICE: Before removing the seat to access the batteries, make sure any wire or metal items

Battery Inspections

Inspect battery terminal connections monthly. Clean batteries as recommended. Using an insulated wrench, torque bolts to 8 ft. lbs. (11 Nm).

Battery Cleaning

Always keep battery terminals and connections free of corrosion. T o clean, remove 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 battery terminals with dielectric grease or petroleum jelly.

NOTICE: Do not allow cleaning solution or tap water to enter the batteries.

Battery Replacement

With proper care and maintenance as outlined in this owner’s manual, battery life could be extended up to four years or longer, depending on the amount of use. When battery replacement is necessary, please see your authorized POLARIS dealer.

WARNING! Handling batteries and electrical components improperly can result in serious injury or death. Do not attempt to remove batteries or battery cables. Always see your dealer for battery-related service.

(including seat belt latches) remain clear of the battery compartment to avoid causing a short circuit to the electrical system.

Battery Fluid

A poorly maintained battery will deteriorate rapidly . Check the battery fluid level often. Add only distilled water. Tap water contains minerals that are harmful to a battery.

Unless the plates are exposed before charging, distilled water should be added to a battery after charging. If the plates are exposed, add water to about 1/8 inch (3 mm) above the plat es, then charge. Check the fluid level again after charging. Maintain the fluid level 1/4 inch (6 mm) below the bottom of the fill well in the cell cover. Do not overfill.

Fill

Well

1/4” (6 mm)

Cell Covers

Plates

Page 66

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.

• Avoid directing water toward electrical components, including batteries, wiring and

switches.

by hand or with a garden hose, using mild soap. Do not allow these types of products to contact the vehicle.

last.

Washing the Vehicle

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

• Main gearcase seals

•Brakes

• Cab and body panels

• Labels and decals

• Switches and controls

• Electrical components and wiring

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.

Grease all zerk fittings immediately after washing.

Page 67

MAINTENANCE

Cleaning and Storage

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.

Polishing Tips

• 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.

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.

Page 68

MAINTENANCE

Cleaning and Storage

Storage Tips

Clean the Exterior

Make any necessary repairs and clean the vehicle as recommended. See page 64.

Inspect and Lubricate

Inspect all cables and lubricate all areas of the vehicle as recommended in the Periodic Maintenance Chart beginning on page 52.

Battery Maintenance

See pages 61-63 for procedures.

Fluid Levels

Inspect the fluid levels. Add or change fluids as recommended in the Periodic Maintenance Chart beginning on page 52.

• Front and rear gearcase fluid (if equipped)

• Main gearcase fluid

• Brake fluid (change every two years and any time the fluid looks dark or contaminated)

Page 69

MAINTENANCE

Storing the Vehicle

Any time the vehicle will be parked for more than a few hours, follow the recommended storage procedures:

1. Make any necessary repairs and clean the vehicle. See page 64.

2. Clean the batteries. See page 63.

3. Store the vehicle out of the sun in a cool, dry place.

4. Be sure the storage area is well ventilated.

5. Turn the key off.

6. Do not set the park brake.

7. Verify that tire pressure is at specification.

8. Block the wheels to prevent rolling.

9. Fully charge the batteries. Leave the charger connected to maintain a full charge during

the storage period, or check battery voltage each month during storage and recharge as needed to maintain a full charge. If the charger remains connected, check it monthly to verify proper operation.

Tip: Do not use plastic or coated materials. They do not allow enough ventilation to prevent

condensation, and may promote corrosion and oxidation.

WARNING! Do not cover the vehicle while the charger is connected. Dangerous levels of hydrogen gas could accumulate.

Removal from Storage

1. Inspect all battery connections.

2. Verify that batteries are fully charged.

3. Verify that tire pressure is at specification.

4. Perform the pre-ride inspection. See page 33.

5. Inspect and verify the tightness of the bolts, nuts and other fasteners.

6. Lubricate at the intervals outlined in the Periodic Maintenance Chart beginning on page

52.

Page 70

SPECIFICATIONS

RANGER EV

Dimensions

Dry Weight 1750 lbs. (793.8 kg) Test GVW - Rollover Protection

System (ROPS) Ground Clearance 10 in. (25.4 cm) Length 108 in. (274.3 cm) Width 56.5 in. (143.5 cm) Height 73 in. (185.4 cm) Wheelbase 72 in. (183 cm) Turning Radius 150 in. (381 cm)

Box Dimensions (Inside) 32 x 42 x 11.5 in. (81 x 107 x 29 cm) Box Capacity 500 lbs. (227 kg) Payload Capacity 1000 lbs. (455 kg) Hitch Towing Capacity 1250 lbs. (567 kg) Cargo System Seating 2 Skid Plate Plastic

Motor configuration Single, 48-volt, high efficiency, AC induction motor Motor peak 30 HP Controller 650 - Amp Sevcon Gen IV controller with mu lti-mode driving and

Battery pack 1 1.7 kw battery pack at 48V DC with 8 12-volt, US12VXC batteries

Maximum speed 25 MPH (40.2 km/h) Range (in Max Range mode on

flat ground) Throttle Redundant, non-contact, inductive-sensing pedal On-board charger Delta Q 120-volt AC input; 48-volt DC output Charge time 8 hours (dependent on depth of discharge)

Main gearcase (transaxle) Direct drive motor-to-transaxle with low-noise gears Drive On demand AWD, 2WD, turf mode

2750 lbs. (1247 kg) per OSHA 29 CFR 1928.53

Load Capacity

Lock & Ride

Performance

regenerative braking

in series-parallel configuration

50 miles (80.5 km) (may vary with driving conditions)

Drivetrain

Page 71

SPECIFICATIONS

RANGER EV

Brake System

Brakes 4-Wheel hydraulic disc w/dual bore front calipers Park Brake Dash-mounted lever-activated mechanical park brake

Suspension

Front suspension Independent Macpherson struts w/8 in. (20.3 cm) travel Rear suspension Dual A-Arm w/9 in. (22.9 cm) travel Tires 25x9-12 Carlisle All Trail II Tire pressure 20 psi (137.9 kPa)

Features

Cup holders Dual cup holders Indicator panel Indicates directional selection, park brake, and motor or controller

Charge indicator Digital, indicates battery discharge Hour meter Digital, indicates cumulative hours of vehicle movement Auxiliary power 12-volt accessory outlet Rider restraints Automotive-style 3-point seat belts Multi-mode switch L/M/H (Low/Max Range/High) Headlights/taillights/brake lights Dual 50-watt Storage Glove box

malfunction

Page 72

POLARIS PRODUCTS

Part Number Description

Gearcase Lubricants

2876160 ATV Angle Drive Fluid (qt./.95 l) 2872276 ATV Angle Drive Fluid (2.5 gal./9.5 l) 2877922 Demand Drive Fluid (qt./.95 l) 2877923 Demand Drive Fluid (2.5 gal./9.5 l)

Grease / Specialized Lubricants

2871312 Grease Gun Kit, All Sea son 2871322 All Season Gre ase (3 oz./89 ml cartridge) 2871423 All Season Grease (14 oz./414 ml cartridge) 2871515 U-Joi nt Grease (3 oz./89 ml cartridge) 2871551 U-Joint Grease (14 oz./414 ml cartridge) 2871329 Dielectric Grease (Nyogel™)

Additives / Miscellaneous

2872189 DOT 4 Brake Fluid

TROUBLESHOOTING

Vehicle Will Not Operate

Possible Cause Solution

Low battery voltage Recharge the battery overnight Loose battery connections Check all connections and tighten Loose contactor connections Check all connections and tighten Loose electronic control box connections Inspect, clean, reinstall connectors Required torque exceeds motor capability In neutral, cycle key off and on, select low range, then

select direction

Page 73

WARRANTY

LIMITED WARRANTY

POLARIS Sales 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 arrestor 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 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.

Page 74

WARRANTY

LIMITATIONS OF WARRANTIES AND REMEDIES

This warranty excludes damages or failures caused by abuse, accident, fire, or any other cause o ther than a defect in materials or workmanship and provides no coverage for consumable components, general wear items, or any parts exposed to friction surfaces, stresses, environmental conditions and/or contamination for which they were not designed or not intended, including but not limited to the following items:

• Wheels and tires • Finished and unfinished surfaces

• Suspension components • Carburetor/Throttle body components

• Brake components • Engine components

• Seat components • Drive belts

• Clutches and components • Hydraulic components and fluids

• Steering components • Circuit breakers/Fuses

• Batteries • Electronic components

• Light bulbs/Sealed beam lamps • Spark plugs

• Filter • Sealants

• Lubricants • Coolants

• Bushings • Bearings

Lubricants and Fluids

1. Mixing oil brands or using non-recommended oil may cause engine damage. We recommend the use of POLARIS engine oil.

2. Damage or failure resulting from the use of non-recommended lubricants or fluids is not covered by this warranty.

This warranty provides no coverage for personal loss or expense, including mileage, transportation costs, hotels, meals, shipping or handling fees, product pick-up or delivery, replacement rentals, loss of product use, loss of profits, or loss of vacation or personal time.

THE EXCLUSIVE REMEDY FOR BREACH OF THIS WARRANTY SHALL BE, AT POLARIS’ OPTION, REPAIR OR REPLACEMENT OF ANY DEFECTIVE MATERIALS, COMPONENTS, OR PRODUCTS. THE REMEDIES SET FORTH IN THIS WARRANTY ARE THE ONLY REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF THIS WARRANTY. POLARIS SHALL HAVE NO LIABILITY TO ANY PERSON FOR INCIDENTAL, CONSEQUENTIAL OR SPECIAL DAMAGES OF ANY DESCRIPTION, WHETHER ARISING OUT OF EXPRESS OR IMPLIED W ARRANTY OR ANY OTHER CONTRACT, NEGLIGENCE, OR OTHER TORT OR OTHERWISE. THIS EXCLUSION OF CONSEQUENTAL, INCIDENTAL, AND SPECIAL DAMAGES IS INDEPENDENT FROM AND SHALL SURVIVE ANY FINDING THAT THE EXCLUSIVE REMEDY FAILED OF ITS ESSENTIAL PURPOSE.

THE IMPLIED WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE IS EXCLUDED FROM THIS LIMITED WARRANTY. ALL OTHER IMPLIED WARRANTIES (INCLUDING BUT NOT LIMITED TO THE IMPLIED WARRANTY OF MERCHANTABILITY) ARE LIMITED IN DURATION TO THE ABOVE SIX MONTH WARRANTY PERIOD. P0LARIS DISCLAIMS ALL EXPRESS WARRANTIES NOT STATED IN THIS WARRANTY. SOME STATES DO NOT PERMIT THE EXCLUSION OR LIMITATION OF INCIDENT AL OR CONSEQUENTIAL DAMAGES OR ALLOW LIMITATIONS ON THE DURATION OF IMPLIED WARRANTIES, SO THE ABOVE LIMITATIONS MAY NOT APPLY TO YOU IF INCONSISTENT WITH CONTROLLING STATE LAW.

Page 75

WARRANTY

HOW TO OBTAIN WARRANTY SERVICE

If your vehicle requires warranty service, you must take it to a POLARIS Servicing Dealer. When requesting warranty service you must present your copy of the Warranty Registration From to the dealer. (THE COST OF TRANSPORTATION TO AND FROM THE DEALER IS YOUR RESPONSIBILITY). POLARIS suggests that you use your original selling dealer; however, you may use any POLARIS Servicing Dealer to perform warranty service.

In the country where your product was purchased:

Warranty or Service Bulletin repairs must be done by an authorized POLARIS dealer. If you move or are traveling within the country where your product was purchased, Warranty and Service Bulletin repairs may be requested from any authorized POLARIS dealer that sells the same line as your product.

Outside the country where your product was purchased:

If you are traveling temporarily outside the country where your product was purchased, you should take your product to an authorized POLARIS dealer. You must show the dealer photo identification from the country of the selling dealer’s authorized location as proof of residence. Upon residence verification, the servicing dealer will be authorized to perform the warranty repair.

If you move:

If you move to another country , be sure to contact POLARIS Customer Assistance and the customs department of the destination country before you move. Product importation rules vary considerably from country to country. You may be required to present documentation of your move to POLARIS in order to continue your warranty coverage. You may also be required to obtain documentation from POLARIS in order to register your product in your new country. You should warranty register your product at a local POLARIS dealer in your new country immediately after you move to continue your warranty coverage and to ensure that you receive information and notices regarding your vehicle.

If you purchase from a private party:

If you purchase a POLARIS product from a private party, to be kept and used outside of the country in which the product was originally purchased, all warranty coverage will be denied. You must nonetheless register your product under your name and address with a local POLARIS dealer in your country to ensure that you receive safety information and notices regarding your product.

Page 76

WARRANTY

EXPORTED PRODUCTS

EXCEPT WHERE SPECIFICALLY REQUIRED BY LAW, THERE IS NO WARRANTY OR SERVICE BULLETIN COVERAGE ON THIS PRODUCT IF IT IS SOLD OUTSIDE THE COUNTRY OF THE SELLING DEALER’S AUTHORIZED LOCATION. This policy does not apply to products that have received authorization for export from POLARIS. Dealers may not give authorization for export. You should consult an authorized dealer to determine this product’s warranty o r service coverage if you have any questions. This po licy does not apply to products registered to government officials or military personnel on assignment outside the country of the selling dealer’s authorized location. This policy does not apply to Safety Bulletins.

NOTICE

If your product is registered outside of the country where it was purchased and you have not followed the procedure set above, your product will no longer be eligible for warranty or service bulletin coverage of any kind, other than safety bulletins. Products registered to Government officials or military personnel on assignment outside of the country where the product was purchased will continue to be covered by the Limited Warranty.

Please work with your dealer to resolve any warranty issues. Should your dealer require any additional assistance, they will contact the appropriate person at POLARIS.

This warranty gives you specific legal rights, and you may also have other rights which vary from state to state or in different countries. If any of the above terms are void because of federal, state, local law, all other warranty terms will remain in effect.

For questions call POLARIS Customer Assistance:

United States & Canada: 1-800-POLARIS (1-800-765-2747) French: 1-800-268-6334

Page 77

Use the following chart to record periodic maintenance.

MAINTENANCE LOG

DATE MILES (KM)

OR HOURS

TECHNICIAN SERVICE PERFORMED / COMMENTS

Page 78

MAINTENANCE LOG

DATE MILES (KM)

OR HOURS

TECHNICIAN SERVICE PERFORMED / COMMENTS

Page 79

INDEX

Accelerator Pedal . . . . . . . . . . . . . . . . . . . . . . . . . 31

All Wheel Drive

Disengaging AWD. . . . . . . . . . . . . . . . 42

Engaging AWD . . . . . . . . . . . . . . . . . . 42

Locking the Differential. . . . . . . . . . . . 42

Auxiliary 12-Volt Terminal Board . . . . . . . . . . . . 22

Auxiliary Outlets. . . . . . . . . . . . . . . . . . . . . . . . . . 22

AWD. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

AWD Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Axle Nut Torque. . . . . . . . . . . . . . . . . . . . . . . . . . 58

Batteries

Accessing . . . . . . . . . . . . . . . . . . . . . . . 63

Ambient Temperature Implications. . . 29

Charge Status Indicator . . . . . . . . . 23, 27

Charger Operation . . . . . . . . . . . . . . . . 29

Charging. . . . . . . . . . . . . . . . . . . . . . . . 62

Charging Cord . . . . . . . . . . . . . . . . 22, 29

Cleaning . . . . . . . . . . . . . . . . . . . . . . . . 63

Conditioning. . . . . . . . . . . . . . . . . . . . . 29

Discharge Indicator . . . . . . . . . . . . . . . 22

Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

Handling Precautions . . . . . . . . . . . . . . 28

Inspections . . . . . . . . . . . . . . . . . . . . . . 63

Main Power Connector . . . . . . . . . . . . 30

Operation Range . . . . . . . . . . . . . . . . . 29

Replacement. . . . . . . . . . . . . . . . . . . . . 63

Boots. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Brake Lever, Park. . . . . . . . . . . . . . . . . . . . . . . . . 23

Brake Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

Brake Pedal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Brakes

Brake Fluid. . . . . . . . . . . . . . . . . . . . . . 56

Brake Inspection . . . . . . . . . . . . . . . . . 56

Cab Frame, ROPS. . . . . . . . . . . . . . . . . . . . . . . . . 31

Cargo. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Cargo Box, Dumping . . . . . . . . . . . . . . . . . . . . . . 41

Charge Status Indicator. . . . . . . . . . . . . . . . . . 23, 27

Charger Operation. . . . . . . . . . . . . . . . . . . . . . . . . 29

Charging Batteries . . . . . . . . . . . . . . . . . . . . . . . . 62

Charging Cord. . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Chrome Wheel Care . . . . . . . . . . . . . . . . . . . . . . . 65

Cleaning and Storage . . . . . . . . . . . . . . . . . . . 64-66

Clothing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Component Locations. . . . . . . . . . . . . . . . . . . . . . 20

Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-26

Corrosion Removal, Chrome . . . . . . . . . . . . . . . . 65

Differential Locking . . . . . . . . . . . . . . . . . . . . . . . 42

Direction Selector . . . . . . . . . . . . . . . . . . . . . . . . . 25

Discharge Indicator. . . . . . . . . . . . . . . . . . . . . . . . 22

Disengaging AWD . . . . . . . . . . . . . . . . . . . . . . . . 42

Drive Mode Switch. . . . . . . . . . . . . . . . . . . . . . . . 24

Driving Downhill . . . . . . . . . . . . . . . . . . . . . . . . . 36

Driving in Reverse . . . . . . . . . . . . . . . . . . . . . . . . 38

Driving on a Sidehill. . . . . . . . . . . . . . . . . . . . . . . 36

Driving on Slippery Surfaces . . . . . . . . . . . . . . . . 35

Driving Over Obstacles . . . . . . . . . . . . . . . . . . . . 37

Driving Procedure. . . . . . . . . . . . . . . . . . . . . . . . . 34

Driving Through Water . . . . . . . . . . . . . . . . . . . . 37

Driving Uphill. . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Dumping the Cargo Box. . . . . . . . . . . . . . . . . . . . 41

Equipment Modifications . . . . . . . . . . . . . . . . . . . 14

Eye Protection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Fluid Change

Front Gearcase . . . . . . . . . . . . . . . . . . . 55

Main Gearcase . . . . . . . . . . . . . . . . . . . 54

Transaxle . . . . . . . . . . . . . . . . . . . . . . . 54

Fluid Level

Front Gearcase . . . . . . . . . . . . . . . . . . . 55

Main Gearcase . . . . . . . . . . . . . . . . . . . 54

Transaxle . . . . . . . . . . . . . . . . . . . . . . . 54

Fluid Levels During Storage. . . . . . . . . . . . . . . . . 66

Fluid Recommendation, Gearcases . . . . . . . . . . . 54

Fluid, Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

Fluid, Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

Front Gearcase . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

Fuel Stabilizer. . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

Gearcase Specification Chart . . . . . . . . . . . . . . . . 54

Gearcase, Front. . . . . . . . . . . . . . . . . . . . . . . . . . . 55

Gearcase, Main . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

Gearcases . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54-55

Gloves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Hauling Cargo. . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Headlight Beam Adjustment. . . . . . . . . . . . . . . . . 59

Headlight Lamp Replacement . . . . . . . . . . . . . . . 59

Headlight Switch . . . . . . . . . . . . . . . . . . . . . . . . . 25

Helmet. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Hitch Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Hitch Weight. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Hour Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Page 80

INDEX

Indicator Light Replacement. . . . . . . . . . . . . . . . 60

Indicator Lights . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Indicator, Charge Status. . . . . . . . . . . . . . . . . . . . 23

Key Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Key, Periodic Maintenance Chart . . . . . . . . . . . . 52

Lamp Replacement, Indicator Lights . . . . . . . . . 60

Lights

Brake Lights . . . . . . . . . . . . . . . . . . . . 60

Headlight Beam Adjustment. . . . . . . . 59

Headlight Lamp Replacement . . . . . . 59

Indicator Lamp Replacement . . . . . . . 60

Indicator Lights. . . . . . . . . . . . . . . . . . 26

Lubrication Recommendations . . . . . . . . . . . . . . 53

Main Gearcase . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

Main Power Connector . . . . . . . . . . . . . . . . . . . . 30

Maintenance Log. . . . . . . . . . . . . . . . . . . . . . . . . 75

Maintenance Precautions. . . . . . . . . . . . . . . . . . . 19

Maintenance, Periodic . . . . . . . . . . . . . . . . . . . 52-53

Malfunction Indicator . . . . . . . . . . . . . . . . . . . . . 27

Modifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Obstacles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Oil Change

Front Gearcase . . . . . . . . . . . . . . . . . . 55

Main Gearcase . . . . . . . . . . . . . . . . . . 54

Transaxle. . . . . . . . . . . . . . . . . . . . . . . 54

Oil Level

Front Gearcase . . . . . . . . . . . . . . . . . . 55

Main Gearcase . . . . . . . . . . . . . . . . . . 54

Transaxle. . . . . . . . . . . . . . . . . . . . . . . 54

Operation Range . . . . . . . . . . . . . . . . . . . . . . . . . 29

Operator Safety . . . . . . . . . . . . . . . . . . . . . . . . 13-19

Park Brake Lever. . . . . . . . . . . . . . . . . . . . . . . . . 23

Parking on an Incline. . . . . . . . . . . . . . . . . . . . . . 38

Parking the RANGER . . . . . . . . . . . . . . . . . . . . . 38

Periodic Maintenance Chart . . . . . . . . . . . . . . 52-53

Polaris Products . . . . . . . . . . . . . . . . . . . . . . . . . . 70

Polishing the Vehicle. . . . . . . . . . . . . . . . . . . . . . 65

Pre-Ride Inspection . . . . . . . . . . . . . . . . . . . . . . . 33

Pressure, Tire. . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Range of Operation . . . . . . . . . . . . . . . . . . . . . . . . 29

Removing the Vehicle from Storage . . . . . . . . . . . 67

Reverse Operaton . . . . . . . . . . . . . . . . . . . . . . . . . 38

Riding Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Roll-Over Protection System. . . . . . . . . . . . . . . . . 31

ROPS Cab Frame . . . . . . . . . . . . . . . . . . . . . . . . . 31

Safety Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-12

Safety Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Safety, Winch Maintenance . . . . . . . . . . . . . . . . . . 51

Seat Belt Inspection. . . . . . . . . . . . . . . . . . . . . . . . 32

Seat Belts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Seat Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Severe Use Definition . . . . . . . . . . . . . . . . . . . . . . 52

Shock Loading the Winch . . . . . . . . . . . . . . . . . . . 50

Shock Spring Adjustment . . . . . . . . . . . . . . . . . . . 57

Signal Words . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Specifications, Gearcase . . . . . . . . . . . . . . . . . . . . 54

Speed, Towing. . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Steering Wheel Inspection. . . . . . . . . . . . . . . . . . . 57

Storage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64-66

Storage Tips. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

Storage, Removal . . . . . . . . . . . . . . . . . . . . . . . . . 67

Storing the Vehicle . . . . . . . . . . . . . . . . . . . . . . . . 67

Switches

AWD Switch. . . . . . . . . . . . . . . . . . . . 25

Direction Selector. . . . . . . . . . . . . . . . 25

Drive Mode Switch. . . . . . . . . . . . . . . 24

Headlight Switch . . . . . . . . . . . . . . . . 25

Key Switch . . . . . . . . . . . . . . . . . . . . . 23

Tire Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Tires

Nut Torque . . . . . . . . . . . . . . . . . . . . . 58

Tread Depth . . . . . . . . . . . . . . . . . . . . 58

Wheel Installation. . . . . . . . . . . . . . . . 58

Wheel Removal . . . . . . . . . . . . . . . . . 58

Towing Loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Towing Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Towing the RANGER . . . . . . . . . . . . . . . . . . . . . . 40

Trailer Hitch Bracket. . . . . . . . . . . . . . . . . . . . . . . 30

Transaxle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

Transporting the RANGER. . . . . . . . . . . . . . . . . . 41

Troubleshooting

Charge Status Indicator. . . . . . . . . . . . 27

Malfunction Indicator. . . . . . . . . . . . . 27

Vehicle Will Not Operate . . . . . . . . . . 70

Page 81

Vehicle Identification Numbers . . . . . . . . . . . . . . . 6

Vehicle Range. . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Vehicle Will Not Operate. . . . . . . . . . . . . . . . . . . 70

Warning Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Washing the Vehicle. . . . . . . . . . . . . . . . . . . . . . . 64

Weight, Hitch . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Wheel Installation. . . . . . . . . . . . . . . . . . . . . . . . . 58

Wheel Nut Torque . . . . . . . . . . . . . . . . . . . . . . . . 58

Wheel Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . 58

Winch Cable Care. . . . . . . . . . . . . . . . . . . . . . . . . 49

Winch Maintenance and Service Safety. . . . . . . . 51

Winch Operation. . . . . . . . . . . . . . . . . . . . . . . 45-48

Winch Safety Precautions. . . . . . . . . . . . . . . . 43-44

Winch Shock Loading . . . . . . . . . . . . . . . . . . . . . 50

INDEX

Page 82

WARNING

Improper vehicle use can result in SEVERE INJURY or DEATH.

NEVER Operate:

If you are under age 16 and without a valid driver’s license. At speeds too fast for your skills or the conditions. After or while using Alcohol or Drugs. On hills steeper than 15 degrees 15 . On public roads. A collision can occur with another vehicle. With more than ONE passenger, or with passengers under age

twelve or who cannot comfortably reach the floor and hand holds. On paved surfaces - pavement may seriously affect handling

and control. With non-Polaris approved accessories - they may seriously affect

stability.

PMS 419

ALWAYS:

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

helmet, eye protection, gloves, long-sleeve shirt, long pants and

Wear a

over-the-ankle boots

Reduce speed and use extra caution when carrying a passenger. Avoid sharp turns or turns while applying heavy throttle. Operate slowly in reverse - avoid sharp turns or sudden braking. Make sure passenger reads and understands all safety labels. Watch for branches or other hazards that could enter vehicle.

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

For your nearest Polaris dealer, call 1-800-POLARIS or visit www.polaris.com Polaris Sales Inc. 2100 Hwy. 55 Medina, MN 55340 Phone 1-888-704-5290 Part No. 9924304 Rev 01 Printed in USA