Polaris Ranger XP User Manual

Pantone 426C

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 another vehicle. With more than two passengers on the 4X4 or 6X6, with more than

5 passengers on the CREW, 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.

ALWAYS:

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

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

Reduce speed and use extra caution when carrying passengers. Avoid sharp turns or turns while applying 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.polarisindustries.com Polaris Sales Inc., 2100 Hwy. 55, Medina, MN 55340 Phone 1-888-704-5290 Part No. 9922522 Rev 02 Printed in USA

WARNING

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

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

WARNING

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

The text is printed on 100% recycled

with 40% post-consumer waste (PCW).

WELCOME

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

• Snowmobiles

• All-terrain vehicles (ATVs)

• RANGER

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

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

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

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

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

utility vehicles

(MSD)

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

Copyright 2009 Polaris Sales Inc. All information contained within this publication is based on the latest product information at the time of publication. Due to constant improvements in the design and quality of production components, some minor discrepancies may result between the actual vehicle and the information presented in this publication. Depictions and/or procedures in this publication are intended for reference use only. No liability can be accepted for omissions or inaccuracies. Any reprinting or reuse of the depictions and/or procedures contained within, whether whole or in part, is expressly prohibited.

Printed in U.S.A. 2010 RANGER XP/HD / RANGER 6X6 / RANGER CREW Owner’s Manual P/N 9922522

TABLE OF CONTENTS

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

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

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

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Emission Control Systems . . . . . . . . . . . . . . . 61

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

Specifications. . . . . . . . . . . . . . . . . . . . . . . . . 110

Polaris Products. . . . . . . . . . . . . . . . . . . . . . . 116

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . 117

Declaration of Conformity . . . . . . . . . . . . . . . 121

Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122

Maintenance Log . . . . . . . . . . . . . . . . . . . . . . 129

Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132

INTRODUCTION

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

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

The safety alert symbol indicates a potential personal injury hazard.

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

death or serious injury.

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

minor or moderate injury.

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

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

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

INTRODUCTION

WARNING

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

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

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

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

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

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

INTRODUCTION

Engine Serial Number

Key

Number

VIN (4X4, 6X6)

####

VIN (Crew)

Vehicle Identification Numbers

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

Vehicle Model Number: ___________________________________________________

Frame VIN: ____________________________________________________________

Engine Serial Number: ___________________________________________________

Key Number ____________________________________________________________

SAFETY

Safety Labels and Locations

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

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

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

WARNING

Remove flammable material containers from box before filling.

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

• Never carry passengers in cargo box.

Maximum 4X4 Box Load 1000 lbs. (455 kg)

Maximum 6X6 Box Load 1250 lbs. (567 kg), Storage Box Load 250 lbs. (113 kg)

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

TIRE PRESSURE IN PSI (KPa):

RANGER - 4X4 FRONT 10 (69) REAR 10 (69)

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

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

RANGER 4X4 is 1500 LBS. (682 KG)

RANGER 6X6 is 2000 LBS. (907 KG)

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

Read Owner's Manual for more detailed loading information.

7176334

SAFETY

Safety Labels and Locations

Container/Passenger/Tire Pressure Warning (Crew)

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

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

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

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

Read Owner's Manual for more detailed loading information.

7175214

SAFETY

Clutch Cover

Warning

Discretionary

Warning

Age 16

Warning

Shift

Caution

Safety Labels and Locations

Clutch Cover Warning

WARNING NO STEP

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

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

Age 16 Warning

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

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

Shift Caution

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

7172563

7175566

7172674

SAFETY

Safety Labels and Locations

Discretionary Warning (4X4/6X6)

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

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

• After or while using Alcohol or Drugs.

• On hills steeper than 15 degrees 15°.

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

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

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

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

ALWAYS:

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

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

• Reduce speed and use extra caution when carrying passengers.

• 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.

7176128

SAFETY

Safety Labels and Locations

Discretionary Warning (Crew)

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

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

• After or while using Alcohol or Drugs.

• On hills steeper than 15 degrees 15°.

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

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

cannot comfortably reach the floor and hand holds.

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

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

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

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

times.

• Reduce speed and use extra caution when carrying passengers.

• Avoid sharp turns or turns while applying 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

7176321

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 manual and all labels carefully. Follow the operating procedures described.

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

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

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

• The driver and any passenger should wear helmet, eye protection and seat belt at all times.

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

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

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

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

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

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

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

• Never attempt jumps or other stunts.

SAFETY

Operator Safety

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

operating condition. Always follow the inspection procedures described in this manual.

• Always travel slowly and use extra caution when operating on unfa-

miliar terrain. Be alert to changing terrain.

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

• Always follow proper procedures for turning. Practice turning at slow

speeds before attempting to turn at faster speeds. Never turn at excessive speeds.

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

has been involved in an accident.

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

abilities. Practice on smaller hills before attempting larger hills.

• Always follow proper procedures for climbing hills as described in

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

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

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

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

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

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

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

SAFETY

Operator Safety

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

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

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

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

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

• Always engage the park brake before getting out of the vehicle. See page 29.

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

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

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

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

SAFETY

Operator Safety

Equipment Modifications

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

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

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

SAFETY

WARNING

Operator Safety

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

Age Restrictions

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

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

Operating Without Instruction

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

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

Using Alcohol or Drugs

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

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

SAFETY

Operator Safety

Seat Belts

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

Failure to Inspect Before Operating

Failure to inspect and verify that the vehicle is in safe operating condition before operating increases the risk of an accident.

Always inspect your RANGER before each use to make sure it's in safe operating condition.

Always follow all inspection and maintenance procedures and schedules described in the owner's manual.

Handling Gasoline

Gasoline is highly flammable and explosive under certain conditions.

• Always exercise extreme caution whenever handling gasoline.

• Always stop the engine when refueling.

• Always refuel outdoors or in a well ventilated area.

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

fuel.

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

eling is performed or where gasoline is stored.

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

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

and water and change clothing.

SAFETY

Operator Safety

Exposure to Exhaust

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

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

Operating a Damaged Vehicle

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

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 your passenger’s skills.

Operating on Pavement

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

Avoid operating the vehicle on pavement. If it's unavoidable, travel slowly and avoid sudden turns or stops.

SAFETY

Operator Safety

Operating on Public Roads

Operating this vehicle on public streets, roads or highways could result in a collision with another vehicle.

Never operate this vehicle on any public street, road or highway, including dirt and gravel roads. In some areas it's unlawful to operate this vehicle on public streets, roads and highways.

Turning Improperly

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

Jumps and Stunts

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

Operating in Unfamiliar Terrain

Failure to use extra caution when operating on unfamiliar terrain could result in an accident or overturn. Unfamiliar terrain may contain hidden rocks, bumps, or holes that could cause loss of control or overturn.

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

SAFETY

Operator Safety

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 overturn.

Do not operate on excessively slippery surfaces. Always reduce speed and use additional caution when operating on slippery

surfaces.

Improper Hill Climbing

Climbing hills improperly can cause loss of control or vehicle overturn. Always follow proper procedures for climbing hills as described in the owner's manual. See page 48.

Stalling While Climbing a Hill

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

If all forward speed is lost:

• Apply the brakes.

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

If you begin rolling downhill:

• Never apply engine power.

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

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

SAFETY

Operator Safety

Improper Tire Maintenance

Operating this vehicle with improper tires or with improper or uneven tire pressure could cause loss of control or accident.

Always use the size and type of tires specified for your vehicle. Always maintain proper tire pressure as described in the owner's manual and on

safety labels.

Operating on 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.

Unauthorized Use of the Vehicle

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

Hot Exhaust Systems

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

FEATURES AND CONTROLS

Headlights

Front Bumper/Brush Guard

Radiator

ROPS Cab

Frame

Console

Hip Bar

Cargo Box

Fuel Tank Cap

Component Locations

Not all models come with all features. Refer to the specifications section beginning on page 110.

FEATURES AND CONTROLS

Tailgate

Latch Release

Receiver

Hitch

CV Boot/Rear Caliper

Muffler (Spark Arrestor)

Tailgate

6X6 Storage Box

Storage

Compartment

Component Locations

FEATURES AND CONTROLS

Cup Holder

12V Auxiliary

Outlets

Mode

Button

Storage

Tray

Instrument

Cluster

Gear Selector

(Shifter)

Park Brake

Lever

Storage

Compartment

12V Accessory

Outlet

Console

Auxiliary Outlets

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

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

FEATURES AND CONTROLS

Console

Mode Button

The yellow button located directly under the speedometer is used to toggle through mode options available such as odometer, trip meter, hour meter and tachometer. See page 35 for operation of the modes.

Gear Selector

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

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

move the lever to the desired gear.

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

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

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

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

FEATURES AND CONTROLS

Ignition Switch

Light

Switch

AWD/Differential Switch

OFF

Switches

Ignition Switch

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

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

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

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

The key returns to the ON position when released.

Light Switch

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

FEATURES AND CONTROLS

AWD

Differential Lock

Differential Unlock

Switches

AWD/Differential Lock Switch

The AWD/Differential Switch has three positions:

• All Wheel Drive (AWD)

• Differential Lock (2WD)

• Differential Unlock Press the top of the rocker switch to

engage All Wheel Drive (AWD). See page 59 for operating instructions.

Move the rocker switch to the center position to lock the differential and operate in rear wheel drive. Press the bottom of the switch to unlock the differential and allow the two rear drive wheels to operate independently. See page 60 for differential lock operating instructions.

FEATURES AND CONTROLS

Throttle

Pedal

Brake Pedal

Trailer Hitch Bracket

This vehicle is equipped with a receiver hitch bracket for a trailer hitch. To avoid injury and property damage, always heed the warnings and towing capacities outlined on pages 54-56.

Brake Pedal

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

Throttle Pedal

Push the throttle pedal down to increase engine speed. Spring pressure returns the pedal to the rest position when released. Always check that the throttle pedal returns normally before starting the engine. Make sure there's adequate throttle pedal freeplay. See page 89 for throttle pedal adjustment procedures.

Adjustable Steering Wheel

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

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

FEATURES AND CONTROLS

Park Brake Lever

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

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

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

Inspect and adjust park brake cable tension after the first 25 hours of operation and every 100 hours thereafter to ensure proper cable tension. See page 92.

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

1. Apply the brakes.

2. Pull the park brake lever

downward as far as possible.

3. To release the park brake,

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

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

FEATURES AND CONTROLS

Buckle

Latch Plate

Seat Belts

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

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

To wear the seat belt properly, follow this procedure:

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

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

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

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

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

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

center.

FEATURES AND CONTROLS

Seat Belts

Seat Belt Inspection

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

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

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

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

releases freely.

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

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

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

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

Seat Removal

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

Fuel Cap

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

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

FEATURES AND CONTROLS

6X6 Storage

Box

ROPS

(all models)

Large Storage

Compartment

(Crew only)

Small Storage

Compartment

(left side only)

Rollover Protective Structure (ROPS)

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

1928.53 rollover performance requirements. Always have your autho-

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

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

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

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

Storage Compartments

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

FEATURES AND CONTROLS

Rider

Information

Center

Speedometer

Needle

Park Brake

Indicator

Instrument Cluster

The instrument cluster measures distance traveled by the vehicle, as well as time, hours of operation and engine RPM.

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

a low fuel condition exists.

FEATURES AND CONTROLS

345

Instrument Cluster

Rider Information Center

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

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

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

1. Gear Indicator - This

indicator displays gear shifter position. H = High Gear L = Low Gear N = Neutral R = Reverse Gear)

2. AWD Indicator - This

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

3. Engine Hour Display Indicator

4. Service Interval/Diagnostic Mode Indicator

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

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

6. Odometer/Tachometer/Tripmeter/ Hour Meter

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

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

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

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

FEATURES AND CONTROLS

Instrument Cluster

Rider Information Center

Standard Modes

Use the yellow mode button located under the speedometer to toggle through the mode options. See page 24.

Odometer Mode

The odometer records the miles traveled by the vehicle.

Trip Meter Mode

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

Tip: In the Rider Information Center, the trip meter display contains a decimal

point, but the odometer displays without a decimal point.

Hour Meter Mode

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

Tachometer Mode

The engine RPM is displayed digitally. Small fluctuations in the RPM from day to day may be normal because of changes in humidity, temperature and elevation.

FEATURES AND CONTROLS

Instrument Cluster

Rider Information Center

Diagnostic Mode

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

To enter the diagnostics mode:

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

2. Lock the parking brake.

3. Place the transmission in neutral.

4. Hold the mode button and turn the key switch on. Release the

switch as soon as the display is activated.

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

FEATURES AND CONTROLS

Instrument Cluster

Rider Information Center

Diagnostic Mode

Battery Voltage Screen

View this screen to check battery voltage level.

Tachometer Screen

View the tachometer to check engine speed.

AWD Diagnostic Screen

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

Gear Circuit Diagnostic Screen

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

Programmable service interval

When the hours of engine operation equal the programmed service interval setting, the wrench icon will flash for 5 seconds each time the engine is started. When this feature is enabled, it provides a convenient reminder to perform routine maintenance. See page 38.

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

FEATURES AND CONTROLS

Instrument Cluster

Rider Information Center

Diagnostic Mode

Programmable service interval

To enable or disable the service interval:

1. Enter the diagnostic mode.

2. Toggle to the service interval screen.

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

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

To reset the service interval:

1. Enter the diagnostic mode.

2. Toggle to the service interval screen.

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

icon flashes. Release the button.

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

one hour. Press and hold the mode button to advance the hours quickly. If you scroll past the intended number, press and hold the button until the hours cycle back to zero.

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

stops flashing. The new service interval is now programmed.

Miles/Kilometers toggle

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

1. Enter the diagnostic mode.

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

(MP).

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

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

FEATURES AND CONTROLS

Instrument Cluster

Rider Information Center

Accessing Blink Codes

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

See page 40 for Blink Codes and Failure Descriptions. Use the following procedure to access blink codes (failure codes) from the EFI module.

1. Apply the brakes.

2. Engage the park brake.

3. Stop the engine.

4. Turn the key switch to the ON position.

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

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

FEATURES AND CONTROLS

Instrument Cluster

Rider Information Center

Blink Code Descriptions

Blink Code

-- No RPM Signal 21 Loss of Synchronization 45 Barometric Pressure Sensor: Circuit Low Input 46 Barometric Pressure Sensor: Circuit High Input 22 TPS: Open or Short Circuit to Ground 22 TPS: Short Circuit to Battery 23 RAM Error: Defective ECU 42 Engine Temp Sensor Circuit: Short to Ground 42 Engine Temp Sensor Circuit: Open or Short to Battery 51 Injector 1: Open Load 51 Injector 1: Short Circuit to Ground 51 Injector 1: Short Circuit to Battery 52 Injector 2: Open Load 52 Injector 2: Short Circuit to Ground 52 Injector 2: Short Circuit to Battery 53 Rear Differential: Open Load (RANGER 4X4 only) 53 Rear Differential: Short Circuit to Ground (RANGER 4X4 only) 53 Rear Differential: Short Circuit to Battery (RANGER 4X4 only) 54 Engine Temp Lamp: Open Load 54 Engine Temp Lamp: Short Circuit to Ground 54 Engine Temp Lamp: Short Circuit to Battery 55 Diag Lamp: Open Load 55 Diag Lamp: Short Circuit to Ground 55 Diag Lamp: Short Circuit to Battery 56 Pump Relay: Open Load 56 Pump Relay: Short Circuit to Ground 56 Pump Relay: Short Circuit to Battery 57 Reverse Beeper: Open Load 57 Reverse Beeper: Short Circuit to Ground 57 Reverse Beeper: Short Circuit to Battery 58 Cooling Fan: Open Load 58 Cooling Fan: Short Circuit to Ground 58 Cooling Fan: Short Circuit to Battery 41 Intake Air Temp Sensor: Open or Short Circuit to +Sensor Voltage 41 Intake Air Temp Sensor: Short Circuit to Ground 61 END

Failure Description

OPERATION

WARNING

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

Break-In Period

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

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

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

OPERATION

Break-In Period

Engine and Drivetrain Break-in

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

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

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

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

5. Perform regular checks on fluid levels, controls and areas outlined on the daily pre-ride inspection checklist. See page 43.

6. Pull only light loads.

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

8. Inspect and adjust park brake cable tension after the first 25 hours of operation and every 100 hours thereafter to ensure proper cable tension. See page 92.

PVT Break-in (Clutches/Belt)

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

OPERATION

Pre-Ride Inspection

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 28

Brake fluid Ensure proper level 90

Front suspension Inspect, lubricate if necessary 67

Rear suspension Inspect, lubricate if necessary 67

Steering Ensure free operation 92

Tires Inspect condition and pressure 94

Wheels/fasteners Inspect, ensure fastener tightness 94

Frame nuts, bolts, fasteners Inspect, ensure tightness -

Fuel and oil Ensure proper levels 34

Coolant level Ensure proper level 80

Coolant hoses Inspect for leaks -

Throttle Ensure proper operation 88

Indicator lights/switches Ensure operation 26

Air filter, pre-filter Inspect, clean 85

Air box sediment tube Drain deposits whenever visible 85

Headlamp Check operation, apply Polaris dielec-

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

Seat Belts Check length of belt for damage,

tric grease when lamp is replaced

check latches for proper operation

OPERATION

Starting the Engine

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

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

3. Apply the brakes. Engage the park brake.

4. Shift the transmission to neutral.

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

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

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

NOTICE: Operating the vehicle immediately after starting could cause engine

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

OPERATION

Stopping the Engine

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

2. Turn the engine off.

3. Engage the park brake.

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

Braking

1. Release the throttle pedal completely.

2. Press on the brake pedal evenly and firmly.

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

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

near an idle, the vehicle has no engine braking.

OPERATION

Driving Procedure

1. Wear a helmet and eye protection.

2. Perform the pre-ride inspection. See page 43.

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

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

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

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

7. Release the park brake.

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

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

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

OPERATION

WARNING

Sideways

skid

Turn in

direction of

skid

Driving on Slippery Surfaces

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

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

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

2. Slow down before entering slippery areas.

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

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

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

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

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

skid. Never apply the brakes during a skid.

OPERATION

15° maximum

Driving Uphill

Whenever traveling uphill, follow these precautions:

1. Always travel straight uphill.

2. Avoid steep hills (15° maximum).

3. Keep both feet on the floor.

4. Always check the terrain carefully before ascending any hill.

5. Never climb hills with excessively slippery or loose surfaces.

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

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

OPERATION

15° maximum

Driving on a Sidehill (Sidehilling)

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

If crossing a sidehill is unavoidable, follow these precautions:

1. Slow down.

2. Exercise extreme caution.

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

Driving Downhill

When driving downhill, follow these precautions:

1. Avoid steep hills (15° maximum).

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

3. Slow down.

4. Apply the brakes slightly to aid in slowing.

OPERATION

Floorboard

Driving Through Water

You r P ol a r i s RANGER can operate through water up to a maximum recommended depth equal to the floorboards.

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

Follow these procedures when operating through water:

1. Determine water

2. Choose a crossing

3. Proceed slowly,

4. Avoid operating

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

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

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

correctly and promptly. After immersion, always take the vehicle to your dealer service. Do not start the engine! If it's impossible to bring the vehicle to your dealer before starting the engine, perform the service outlined on page 84, and take the vehicle to your dealer at the first opportunity.

depths and current before entering water.

where both banks have gradual inclines.

avoiding rocks and obstacles.

through deep or fastflowing water.

sure to the pedal repeatedly until braking action is normal.

services outlined in the Periodic Maintenance Chart beginning on page 62. Give special attention to engine oil, transmission oil, all gearcase fluids, and all grease fittings.

OPERATION

Driving Over Obstacles

Follow these precautions when operating over obstacles:

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

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

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

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 open the throttle suddenly.

OPERATION

15° maximum

Parking on an Incline

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

1. Apply the brakes.

2. Place the transmission in gear.

3. Engage the park brake.

4. Turn the engine off.

5. Block the rear wheels on the downhill side.

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 downhill.

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

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

OPERATION

Hauling Cargo

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

Model Maximum Total

RANGER 4X4 1500 lbs. (681 kg) 1000 lbs. (454 kg)

RANGER 6X6 2000 lbs. (907 kg) 1250 lbs. (567 kg) Cargo Box

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

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

Weight Capacity

(Level Ground)

Maximum Cargo Box

Weight Capacity

250 lbs. (113 kg) Storage Box

OPERATION

Towing Loads

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

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

2. Do not operate the vehicle faster than 10 mph (16 km/h) when towing. See page 54. 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 110.

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 4x4 2000 lbs.

RANGER 6x6 2000 lbs.

RANGER CREW 2000 lbs.

Load Weight

(Level Ground)

(907 kg)

Total Towed

Load Weight

(15° grade)

850 lbs. (386 kg)

Tota l H i t c h

Vertical

Weight

150 lbs.

(68.1 kg)

150 lbs.

(68.1 kg)

150 lbs.

(68.1 kg)

Maximum

Tow i n g

Speed

10 mph

(16 kph)

10 mph

(16 kph)

10 mph

(16 kph)

Belt Life

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

OPERATION

Release Lever

Dumping the Cargo Box

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

2. Apply the brakes.

3. Place the transmission in gear.

4. Engage the park brake.

5. Dismount the vehicle.

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

7. Release the tailgate by pulling up on the tailgate latch.

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

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

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

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

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

OPERATION

Parking the Vehicle

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

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

3. Turn the engine off.

4. Engage the park brake.

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

OPERATION

All Wheel Drive (AWD)

Engaging AWD

Press the top of the rocker switch to engage All Wheel Drive (AWD). The illuminated amber AWD switch indicates that the vehicle is in AWD.

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

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

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

NOTICE: Switching to AWD while the rear wheels are spinning may cause

Disengaging AWD

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

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

1. Stop the vehicle.

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

3. Stop completely.

4. Shift into low gear and drive forward.

5. If the front gearcase remains locked after following these instruc-

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

tions, see your dealer for service.

OPERATION

4X4 Models

6X6 Models

All Wheel Drive (AWD)

Locking the Differential

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

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

all four rear wheels will be drive wheels.

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

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

EMISSION CONTROL SYSTEMS

Noise Emission Control System

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

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

Polaris warrants that the spark arrestor in this vehicle 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.

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

Crankcase Emission Control System

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

Exhaust Emission Control System

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

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

Electromagnetic Interference

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

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

MAINTENANCE

Periodic Maintenance Chart

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

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

Record maintenance and service in the Maintenance Log beginning on page 129.

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

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

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

Severe Use Definition

• Frequent immersion in mud, water or sand

• Racing or race-style high RPM use

• Prolonged low speed, heavy load operation

• Extended idle

• Short trip cold weather operation

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

MAINTENANCE

Periodic Maintenance Chart

Maintenance Chart Key

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

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

Q Have an authorized Polaris dealer perform these services.

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

MAINTENANCE

Periodic Maintenance Chart

Perform all services at whichever maintenance interval is reached first.

Item Maintenance Interval

Steering - Pre-Ride - Make adjustments as need

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

Tires - Pre-Ride -

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

Brake system - Pre-Ride -

Wheels/fasteners - Pre-Ride -

Frame fasteners - Pre-Ride -

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

XEAir box sediment

tube

Coolant (if applicable)

Headlamp/tail lamp

XEAir filter,

main element

Brake pad wear 10 H Monthly - Inspect periodically

Battery 20 H Monthly - Check terminals; clean; test

X Front Gearcase Oil

(if equipped)

X Middle Gearcase

Oil (if equipped)

X Rear gearcase oil

(if equipped)

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

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

E Emission-Related Service

Q Have an authorized Polaris dealer perform these services.

(whichever comes first)

Hours Calendar Miles

- Daily - Drain deposits when visible

- Daily - Check level daily, change

- Daily - Check operation; apply

- Weekly - Inspect; replace as needed

25 H Monthly - Inspect level; change yearly

(Km)

ed. See Pre-Ride Checklist on page 43.

as needed

coolant every 2 years

dielectric grease if replacing

Remarks

Periodic Maintenance Chart

MAINTENANCE

Item Maintenance Interval

XEEngine breather

filter (if equipped)

X Engine oil change

(break-in)

Park brake cable tension

X General

lubrication

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

Steering 50H 6 M - Lubricate

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

Throttle cable/

ETC switch

E Throttle body air

intake ducts/flange

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

Cooling system (if applicable)

Park brake cable tension

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

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

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

E Emission-Related Service

Q Have an authorized Polaris dealer perform these services.

(whichever comes first)

Hours Calendar Miles

25 H Monthly - Inspect; replace if necessary

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

25 H 1 M - Check tension, adjust

50 H 3 M - Lubricate all fittings, pivots,

50 H 6 M - Inspect; adjust; lubricate;

50 H 6 M - Inspect duct for proper seal-

50 H 6 M - Inspect coolant strength

100 H 6 M - Check tension, adjust

(Km)

at one month

cables, etc.

replace if necessary

ing/air leaks

needed

seasonally; pressure test system yearly

at one month

Remarks

MAINTENANCE

Periodic Maintenance Chart

Item Maintenance Interval

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

Fuel filter 100 H 12 M - Replace yearly

X Radiator

(in applicable)

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

Exhaust muffler/ pipe

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

Ignition timing 100 H 12 M - Inspect

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

Clutches (drive and driven)

Front wheel bearings

Brake fluid 200 H 24 M - Change every two years

Spark arrestor 300 H 36 M - Clean out

Idle speed - Adjust as needed

Toe adjustment - Inspect periodically; adjust

Auxiliary brake (if

equipped)

Headlight aim - Adjust as needed

X Perform these procedures more often for vehicles subjected to severe use. E Emission-Related Service

Q Have an authorized Polaris dealer perform these services

(whichever comes first)

Hours Calendar Miles

100 H 12 M - Inspect; clean external

100 H 12 M - Inspect

100 H 12 M - Inspect; clean; replace worn

100 H 12 M - Inspect; replace as needed

(Km)

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

surfaces

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

parts

when parts are replaced

- Inspect daily; adjust as needed

Remarks

MAINTENANCE

6X6 Prop Shaft U-Joints

Lubrication Recommendations

Check and lubricate all components at the intervals outlined in the Periodic Maintenance Chart beginning on page 62, or more often under severe use, such as wet or dusty conditions. Items not listed in the chart should be lubricated at the general lubrication interval.

Item Lube Method

Engine Oil PS-4 PLUS 2W-50 Add to proper level on dipstick.

Brake Fluid DOT 4 Maintain level between fill lines.

Main Gearcase Oil (Transmission)

Front Gearcase Oil Premium Demand Drive

Middle Gearcase Oil (6X6) Premium ATV Angle Drive

Rear Gearcase Oil (6X6) Premium ATV Angle Drive

Prop Shaft U-joints (6X6) Polaris Premium U-Joint

Front Prop Shaft Yoke Polaris Premium U-Joint

Premium AGL Synthetic Gearcase Lube

Hub Fluid

Fluid

Lube

See page 69.

See page 90.

See page 74 (6X6). See page 73 (4X4/Crew).

See page 75.

See page 76.

See page 77.

Locate fittings and grease.

Locate fittings and grease (3 pumps maximum).

MAINTENANCE

Engine Intake Restrictor Plate

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

the warranty on the vehicle.

Engine Oil

Always check and change the engine oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 62. Always change the oil filter whenever changing oil.

WARNING! Vehicle operation with insufficient, deteriorated, or contaminated engine oil will cause accelerated wear and may result in engine seizure, accident, and injury. Always perform the maintenance procedures as outlined in the Periodic Maintenance Chart.

Oil Recommendations

Polaris recommends the use of Polaris PS-4 PLUS Performance Synthetic 2W-50 4-cycle oil or a similar oil. See page 116 for the part numbers of Polaris products.

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

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

MAINTENANCE

Safe

{

Safe

Range

Check Level

on Top Side

Dipstick

Engine Oil

Always check and change the oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 62. Always use the recommended engine oil.

Oil Check

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

1. Position the vehicle on a level surface.

2. Lift the lever lock to remove the dipstick. Wipe it dry with a clean cloth.

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

4. Remove the dipstick and check the oil level. Maintain the oil level in the safe range. Do not overfill.

Tip: Due to the dipstick entry angle into

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

5. After reinstalling the dipstick, be sure to seat the lever lock.

MAINTENANCE

Engine Oil

Oil and Filter Change

Always change the oil and filter at the intervals outlined in the Periodic Maintenance Chart beginning on page 62. Always change the oil filter whenever changing oil.

1. Position the vehicle on a level surface.

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

3. Clean the area around the drain plug.

4. Place a drain pan beneath engine crankcase.

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

5. Remove the drain plug.

6. Allow the oil to drain completely.

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

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

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

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

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

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

MAINTENANCE

Engine Oil

Oil and Filter Change

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

14. Shift the transmission to neutral.

15. Apply the brakes. Engage the park brake.

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

17. Stop the engine. Inspect for leaks.

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

19. Dispose of used filter and oil properly.

MAINTENANCE

Gearcases

Gearcase Specification Chart

RANGER 4X4 Gearcase Specifications

Gearcase Lubricant Capacity Fill Plug

Main Gearcase (Transmission)

Front Gearcase Premium Demand

Gearcase Lubricant Capacity Fill Plug

Main Gearcase (Transmission)

Front Gearcase Premium Demand

Middle Gearcase Premium ATV

Rear Gearcase Premium ATV

Premium AGL

Synthetic

Gearcase Lube

Drive Hub Fluid

34 oz.

(1000 ml)

9.3 oz.

(275 ml)

8-10 ft. lbs.

(11-13.6 Nm

RANGER 6x6 Gearcase Specifications

Premium AGL

Synthetic

Gearcase Lube

Drive Hub Fluid

Angle Drive Fluid

43.6 oz.

(1290 ml)

9.3 oz.

(275 ml)

6.75 oz. (200 ml)

18 oz.

(532 ml)

8-10 ft. lbs.

(11-13.6 Nm

To r q u e

12 ft. lbs.

(16.3 Nm)

To r q u e

12 ft. lbs.

(16.3 Nm)

14 ft. lbs.

(19.4 Nm)

14 ft. lbs.

(19.4 Nm)

Drain Plug

To r q u e

12 ft. lbs.

(16.3 Nm)

11 ft. lbs.

(15 Nm)

Drain Plug

To r q u e

12 ft. lbs.

(16.3 Nm)

11 ft. lbs.

(15 Nm)

14 ft. lbs.

(19.4 Nm)

14 ft. lbs.

(19.4 Nm)

RANGER CREW Gearcase Specifications

Gearcase Lubricant Capacity Fill Plug

Main Gearcase (Transmission)

Front Gearcase Premium Demand

Premium AGL

Synthetic

Gearcase Lube

Drive Hub Fluid

34 oz.

(1000 ml)

9.3 oz.

(275 ml)

8-10 ft. lbs.

(11-13.6 Nm

To r q u e

12 ft. lbs.

(16.3 Nm)

Drain Plug

To r q u e

12 ft. lbs.

(16.3 Nm)

11 ft. lbs.

(15 Nm)

MAINTENANCE

Drain Plug

Fill Plug

Gearcases

Transmission (Main Gearcase) (4X4/Crew)

Always check and change the transmission oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 62. Maintain the oil level even with the bottom of the fill plug hole threads.

Refer to the Gearcase Specifications Chart on page 72 for recommended lubricants, capacities and torque specifications. See page 116 for the part numbers of Polaris products.

Oil Check

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

1. Position the vehicle on a level surface.

2. Remove the fill plug.

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

4. Reinstall the fill plug. Torque to specification.

Oil Change

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

1. Remove the fill plug.

2. Place a drain pan under the gearcase.

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

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

5. Add the recommended oil.

6. Reinstall the fill plug. Torque to specification.

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

MAINTENANCE

Drain Plug

Fill

Plug

Gearcases

Transmission (Main Gearcase) (6X6)

Always check and change the transmission oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 62. Maintain the oil level even with the bottom of the fill plug hole.

Refer to the Gearcase Specifications Chart on page 72 for recommended lubricants, capacities and torque specifications. See page 116 for the part numbers of Polaris products.

Oil Check

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

1. Position the vehicle on a level surface.

2. Remove the fill plug.

3. Check the oil level.

4. Add the recommended oil as needed.

5. Reinstall the fill plug. Torque to specification.

Oil Change

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

1. Remove the fill plug.

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

3. Wipe the magnetic end of the drain plug clean to remove accumulated metallic filings. Install a new sealing washer.

4. Reinstall the drain plug. Torque to specification.

5. Add the recommended oil. Do not overfill.

6. Reinstall the fill plug. Torque to specification.

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

MAINTENANCE

Drain

Plug

Fill

Plug

Gearcases

Front Gearcase

Always check and change the front gearcase oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 62. Maintain the oil level even with the bottom thread of the fill plug hole.

Refer to the Gearcase Specifications Chart on page 72 for recommended lubricants, capacities and torque specifications. See page 116 for the part numbers of Polaris products.

Oil Check

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

1. Position the vehicle on a level surface.

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

3. Add the recommended oil as needed.

4. Reinstall the fill plug. Torque to specification.

Oil Change

1. Support the vehicle securely with a jackstand.

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

3. Remove the fill plug.

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

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

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

7. Add the recommended oil.

8. Reinstall the fill plug. Torque to specification.

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

MAINTENANCE

Drain Plug

Fill Plug

Gearcases

Middle Gearcase (6X6)

Always check and change the middle gearcase oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 62. Maintain the oil level even with the bottom thread of the fill plug hole.

Refer to the Gearcase Specifications Chart on page 72 for recommended lubricants, capacities and torque specifications. See page 116 for the part numbers of Polaris products.

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

Oil Check

1. Position the vehicle on a level surface.

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

3. Add the recommended oil as needed.

4. Reinstall the fill plug. Torque to specification.

Oil Change

1. Remove the fill plug.

2. Place a drain pan under the drain plug.

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

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

5. Add the recommended fluid.

6. Reinstall the fill plug. Torque to specification.

7. Check for leaks. Discard used oil properly.

MAINTENANCE

Fill

Plug

Drain Plug

Gearcases

Rear Gearcase (6X6)

Always check and change the rear gearcase oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 62.

Refer to the Gearcase Specifications Chart on page 72 for recommended lubricants, capacities and torque specifications. See page 116 for the part numbers of Polaris products.

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

Oil Check

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

1. Position the vehicle on a level surface.

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

3. Add the recommended oil as needed.

4. Reinstall the fill plug. Torque to specification.

Oil Change

1. Remove the fill plug.

2. Place a drain pan under the drain plug.

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

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

5. Add the recommended oil.

6. Reinstall the fill plug. Torque to specification.

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

MAINTENANCE

Spark Plugs

Spark Plug Recommendations

Refer to the specifications section beginning on page 110 for the recommended spark plug type for your vehicle. Always torque spark plugs to specification.

NOTICE: Using non-recommended spark plugs can result in serious engine

Spark Plug Gap/Torque

Spark Plug Inspection

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

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

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

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

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

damage. Always use Polaris-recommended spark plugs.

Model Electrode Gap New Plug

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

To r q u e

(24 Nm)

plug by rotating it counterclockwise.

cation.

Used Plug

To r q u e

18 ft. lbs.

(24 Nm)

Normal Plug

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

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

Wet Fouled Plug

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

MAINTENANCE

Cooling System

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

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

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

Adding or Changing Coolant

To ensure that the coolant maintains its ability to protect the engine, we recommend that the system be completely drained every two years and a fresh mixture of antifreeze and water added. Polaris recommends the use of Polaris Premium 60/40 anti-freeze/coolant or a 50/50 mixture of high quality aluminum compatible anti-freeze/coolant and distilled water. Polaris Premium 60/40 is already premixed and ready to use. Do not dilute with water. See page 116 for the part numbers of Polaris products.

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

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

MAINTENANCE

Cooling System

Radiator and Cooling Fan

Always check and clean the screen and radiator fins at the intervals outlined in the Periodic Maintenance Chart beginning on page 62. Do not obstruct or deflect air flow through the radiator by installing unauthorized accessories in front of the radiator or behind the cooling fan. Interference with the radiator air flow can lead to overheating and consequent engine damage.

NOTICE: Washing the vehicle with a high-pressure hose could damage the

Overflow Bottle Coolant Level

Always check and change the coolant at the intervals outlined in the Periodic Maintenance Chart beginning on page 62. Maintain the coolant level between the minimum and maximum marks on the bottle (when the fluid is cool).

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

1. Position the vehicle on a level surface.

2. View the coolant level in the overflow bottle.

3. If the coolant level is below the

Tip: If coolant must be added often, or if

radiator fins and impair the radiator's effectiveness. Using a highpressure system is not recommended.

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

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

MAINTENANCE

Cooling System

Radiator Coolant Level

1. Lift the hood.

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

2. Slowly remove the radiator cap.

3. View the coolant level through the opening.

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

Tip: This procedure is required only if the cooling system has been drained for

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

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

MAINTENANCE

WARNING

Polaris Variable Transmission (PVT) System

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

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

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

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

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

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

When To Use Low Range and High Range

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

Condition Range to Use

Operating at speeds less than 7 MPH (11 km/h) Low

Towing heavy loads Low

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

Operating at speeds greater than 7 MPH (11 km/h) High

MAINTENANCE

PVT System

PVT Drying

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

1. Position the vehicle on a level surface.

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

3. Apply the brakes. Start the engine.

4. Engage the park brake.

5. Shift the transmission to neutral.

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

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

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

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

MAINTENANCE

Vehicle Immersion

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

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

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

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

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

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

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

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

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

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

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

footrests.

if water is present.

the electric start.

dure.

whether you succeed in starting it or not.

page 83 for drying.

MAINTENANCE

Air Filter

Filter Systems

Air Filter

Always change the air filter at the intervals outlined in the Periodic Maintenance Chart beginning on page 62. Service the air filter more frequently if the vehicle is operated in wet conditions or at high throttle openings for extended periods.

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

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

3. Remove the air filter.

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

Tip: Apply a small amount of

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

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

Fuel Filter

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

MAINTENANCE

WARNING

Spark Arrestor

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

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

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

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

Never go under the vehicle while it's inclined.

MAINTENANCE

Clean-Out

Plugs

Exhaust

Outlet

Spark Arrestor

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

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

2. Place the transmission in neutral.

3. Engage the park brake.

4. Start the engine.

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

6. If carbon is expelled, cover or plug the exhaust outlet and rap on the pipe around the clean-out plugs while revving the engine several more times.

7. If particles are still suspected to be in the muffler, elevate the rear of the vehicle one foot higher than the front. Block the wheels.

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

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

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

MAINTENANCE

WARNING

Throttle

Pedal

Throttle System

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

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

Throttle Freeplay

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

Check the throttle pedal freeplay at the intervals outlined in the Periodic Maintenance Chart beginning on page 62. Adjust the freeplay if necessary.

Throttle Freeplay Inspection

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

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

3. Measure the distance the throttle pedal moves before the engine begins to pick up speed. Freeplay should be 1/16 to 1/8 inches (1.6-

3.2 mm).

MAINTENANCE

Boot

Adjuster

Lock Nut

Throttle System

Throttle Body/Idle RPM

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

Throttle Freeplay Adjustment

1. Remove the seat.

2. Locate the throttle cable adjuster.

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

4. Loosen the adjuster lock nut.

5. Rotate the boot to turn the adjuster until 1/16" to 1/8" (1.5-3 mm) of freeplay is achieved at the throttle pedal. See page 88.

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

6. Tighten the lock nut.

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

MAINTENANCE

Maximum

Minimum

Brakes

The front and rear brakes are hydraulic disc type brakes activated by the brake pedal. See page 28.

Brake Fluid

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

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

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

1. Position the vehicle on a level surface.

2. View the brake fluid level at the reservoir in the driver’s side wheel well.

3. The level should be between the upper (MAX) and lower (MIN) level lines.

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

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

Brakes

3/64" (1mm)

Park Brake Release

Brake Inspection

1. Check the brake system for fluid leaks.

2. Check the brake pedal for excessive travel or a spongy feel.

3. Check the friction pads for wear, damage and looseness.

4. Inspect the brake disc spline and pad wear surface for excessive wear.

5. Change pads when worn to 3/64" (1 mm).

Park Brake Inspection

1. Apply the brakes.

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

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

MAINTENANCE

Brakes

Park Brake Adjustment

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

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

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

1. Position the vehicle on a level surface.

2. Shift the transmission to neutral.

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

Steering Wheel Inspection

Check the steering wheel for specified freeplay and smooth operation at the intervals outlined in the Periodic Maintenance Chart beginning on page 62.

1. Position the vehicle on level ground.

2. Lightly turn the steering wheel left and right.

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

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

MAINTENANCE

Outside Mounting Holes

Inside Mounting Holes

Cam

Rear Suspension Shown

Adjustment is similar for Front Suspension

Suspension Adjustments

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

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

2. Reposition the shocks to the outside mounting holes.

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

Spring Adjustment

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

MAINTENANCE

WARNING

1/8" (3 mm)

Tires

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

Tire Tread Depth

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

Axle and Wheel Nut Torque Specifications

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

Do not lubricate the stud or the lug nut.

Nut Type Location Nut Torque

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

2-Piece Flange Nut

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

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

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

MAINTENANCE

Tires

Wheel Removal

1. Apply the brakes. Engage the park brake.

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

3. Loosen the wheel nuts slightly.

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

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

Wheel Installation

1. Apply the brakes.

2. Place the transmission in gear.

3. Engage the park brake.

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

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

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

6. Carefully lower the vehicle to the ground.

7. Torque the wheel nuts to specification. See page 94.

MAINTENANCE

Wiring Harness

Lights

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

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

Headlight Lamp Replacement

1. Open the hood.

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

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

3. Turn the lamp counterclockwise to remove it.

4. Install the new lamp.

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

5. Reinstall the harness assembly into the headlight assembly.

Brake Lights

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

1. Turn the ignition switch to the ON position.

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

Polaris Ranger XP User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual