Polaris RANGER XP 4X4 700 EFI User Manual

WARNING

The engine exhaust from this

product contains chemicals known

to cause cancer, birth defects or

other reproductive harm.

WELCOME

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

S Snowmobiles
S All-terrain vehicles (ATVs)
S RANGER utility vehicles
S V ictory motorcycles

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

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

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

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!

1

Copyright 2005 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.

2006 RANGER XP 4X4 700 EFI/RANGER 6X6 700 EFI
Owner’s Manual P/N 9920220

2

TABLE OF CONTENTS

VEHICLE IDENTIFICATION NUMBERS 4........

SAFETY 5...................................

FEATURES AND CONTROLS 23...............

OPERATION 33..............................

EMISSION CONTROL SYSTEMS 52............

MAINTENANCE AND LUBRICATION 53.........

POLARIS PRODUCTS 99......................

SPECIFICATIONS 100........................

TROUBLESHOOTING 104.....................

WARRANTY 107..............................

MAINTENANCE LOG 116......................

INDEX 118...................................

3

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.
Your key can be duplicated only by mating a Polaris key blank with
one of your existing keys, so if both keys are lost, the ignition switch
must be replaced.

2

31XX

3

1

Vehicle Model Number:
(behind left front wheel)

Frame VIN (1):
(under hood)

Engine Serial Number (2):
(right front side of engine crankcase)

Key Number (3):

4

SAFETY

Operator Safety

WARNING

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

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

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

Age Restrictions

This vehicle is an ADULT VEHICLE ONLY. Operation is prohibited
for anyone under 16 years of age. No person under the age of 5 may
ride as a passenger in this vehicle.

Know Your Vehicle

As the operator of the vehicle, you are responsible for your personal
safety, t he safety of others, and the protection of our environment.
Read and understand your owner’s manual, which includes valuable
information about all aspects of your vehicle, including safe operating
procedures.

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

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

5

SAFETY

Operator Safety

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

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

WARNING

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

CAUTION

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

CAUTION

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

NOTE:

A note will alert you to important information or instructions.

6

SAFETY

Operator Safety

WARNING

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

S Read this manual and all labels carefully. Follow the operating pro-

cedures described.

S Never allow anyone without a valid driver’s license to operate this

vehicle.

S Minimum age recommendation for passengers is five years old. Pas-

sengers under five years of age require special restraints which are
not available with this vehicle. Driver and passenger should wear
their seat belts at all times.

S Never permit a guest to operate this vehicle unless the guest has read

this manual and all product labels.

S To reduce tipover risk, be especially careful when encountering ob-

stacles and slopes and when braking on hills or during turns.

S This vehicle is for off road use only. Never operate on public roads.

Always avoid paved surfaces.

S Helmets are recommended whenever driving this vehicle in an

aggressive manner. Eye protection is recommended at all times.

S Never consume alcohol or drugs before or while operating this ve-

hicle.

S Never operate at excessive speeds. Always travel at a speed proper

for the terrain, visibility and operating conditions, and your experi­ence.

S Never attempt wheelies, jumps or other stunts.
S Always inspect your vehicle each time you use it to make sure it’s in

safe operating condition. Always follow the inspection and mainte­nance procedures and schedules described in this manual.

S Always keep both hands on the steering wheel and both feet on the

floorboards of the vehicle during operation.

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

miliar terrain. Be alert to changing terrain.

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

7

SAFETY

Operator Safety

S Always follow proper procedures for turning as described in this

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

S Always have this vehicle checked by an authorized Polaris dealer if

it has been involved in an accident.

S Never operate this vehicle on hills too steep for the vehicle or for

your abilities. Practice on smaller hills before attempting larger hills.

S 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.

S Always follow the proper procedures outlined in this manual for

traveling 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.

S 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.

S 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.

S 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.

S 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.

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

Always maintain proper tire pressure as specified on page 19.

8

SAFETY

Operator Safety

S Never modify this vehicle through improper installation or use of

accessories.

S 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.

S Always wear the seat belts when operating this vehicle. Seat belts

reduce the severity of injury in case of a sudden stop or collision.

S Always keep arms and l egs inside the cab frame while the vehicle is

in motion.

S Always engage the park brake before getting out of the vehicle. See

page 32.

S Always apply the service brakes before releasing the park brake.
S Always turn off the engine before refueling. Make sure the refueling

area is well ventilated and free of any source of flame or sparks.
Gasoline is extremely flammable. See page 22 for refueling instruc­tions.

S 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
1-800-342-3764.

9

SAFETY

Operator Safety

WARNING

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

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

Do not make any modifications to your RANGER.

Equipment Modifications

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

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

NOTE: The addition of certain accessories, including (but not limited

to) 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.

10

Operator Safety

WARNING

POTENTIAL HAZARD
Stalling, rolling backwards while

climbing a hill
WHAT CAN
Vehicle overturn
HOW TO AVOID THE
Maintain a steady speed when

climbing a hill.
Ifyouloseallforward
Apply the brakes.
Engage the park brake after fully stopped.
If you begin rolling
Never apply engine power.
Apply the brakes gradually.
When fully stopped, engage the park brake.
In the event of an accident, have a qualified service dealer check

the complete vehicle for possible damage, including (but not
limited to) brakes, throttle and steering.

HAPPEN

HAZARD

speed:

backwards:

SAFETY

11

SAFETY

Operator Safety

WARNING

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

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

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

HAPPEN

HAZARD

WARNING

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

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

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

HAPPEN

HAZARD

12

SAFETY

Operator Safety

WARNING

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

including dirt or gravel.
In many states it’s illegal to operate vehicles of this type on public

streets, roads and highways.

HAPPEN

HAZARD

WARNING

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

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

HAPPEN

HAZARD

13

SAFETY

Operator Safety

WARNING

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

operating conditions, and your experience.

HAPPEN

HAZARD

WARNING

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

HAPPEN

HAZARD

WARNING

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

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

HAPPEN

HAZARD

14

SAFETY

Operator Safety

WARNING

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

in safe operating condition.
Always follow the inspection and maintenance procedures and

schedules described in the Owner’s Manual.

HAPPEN

HAZARD

WARNING

POTENTIAL HAZARD
Failure to use extra caution when operating this vehicle on

unfamiliar terrain
WHAT CAN
Loss of control, vehicle overturn
HOW TO AVOID THE
Travel slowly and use extra caution when operating on unfamiliar

terrain.
Always be alert to changing terrain conditions when operating the

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

HAPPEN

HAZARD

15

SAFETY

Operator Safety

WARNING

POTENTIAL HAZARD
Failure to follow the minimum age recommendations for this

vehicle
WHAT CAN
Serious injury or death (the child or others)
HOW TO AVOID THE
Only persons with a valid driver’s license should operate a Polaris

RANGER.
Even though a child may be within the age group for which some

vehicles are recommended, he or she may not have the skills,
abilities, or judgment needed to operate the vehicle safely and
may be involved in a serious accident.

HAPPEN

HAZARD

WARNING

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

uneven tire pressure
WHAT CAN
Loss of control, accident and/or overturn
HOW TO AVOID THE
Always use the size and type of tires specified in the Owner’s

Manual for this vehicle. See page 19.
Always maintain proper tire pressure as described on the decal

and in the Owner’s Manual. See page 19.

HAPPEN

HAZARD

16

Operator Safety

WARNING

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

WARNING

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

CAUTION

Always keep combustible materials away from the exhaust
system. Exposure to the hot components could result in a fire.

SAFETY

17

SAFETY

Safety Decals and Locations

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

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

3

2

WARNING

S Moving parts hazard under belt-clutch guard. To

prevent ser io us injury, do not operate vehicle
with guard removed.

S 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.

NO STEP

7172563

Location 1

18

1

SAFETY

Safety Decals and Locations

WARNING

S VEHICLE ROLLOVER could cause severe injury or death.

This cab frame is not designed or intended to provide rollover protection.

S ALWAYS WEAR YOUR SEAT BELT for maximum protection.

7172676

Location 2

Location 3 (inside front of box)

Container/Passenger/Tire Pressure Warning Decal Text

Remove flammable material containers from box before filling.

S Passengers can be thrown off. This can cause serious injury or death.
S Never carry passengers in cargo box.

Maximum 2X4 Box Load 850 lbs. Maximum 4X4 Box Load 1000 lbs.
Maximum 6X6 Box Load 1200 lbs.

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

TIRE PRESSURE (PSI):

RANGER - 2x4 and 4x4 FRONT 10 REAR 10
RANGER - 6x6 FRONT 10 CENTER 10 REAR 10

MAXIMUM WEIGHT CAPACITY (Gross Vehicle Weight)
INCLUDING MACHINE, DRIVER AND CARGO:
RANGER 2X4 and 4X4 is 2750 LBS. RANGER 6X6 is 2900 LBS.

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.

19

SAFETY

Safety Decals and Locations

5

Location 5 (under hood)

6

20

ATTENTION

S Operation of this vehicle without the air filter

element will severely damage the engine.

S Clean pre-filter element often, more

frequent cleaning required in dusty
conditions. Do not operate vehicle without
pre-filter.

Location 6

Location 7

7172921

Safety Decals and Locations

Discretionary Warning Decal

SAFETY

7

8

21

SAFETY

Fuel Safety

WARNING

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

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

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

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

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

22

FEATURES AND CONTROLS

Some Polaris vehicles are equipped with special features such as the
cab frame. Not all models come with all features. Refer to the
specifications section beginning on page 100.

Component Locations

1

3

4

2

6

5

7

1. Cab Frame (if equipped)

2. Hip Bar

3. Console

4. Steering Wheel

5. Seat

6. Storage Box (under driver’s seat)

7. Cargo Box

8. Seat Belts

9. Fuel Tank Cap / Fuel Gauge

10. Battery (under hood)

11. Storage Box (under hood)

10

8

9

23

FEATURES AND CONTROLS

Component Locations

12

15

14

12. Headlights

13. Radiator (if equipped)

14. Front Bumper/Brush Guard

15. Hood Hold Down Strap

24

13

FEATURES AND CONTROLS

Component Locations

17

16

20

16. Taillights

17. Tailgate

18. Tailgate Latch Release

19. Muffler (Spark Arrester)

20. CV Boot/Rear Caliper

21. Air Box

22. Receiver Hitch

18

22

16

19

21

20

25

FEATURES AND CONTROLS

Indicator Lights

1. High Gear

2. Low Gear

3. Neutral Gear

4. Reverse Gear

5. High Temperature

6. Park Brake

6

4

5

2

3

1

Trailer Hitch Bracket

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

To avoid injury and property damage, always heed the warnings and
towing capacities outlined on page 48.

Auxiliary Outlet

The 12-volt receptacle (7)
has spade connections on
the back that may be used to
power an auxiliary light or
other optional accessories or
lights. The connections are
behind the console, under
the hood.

7

26

FEATURES AND CONTROLS

Fuel Cap/Fuel Gauge

The fuel tank filler cap (8) i s located on
the right-hand side of the vehicle near
the passenger seat. It has a built-in fuel
gauge that indicates the amount of fuel
remaining in the tank.

When the indicator needle nears the E
(empty) mark, refuel at the earliest
opportunity.

When refueling, always use either
leaded or unleaded gasoline with a
minimum pump octane number of 87
R+ M/2 octane.

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.

8

27

FEATURES AND CONTROLS

Seat Belts

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

WARNING

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

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

To wear the seat belt properly, follow this procedure:

1. Place the belt across your lap as low on your hips as possible,
taking care that the belt is not twisted.

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

3. Release the strap, it will self tighten.

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

strap.

To unfasten, press the square red button in the buckle’s center.

28

Console

FEATURES AND CONTROLS

4

10

5

9

1

11

2

3

1. Cup Holder

2. Indicator Lights

3. Shift Lever

4. Light Switch

5. AWD/Differential Switch (if equipped)

6. Hour Meter

7. Glove Box with Lid

8. 12V Accessory Plug

9. Storage Tray

10. Ignition Switch

11. Storage Box

6

1

8

7

29

FEATURES AND CONTROLS

Gear Selector

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

NOTE: Low gear is the primary

driving range for the
RANGER XP. High gear is
intended for use on
hard-packed surfaces with
light loads.

H

L

N

R

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

CAUTION

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

Always place the transmission in gear, engage the park brake
and turn the engine off whenever the vehicle is left unattended.

Maintaining shift linkage adjustment is important to assure proper
transmission function. See your dealer if you experience any shifting
problems.

30

FEATURES AND CONTROLS

Switches

Ignition Switch (1)

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 Engine off. All electrical circuits

are off except Acc. 12V.

ON/RUN Electrical circuits are on.

Electrical equipment can be used.

START Electric starter is engaged by

holding ignition switch key in this
position. Upon release, the key
will return to the ON/RUN
position.

2

1

3

WARNING

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

Light Switch (2)

A

The ignition switch key must be in the ON/RUN position
to operate the headlights. The switch has three

B

positions:
A: High Beam

B: Low Beam

C

C: Off

AWD/Differential Lock Switch (3)

The AWD/Differential Switch has three positions:
D: AWD

D

AWD

E

E: Differential Lock (2WD)
F: Off (1WD)

Press the top of the rocker switch to engage AWD.

F

See page 51 for AWD operating instructions.

Move the rocker switch to the center position to
lock the differential and return to 2WD. See page 50 for Differential
Lock operating instructions.

Press the bottom of the switch to unlock the differential and return to
1WD.

31

FEATURES AND CONTROLS

Brake Pedal (1)

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

Throttle Pedal (2)

Push the pedal down to increase
engine speed. Spring pressure
returns the pedal to the rest
position when released. Always
check that the throttle pedal
returns normally before starting
the engine. Make sure there’s
adequate throttle pedal freeplay.
See page 81 for throttle pedal
adjustment procedures.

Park Brake Pedal (3)

Engage the park brake when parking the vehicle to help prevent the
vehicle from rolling. To engage the park brake, apply the brakes, then
push the park brake pedal down firmly and fully with your foot.

Park Brake Release (4)

Always apply the service brakes before releasing the park brake. To
release the park brake, pull the park brake release handle. Make sure
the park brake pedal is functioning properly before each operation.

1

4

3

2

32

OPERATION

Vehicle Break-In Period

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

CAUTION

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

Use of any oils other than those recommended by Polaris may
cause serious engine damage. We recommend the use of
Polaris Premium 4 Synthetic Oil for your 4-cycle engine.

1. Fill the fuel tank with gasoline. Heed the gasoline warnings on
page 22.

2. Check the oil level on the dipstick. See page 61. Add Polaris
Premium 4 Synthetic Oil if necessary 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 34.

6. Pull only light loads.

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

33

OPERATION

Pre-Ride Inspection

WARNING

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

Pre-Ride Checklist

Item Remarks See

Page

Brake system / lever travel Ensure proper operation 82

Brake fluid Ensure proper level 82

Front suspension Inspect, lubricate if necessary 58

Rear suspension Inspect, lubricate if necessary 58

Steering Ensure free operation --

Tires Inspect condition and pressure 86,101

Wheels / fasteners Inspect, ensure fastener tightness 86

Frame nuts, bolts, fasteners Inspect, ensure tightness --

Fuel and oil Ensure proper levels 61

Coolant level Ensure proper level 73

Coolant hoses Inspect for leaks --

Throttle Ensure proper operation 32

Indicator lights / switches Ensure operation 26, 31

Air filter, pre-filter Inspect, clean 78

Air box sediment tube Drain deposits whenever visible --

Headlamp Check operation, apply Polaris dielec-

tric grease when lamp is replaced

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

tric grease when lamp is replaced

88

89

34

OPERATION

Starting the Engine

WARNING

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

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

2. Engage the park brake.

3. Shift the transmission to neutral.

4. Apply the brakes while starting the engine.

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

5. Turn the ignition key past the ON/RUN position to START.
Engage the starter for a maximum of five seconds. Release t he 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.

CAUTION

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

35

OPERATION

Stopping the Engine

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

2. Turn the engine off.

3. Engage the park brake.

WARNING

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

Braking

1. Release the throttle pedal completely.

2. Press on the brake pedal evenly and firmly.

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

NOTE: When the throttle pedal is released completely and the

familiar with the controls.

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

WARNING

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

36

OPERATION

Driving Safely

Driving Procedu res

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

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

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

4. Release the park brake.

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

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

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

XP. High gear is intended for use on hard-packed surfaces
with light loads.

37

OPERATION

Driving Safely

Driving On Slippery Surfaces

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

1. Slow down when entering slippery areas.

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

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

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

CAUTION

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

WARNING

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

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

on slippery surfaces.

38

OPERATION

Driving Safely

Driving Uphill

15_ Maximum

Whenever traveling uphill, follow these precautions:

1. Always travel straight uphill.

2. Avoid steep hills (15_ maximum).

3. Keep both feet on the floor.

4. Proceed at a steady rate of speed and throttle opening.

WARNING

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

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

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

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

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

39

OPERATION

Driving Safely

Sidehilling

WARNING

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

Driving Downhill

Whenever descending a hill, follow these precautions:

1. Proceed directly downhill.

2. Slow down.

3. Apply the brakes slightly toaidinslowing.

WARNING

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

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

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

40

OPERATION

Driving Safely

Driving Through Water

WARNING

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

Your Polaris RANGER can
operate through water up
to a maximum
recommended depth equal
to the floorboards (1).
Follow these procedures
when operating through
water:

1. Always determine
water depths and
current before entering.

2. Choose a crossing
where both banks have
gradual inclines.

3. Proceed slowly, avoiding rocks and obstacles.

4. After leaving water, always dry the brakes by applying light
pressure to the pedal repeatedly until braking action is normal.

1

NOTE: After running your vehicle in water, it’s critical that you

perform the services outlined in the Periodic Maintenance
Chart beginning on page 53. Give special attention to engine
oil, transmission oil, front and rear gearcases, and all grease
fittings.

CAUTION

Immersion can result in major damage if the vehicle isn’t serviced
correctly and promptly. After immersion, always take the vehicle
to your dealer service. Do not start the engine!

If it’s impossible to bring the vehicle to your dealer before starting
the engine, perform the service outlined on page 91, and take the
vehicle to your dealer at the first opportunity .

41

OPERATION

Driving Safely

Driving Over Obstacles

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

WARNING

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

42

OPERATION

Driving Safely

Driving in Reverse

Follow these guidelines when operating in reverse:

1. Back slowly.

2. Apply the brakes lightly for stopping.

3. Avoid turning at sharp angles.

4. Always avoid backing downhill.

5. Never open the throttle suddenly while backing.

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

WARNING

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

43

OPERATION

Driving Safely

ParkingonanIncline

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

1. Place the transmission in gear.

2. Engage the park brake.

3. Turn the engine off.

4. Block the rear wheels on the downhill side.

WARNING

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

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

44

OPERATION

Driving Safely

Hauling Cargo

WARNING

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

REDUCE SPEED AND ALLOW GREATER DIST ANCES 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.

45

OPERATION

Driving Safely

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. Never exceed the following capacities.

Maximum Capacities

(Level Ground)

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

RANGER 6X6 EFI 1750 lbs. (794 kg) 1250 lbs. (567 kg)

Cargo Box

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.

46

OPERATION

Driving Safely

Dumping the Cargo Box

WARNING

Operating the vehicle while the cargo box is raised could result in
severe injury. The box could close unexpectedly and cause injury
to the driver or passenger. The rear tires will also catch the rear
of a raised box, damaging the vehicle and creating hazardous
driving conditions.

Never operate this vehicle with the cargo box in the raised
position.

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

2. Engage the park brake.

3. Dismount the vehicle.

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

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

6. Stand clear and pull up on the cargo box release lever (1).

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

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

1

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.

47

OPERATION

Driving Safely

Towing Loads

WARNING

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

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

Do not operate the vehicle faster than 10 mph (16 km/h) when
towing. See page 45. Towing a trailer increases braking
distance.

Do not tow more than the recommended weight for the vehicle.
See the towing capacity chart below and the specifications charts
beginning on page 100.

Attach a trailer to the trailer hitch bracket only. Do not attach a
trailer to any other location or you may lose control of the vehicle.

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

Maximum Towing Capacities (Level Ground)

RANGER

4x4 XP

RANGER

6X6 EFI

Total To w ed

Load Weight

(level ground)

1500 lbs.

(681 kg)

1750 lbs.

(794 kg)

Total To w ed

Load Weight

(15° grade)

850 lbs.

(386 kg)

1000 lbs.

(454 kg)

Total Hitch

Vertical

Weight

150 lbs.

(68.1 kg)

150 lbs.

(68.1 kg)

Maximum

Towing

Speed

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.

48

OPERATION

Driving Safely

Parking the RANGER

WARNING

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

1. Stop the vehicle on a level surface.

2. Turn the engine off.

3. Engage the park brake.

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

WARNING

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

49

OPERATION

Differential Lock (4X4)

The 4X4 rear axle is equipped with a lockable
differential that allows the operator to choose
between an open differential or a closed
differential. It’s beneficial to lock the
differential in low traction situations.

Move the AWD/Differential Lock rocker switch to
the center position (A) to lock the differential and
return to 2WD. Press the bottom of the switch (B)
to unlock the differential and return to 1WD.

CAUTION

Damage to the differential can occur if it is engaged while the
vehicle is traveling at high speeds or while the rear wheels are
spinning. Slow the vehicle to nearly stopped before engaging the
differential.

AWD

A

B

50

OPERATION

All Wheel Drive (AWD)

The illuminated amber AWD switch (1)
indicates that the vehicle is in AWD.

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

When the RANGER 6X6 AWD switch is
off, the vehicle is in two-wheel drive at all
times.

When the RANGER 4X4 AWD switch is off, the vehicle is in
one-wheel drive at all times. See page 50 for 4X4 two-wheel
drive/differential lock operation.

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

1

CAUTION

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

Disengaging AWD

Under certain conditions, it may be possible for the front gearcase t o
remain locked unnecessarily. This condition causes increased steering
effort and some vehicle speed restriction.

Take the following steps to disengage the AWD system:

1. Stop the vehicle.

2. Shift to reverse and back up a minimum of 10 feet.

3. Stop completely.

4. Shift into low gear and drive forward.

If the front gearcase remains locked after following these instructions,
return the vehicle to your dealer for service.

51

EMISSION CONTROL SYSTEMS

Noise Emission Control System

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

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

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

Operation of off--road vehicles on public lands in the U.S.A. is
regulated by 43 CFR 8343. 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.

Engine idle speed is the only adjustment Polaris recommends that the
operator perform. Any other adjustments should be performed by an
authorized Polaris dealer.

Emissions labels are located on either the recoil cover, the stator
housing or the left side of the engine near the clutch cover.

Electromagnetic Interference

This spark ignition system complies with Canadian ICES--002.

This vehicle complies with European directives 97/24/EC and
89/336/EEC.

52

MAINTENANCE AND LUBRICATION

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 116.

NOTE: 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 10
miles per hour. Vehicles subjected to severe use must be inspected and
serviced more frequently.

Severe Use Definition

S Frequent immersion in mud, water or sand
S Racing or race-style high RPM use
S Prolonged low speed, heavy load operation
S Extended idle
S 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.

53

MAINTENANCE AND LUBRICATION

Periodic Maintenance Chart

Maintenance Chart Key

" Perform these procedures more frequently for vehicles subjected to

severe use.

E Emission Control System Service - 4 Cycle (California)

J Have an authorized Polaris dealer perform these services.

WARNING

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

54

MAINTENANCE AND LUBRICATION

j

onpage3

4

Periodic Maintenance Chart

Perform all services at whichever maintenance interval is reached first.

Item Maintenance Interval

(whichever comes first)

Hours Calendar Miles

Steering -- Pre-Ride --

J

Front suspension -- Pre-Ride --

"

Rear suspension -- Pre-Ride --

"

Tires -- Pre-Ride --

Brake fluid level -- Pre-Ride --

"

Brake pedal travel -- Pre-Ride --

"

Brake systems -- Pre-Ride --

Wheels/fasteners -- Pre-Ride --

Frame fasteners -- Pre-Ride --

Engine oil level -- Pre-Ride --

"

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

"

(Km)

Make adjustments as need­ed. See Pre-Ride Checklist
on page 34.

Remarks

.

E

Air box sediment

"

tube

E

Coolant
(if applicable)

Headlamp/tail
lamp

Air filter,

"

main element

E

Brake pad wear 10 H Monthly -- Inspect periodically

"
J

Battery 20 H Monthly -- Check terminals; clean; test

Front gearcase oil

"

(if equipped)

Middle gearcase

"

oil (if equipped)

Rear gearcase oil

"

(if equipped)

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

"

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

-- Daily -- Drain deposits when visible

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

-- Daily -- Check operation; apply
dielectric grease if replacing

-- Weekly -- Inspect; replace as needed

25 H Monthly -- Inspect level; change yearly

25 H Monthly -- Inspect level; change yearly

25 H Monthly -- Inspect level; change yearly

E Emission Control System Service - 4 Cycle (California)

J Have an authorized Polaris dealer perform these services.

55

MAINTENANCE AND LUBRICATION

Periodic Maintenance Chart

Item Maintenance Interval

(whichever comes first)

Hours Calendar Miles

Engine breather

"

filter (if equipped)

E

Engine oil change

"

(break-in)

General

"

lubrication

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

Steering 50 H 6M -- Lubricate

J

Front suspension 50 H 6M -- Lubricate

"

Rear suspension 50 H 6M -- Lubricate

"

Throttle Cable/

J

ETC Switch

E

Throttle body air

E

intake ducts/
flange

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

Cooling system
(if applicable)

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

"

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

"

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

25 H Monthly -- Inspect; replace if necessary

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

50 H 3M -- Lubricate all fittings, pivots,

50 H 6M -- Inspect; adjust; lubricate;

50 H 6M -- Inspect ducts for proper

50 H 6M -- Inspect coolant strength

(Km)

change at one month

cables, etc.

replace if necessary

sealing/air leaks

needed

seasonally; pressure test
system yearly

change at 25 hours/one
month

Remarks

E Emission Control System Service - 4 Cycle (California)

J Have an authorized Polaris dealer perform these services.

56

MAINTENANCE AND LUBRICATION

Periodic Maintenance Chart

Item Maintenance Interval

(whichever comes first)

Hours Calendar Miles

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

J

E

Fuel filter 100 H 12 M -- Replace yearly

J

Radiator

"

(if applicable)

Cooling hoses

"

(if applicable)

Engine mounts 100 H 12 M -- Inspect

"

Exhaust muffler/
pipe

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

J

100 H 12 M -- Inspect; clean external

100 H 12 M -- Inspect for leaks

100 H 12 M -- Inspect

(Km)

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

surfaces

Remarks

E

Ignition Timing 100 H 12 M -- Inspect

J

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

"

Clutches (drive

J

and driven)

Front wheel

J

bearings

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

J

Spark arrestor 300 H 36 M -- Clean out

Idle speed -- Adjust as needed

Toe adjustment -- Inspect periodically; adjust

J

Auxiliary brake (if

"

equipped)

J

Headlight aim -- Adjust as needed

100 H 12 M -- Inspect; clean; replace worn

100 H 12 M -- Inspect; replace as needed

-- Inspect daily; adjust as

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

parts

when parts are replaced

needed

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

E Emission Control System Service - 4 Cycle (California)

J Have an authorized Polaris dealer perform these services.

57

MAINTENANCE AND LUBRICATION

Lubrication Recommendations

Check and lubricate all components at the intervals outlined in the
Periodic Maintenance Chart beginning on page 53. Items not listed in
the chart should be lubricated at the General Lubrication interval.

Lubrication Chart Key

" More often under severe use, such as wet or dusty conditions

L Polaris Premium all Season Grease or grease conforming to NLGI

No. 2, such as Conoco Superlube M or Mobilegrease Special

F Use Polaris Premium U-Joint Lube every 500 miles, before long

periods of storage, or after pressure washing or submerging.

Item Lube Method

Engine Oil Polaris Premium 4

Brake Fluid DOT 3 or DOT 4 Maintain level between fill lines. See

Main Gearcase Oil
(Transmission)

Front Gearcase Oil Premium Demand

Middle Gearcase Oil
(6X6 only)

Rear Gearcase Oil Premium A TV Angle

(1) Prop Shaft U-joints FGrease Locate fittings and grease

Front Prop Shaft Y oke FGrease Locate fittings and grease

(2) Ball Joint

(3) Swing Arm
Bushings

Synthetic 0W40

Premium AGL Syn­thetic Gearcase Lube

Drive Hub Fluid

Premium ATV Angle
Drive Fluid

Drive Fluid

"LGrease

LGrease

Add to proper level on dipstick.

page 82.

See page 64.

See page 66.

See page 67.

See page 68.

(3 pumps maximum)

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

Locate fittings on swing arm and
grease with grease gun.

58

MAINTENANCE AND LUBRICATION

Lubrication Recommendations

(1)

6X6

4X4
6X6

6X6

4X4
6X6

(3)

(2)

6X6

59

MAINTENANCE AND LUBRICATION

Engine Oil

Always check and change the engine oil at the intervals outlined in the
Periodic Maintenance Chart beginning on page 53. Always change the
oil filter whenever changing oil.

Premium 4 Synthetic Oil

Polaris Premium 4 All Season Synthetic engine oil has been specially
formulated for use in Polaris 4-cycle engines. It’s a fully synthetic,
high performance, multi-viscosity oil designed to provide the ultimate
in lubrication performance and protection. See page 99 for the part
numbers of Polaris products.

Premium 4 possesses unsurpassed film strength over the widest
possible temperature range. It resists viscosity and frictional
breakdown in ambient temperatures from -40° F. to 120° F. I t s
exceptional frictional properties result in more efficient operation, more
power output and lower fuel consumption.

Although Polaris Premium 4 is the only oil recommended for use in
this engine, use of any API certified “SH” oil is allowable as long as
it’s 0W-40. Oil may need to be changed more frequently if Polaris
Premium 4 is not used. Follow the manufacturer’s recommendations
for ambient temperature operation.

CAUTION

Mixing brands or using a non-recommended oil may cause
serious engine damage. We recommend the use of Polaris
Premium 4 All Season synthetic oil or API certified “SH” oil,
0W-40. Never substitute or mix oil brands. Use only 0W-40.

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.

60

MAINTENANCE AND LUBRICATION

Engine Oil

Always check and change the oil at the intervals outlined in the
Periodic Maintenance Chart beginning on page 53. We recommend the
use of Polaris Premium 4 All Season Synthetic engine oil.

Oil Check

The oil dipstick and fill tube (1) is located on the engine.

1. Position the vehicle on a level surface.

2. Apply the brakes. Start the
engine and let it idle for 20-30
seconds, then stop the engine.

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

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

2

5. Remove the dipstick
and check the oil level.
Maintain the oil level
in the safe range (3).
Do not overfill.

NOTE: Due to the dipstick entry

angle into the
crankcase, the oil level
will read higher on the
bottom side of the
dipstick. Always read
the level on the upper
surface (4) of the dipstick.

1

SAFE

ADD 8 OZ

3

4

6. After reinstalling t he dipstick, be
sure to seat the lever lock.

61

MAINTENANCE AND LUBRICATION

Engine Oil

Oil an d Filter Change

CAUTION

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

Always change the oil and filter at the intervals outlined in the Periodic
Maintenance Chart beginning on page 53. Always change the oil filter
whenever changing oil.

1. Position the vehicle on a level surface.

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

3. Clean the area around the drain plug.

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

5. Allow the oil to drain completely.

6. Reinstall the sealing washer on the drain plug.

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

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

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

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

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

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

62

clean and free of burrs, nicks or scratches.

turn the filter counterclockwise to remove.

crankcase.

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

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

MAINTENANCE AND LUBRICATION

Engine Oil

Oil an d Filter Change

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

13. Shift the transmission to neutral.

14. Engage the park brake.

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

16. Stop the engine. Inspect for leaks.

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

18. Dispose of used filter and oil properly.

Gearcases

Gearcase Specification Chart

Gearcase Lubricant Capacity Fill Plug

Main Gearcase
(Transmission)

Front Gearcase Premium Demand

Middle Gearcase

(6X6)

Rear Gearcase

(4X4)

Rear Gearcase

(6X6)

Premium AGL

Synthetic Gearcase

Lube

Drive Hub Fluid

Premium ATV Angle

Drive Fluid

Premium ATV Angle

Drive Fluid

Premium ATV Angle

Drive Fluid

15.2 oz.
(450 ml)

5oz.

(150 ml)

6.75 oz.
(200 ml)

18 oz.

(532 ml)

10 oz.

(300 ml)

(19.4 Nm)

8-10 ft. lbs.

(11-13.6 Nm)

(19.4 Nm)

40-50 ft. lbs.

(54-68 Nm)

(19.4 Nm)

Torque

14 ft. lbs.

14 ft. lbs.

14 ft. lbs.

Drain Plug

Torque

14 ft. lbs.

(19.4 Nm)

11 ft. lbs.

(15 Nm)

14 ft. lbs.

(19.4 Nm)

30-45 in. lbs.

(3-5 Nm)

14 ft. lbs.

(19.4 Nm)

63

MAINTENANCE AND LUBRICATION

Gearcases

Transmission (Main Gearcase)

Always check and change the transmission oil at the intervals outlined
in the Periodic Maintenance Chart beginning on page 53. Maintain the
oil level even with the bottom of the fill plug hole.

The fill plug (1) is located at the rear of
the vehicle.

Refer to the Gearcase Specifications
Chart on page 63 for recommended
lubricants, capacities and torque
specifications. See page 99 for the part
numbers of Polaris products.

Oil Check

1. Position the vehicle on a level surface.

2. Remove the fill plug.

3. Check the oil level.

4. Add the recommended oil as needed.

5. Reinstall the fill plug. Torque to specification.

1

64

MAINTENANCE AND LUBRICATION

Gearcases

Transmission (Main Gearcase)

Oil Change

The drain plug (2) is located on the
bottom of the transmission. Access the
drain plug through the drain hole in the
skid plate.

1. Remove the fill plug.

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

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

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

5. Reinstall the drain plug. Torque to specification.

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

7. Reinstall the fill plug. Torque to specification.

8. Check for leaks.

2

65

MAINTENANCE AND LUBRICATION

Gearcases

Front Gearcase

Always check and change the front gearcase oil at the intervals
outlined in the Periodic Maintenance Chart beginning on page 53.
Maintain the oil level even with the bottom thread of the fill plug hole.

The front gearcase fill plug (1) is located on the right side of the front
gearcase.

Refer to the Gearcase Specifications Chart on page 63 for
recommended l ubricants, capacities and torque specifications. See
page 99 for the part numbers of Polaris products.

Oil Check

1. Position the vehicle on a level
surface.

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

3. Add the recommended oil as
needed.

4. Reinstall the fill plug. Torque to
specification.

Oil Change

1. Support the vehicle securely with a jackstand.

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

3. Remove the fill plug.

4. Place a drain pan under the drain plug (2) on the bottom right-hand
side.

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

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

7. Add the recommended oil.

8. Reinstall the fill plug. Torque to specification.

9. Check for leaks.

2

1

66

MAINTENANCE AND LUBRICATION

Gearcases

Middle Gearcase (RANGER 6X6)

Always check and change the middle gearcase oil at the intervals
outlined in the Periodic Maintenance Chart beginning on page 53.
Maintain the oil level even with the bottom thread of the fill plug hole.

Refer to the Gearcase Specifications Chart on page 63 for
recommended l ubricants, capacities and torque specifications. See page
99 for the part numbers of Polaris products.

The middle gearcase fill plug (1) 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. Remove the drain plug (2) from
the bottom of the gearcase. Drain the oil into a drain pan. Discard
used oil properly.

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

4. Add the recommended fluid.

5. Reinstall the fill plug. Torque to specification.

6. Check for leaks.

2

1

67

MAINTENANCE AND LUBRICATION

Gearcases

Rear Gearcase

Always check and change the rear gearcase oil at the intervals outlined
in the Periodic Maintenance Chart beginning on page 53.

Refer to the Gearcase Specifications Chart on page 63 for
recommended l ubricants, capacities and torque specifications. See
page 99 for the part numbers of Polaris products.

The rear gearcase fill plug (1) is on the driver’ s side of the rear
gearcase.

Oil Check (6X6)

The easiest way to check for adequate oil in the 6X6 is to drain and
refill the gearcase to capacity (see page 63). Perform the oil change as
outlined on page 69.

Oil Check (4X4)

Maintain the oil level 3/4 of an inch
(19 mm) below the bottom thread of
the fill plug hole. Use a light colored
non-absorbent measuring instrument
(such as a white cable tie) to measure
the depth.

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.

1

6X6

2

2

1

4X4

68

MAINTENANCE AND LUBRICATION

Gearcases

Rear Gearcase

Oil Change

1. Remove the fill plug.

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

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

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

5. Add the recommended oil.

6. Reinstall the fill plug. Torque to specification.

7. Check for leaks.

69

MAINTENANCE AND LUBRICATION

Spark Plugs

CAUTION

Using non-recommended spark plugs can result in serious engine
damage. Always use Polaris-recommended spark plugs. Refer
to the specifications section beginning on page 100.

Spark Plug Gap/Torque

Model Electrode Gap New Plug Torque Used Plug Torque

RANGER

4X4 XP

RANGER

6X6 EFI

.035″ (.9 mm)

.035″ (.9 mm)

18 ft. lbs.

(24 Nm)

18 ft. lbs.

(24 Nm)

18 ft. lbs.

(24 Nm)

18 ft. lbs.

(24 Nm)

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.

WARNING

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

1. Normal

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

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

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

70

MAINTENANCE AND LUBRICATION

Spark Plugs

2. Wet Fouled

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

Spark Plug Removal and Replacement

1. Remove the seat to access the engine compartment.

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

3. Reverse the procedure for spark plug installation. Torque to
specification. See page 70.

71

MAINTENANCE AND LUBRICATION

Cooling System

Operation

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

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

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

system is 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 99 for the part numbers of Polaris
products.

NOTE: 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.

72

MAINTENANCE AND LUBRICATION

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 53. Do
not obstruct or deflect air flow through the radiator by installing
unauthorized accessories in front of the radiator or behind the cooling
fan. Interference with the radiator air flow can lead to overheating and
consequent engine damage.

CAUTION

Washing the vehicle with a high-pressure hose could damage the
radiator fins and impair the radiator’s effectiveness. Exercise
caution if a high-pressure syst em is used for washing the vehicle.

Coolant Level

Always check and change the coolant at
the intervals outlined in the Periodic
Maintenance Chart beginning on page 53.
Maintain the coolant level between the
minimum and maximum marks on the
bottle (when the fluid is cool). The
overflow bottle (1) is located in front of
the right front wheel.

1. Position the vehicle on level ground.

2. View the coolant level in the overflow bottle.

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

1

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

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

73

MAINTENANCE AND LUBRICATION

Cooling System

Radiator Coolant Level

Always check and change the coolant at the intervals outlined in the
Periodic Maintenance Chart beginning on page 53.

WARNING

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

1. Lift the hood and slowly
remove the radiator cap (1).

2. View the coolant level
through the opening.

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

NOTE: 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.

1

NOTE: Use of a non-standard pressure cap will not allow the

recovery system to function properly. See your dealer for
the correct replacement part.

74

MAINTENANCE AND LUBRICATION

Polaris Variable Transmission (PVT) System

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

When To Use Low Range vs. High Range

Following is a guideline for when to use low range and high range.

Low Range

S When basic operation is at speeds less than 7 MPH (11 KPH)
S For heavy pulling
S When operating in rough terrain (swamps, mountains, etc.) at low

ground speeds

High Range

S When basic operation is at speeds greater than 7 MPH (11 KPH)
S When operating at high ground speeds

75

MAINTENANCE AND LUBRICATION

PVT System

WARNING

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

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

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

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

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

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

76

MAINTENANCE AND LUBRICATION

PVT System

PVT Drying

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

1. Loosen the bottom screws that secure the clutch cover.

2. Allow the water to drain.

3. Tighten the screws.

4. Apply the brakes. Start the engine.

5. Engage the park brake.

6. Shift the transmission to neutral.

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

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

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

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

77

MAINTENANCE AND LUBRICATION

Filter Systems

Air Filter

Always change the air filter at the intervals outlined in the Periodic
Maintenance Chart beginning on page 53.

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 (1).

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

NOTE: Apply a small amount of

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

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

1

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

in wet conditions or at high throttle openings for extended
periods.

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.

78

MAINTENANCE AND LUBRICATION

Spark Arrestor

WARNING

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

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

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

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

Never go under the vehicle while it’s inclined.

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

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

2. Shift the transmission to neutral.
Apply the brakes. Start the
engine.

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

4. If carbon is expelled, cover or plug the exhaust outlet (2) and rap
on the pipe around the clean-out plugs while revving the engine
several more times.

5. If particles are still suspected to be in the muffler, elevate the rear
of the vehicle one foot higher than the front. Engage the park
brake. Block the wheels. Make sure the transmission is in neutral
and repeat steps 3 and 4 until no more particles are expelled when
the engine is revved.

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

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

2

1

79

MAINTENANCE AND LUBRICATION

Throttle System

WARNING

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

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

Immediately contact your dealer for service if throttle problems
arise.

Always check the pedal for free movement and return before
starting the engine and occasionally during operation.

Throttle Freeplay

If the throttle pedal (1) 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 53.
Adjust the freeplay if necessary.

1

2

Throttle Freeplay Inspection

1. Engage the park brake (2). Shift the transmission to neutral.

2. Apply the brakes. 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).

80

MAINTENANCE AND LUBRICATION

Throttle System

Throttle Freeplay Adjustment

1. Slide the boots (1) off the inline cable adjuster sleeve (2). Loosen
the adjuster locknut (3).

2. Turn the adjuster until 1/16 to 1/8 inch freeplay is achieved.

NOTE: While adjusting, flip the throttle lever back and forth.

3. Tighten the locknut and slide the boots over the cable adjuster until
they touch at the midpoint of adjuster.

1

2

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.

3

1

81

MAINTENANCE AND LUBRICATION

Brakes

The front and rear brakes are hydraulic disc type brakes and are
activated by the brake pedal. See page 32.

Brake Fluid

Routine inspections are recommended to keep the brake system in
good operating condition. Inspect the level of the brake fluid before
each operation.

Change the brake fluid at the intervals outlined in the Periodic
Maintenance Chart beginning on page 53. The brake fluid should also
be changed if it becomes contaminated, if 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 (1) under the hood. The
level should be between the upper
(MAX) and lower (MIN) level
lines.

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

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

1

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.

82

MAINTENANCE AND LUBRICATION

Brakes

Brake Inspection

5. Check the brake system for fluid
leaks.

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

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

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

9. Change pads when worn to 3/64″
(1 mm).

Park Brake Inspection

1. Slowly push the park brake pedal
down with your foot.

2. After 8 to 12 clicks of pedal
travel, check the vehicle for
movement. The vehicle should
not roll while parked. If the
vehicle moves, adjustment is
necessary.

Park Brake Adjustment

1. Position the vehicle on a level surface.

2. Shift the transmission to neutral.

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

3/64″ (1 mm)

1

83

MAINTENANCE AND LUBRICATION

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 53.

1. Position the vehicle on level ground.

2. Lightly turn the steering wheel left and right.

3. There should be 0.8 - 1.0 in (20 - 25 mm) of free play.

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

Suspension Adjustment (4X4)

The 4X4 rear suspension may be adjusted to provide a stiffer
suspension if necessary. The shocks are mounted to the inside
mounting holes (A) at the factory, but they may be relocated to the
outside mounting holes (B).

1. Remove the top shock mounting bolts (A).

2. Reposition the shocks to the outside mounting holes (B).

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

B

A

C

Rear Spring Adjustment

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

84

MAINTENANCE AND LUBRICATION

Seat Belts

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

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

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

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

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

is adjusted to the lowest possible lap
position before riding.

1. To adjust, loosen the bolts (1).

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

1

NOTE: The center belt does not self

adjust. Before riding, pull on the
strap to secure the belt on the lap
of the center passenger.

WARNING

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

85

MAINTENANCE AND LUBRICATION

Tires

WARNING

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

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

Tire Tread Depth

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

Axle and Wheel Nut Torque Specifications

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

1/8I (3 mm)

86

Location Specification

Front Wheel Nuts 35 ft. lbs. (47 Nm)

Rear Wheel Nuts 35 ft. lbs. (47 Nm)

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

Center and Rear Hub

Retaining Nuts

1 10 ft. lbs. (150 Nm)

MAINTENANCE AND LUBRICATION

Tires

WARNING

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

Wheel Removal

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

2. Loosen the wheel nuts slightly.

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

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

Wheel Installatio n

1. Place the
transmission in gear.

2. Engage the park
brake.

3. 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.

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

5. Carefully lower the vehicle to the ground.

6. Torque the wheel nuts to specification. See page 86.

87

MAINTENANCE AND LUBRICATION

Lights

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

WARNING

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

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

Headlight Lamp Replacement

1. Open the hood.

2. Unplug the headlamp from the
wiring harness (1). Be sure to pull
on the connector, not on the wiring.

3. Turn the lamp counterclockwise to
remove it.

4. Install the new lamp.

NOTE: Make sure the tab on the

lamp locates properly in the
housing.

5. Reinstall the harness assembly into
the headlight assembly.

88

1

MAINTENANCE AND LUBRICATION

Lights

Headlight Beam Adjustment

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

2. Measure the distance from the floor to the center of the headlight
and make a mark on the wall at the same height.

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

4. Observe the headlight aim.
The most intense part of the
headlight beam should be
aimed 8″ (20.3 cm) below
the mark placed on the wall
in step 2.

NOTE: Include the weight of a rider on

the seat while performing this step.

5. Adjust the beam to the desired position by turning the adjustment
screw (1).

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 10mm (0.4 in.) of pedal travel. If the light doesn’t come on,
check the bulb.

1

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MAINTENANCE AND LUBRICATION

Lights

Indicator L amp Replacement

1. Lift the hood.

2. Reach in behind the console
panel and lift the release (1) to
unplug the light from the
harness.

3. Using a flathead screwdriver,
press on the tab (2) on the top
of the light to remove the
indicator light assembly from
the console panel.

4. Using a screwdriver, turn the
light that needs to be replaced
1/4 turn counterclockwise.

5. Grip the light with a needle nose plier and remove the light from
the assembly.

6. Install the new light and use a small flat head screwdriver to seat it
into place, 1/4 turn clockwise.

7. Snap the assembly back into the console panel and reconnect the
harness.

8. Close the hood.

1

2

Tool Kit

To help you perform routine maintenance, a tool kit is provided with
your vehicle. Items included in the kit are:

S A screwdriver
S An open-end wrench (8-10 mm)
S An open-end wrench (12-14 mm)
S A tire pressure gauge
S A spark plug wrench and handle
S A spanner wrench (for shock adjustment)

NOTE: Additional tools will be necessary to perform routine

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maintenance.

MAINTENANCE AND LUBRICATION

Vehicle Immersion

CAUTION

If your vehicle becomes immersed, major engine damage can
result if the vehicle is not thoroughly inspected. T ake the vehicle
to your dealer before starting the engine.

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

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

2. Dry any water present in the air box.

NOTE: Filter replacement is required if water is present.

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

4. Remove the spark plugs.

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

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

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

8. Take the vehicle to your dealer for service as soon as possible,
whether you succeed in starting it or not.

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

on page 77 for drying.

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MAINTENANCE AND LUBRICATION

Battery

Keep the battery terminals and connections free of corrosion. If
cleaning is necessary, remove the corrosion with a stiff wire brush.
Wash with a solution of one tablespoon baking soda and one cup water.
Rinse well with tap water and dry off with clean shop towels. Coat the
terminals with dielectric grease or petroleum jelly.

Be careful not to allow cleaning solution or tap water into the battery.

WARNING

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

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

of magnesia, beaten egg, or vegetable oil. Call physician
immediately.

Eyes: Flush with water for 15 minutes and get prompt medical
attention.

Batteries produce explosive gases. Keep sparks, flame,
cigarettes, etc. away. Ventilate when charging or using in an
enclosed space. Always shield eyes when working near
batteries. KEEP OUT OF REACH OF CHILDREN.

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MAINTENANCE AND LUBRICATION

Battery

Replenishing Battery Fluid (Conventional Battery)

A poorly maintained battery will deteriorate
rapidly. Check the battery fluid level often.
The fluid level should be kept between the
upper and lower level marks (1).

To refill use only distilled water. Tap water
contains minerals that are harmful to a battery.

1

WARNING

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

Battery Removal

1. Open the hood.

2. Remove the battery vent
tube from the battery.

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

4. Disconnect the red (positive)
battery cable next.

5. Lift the battery out of the
vehicle, being careful not to
tip it sideways and spill any
electrolyte.

CAUTION

If electrolyte spills, immediately wash it off with a solution of one
tablespoon baking soda and one cup water to prevent damage to
the vehicle.

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MAINTENANCE AND LUBRICATION

Battery

Battery Installation

1. Set the battery in its holder.

2. Install the battery vent tube. It must be free from obstructions and
securely installed. If not, battery gases could accumulate and cause
an explosion. The tube should be routed away from the frame and
body to prevent corrosion. Avoid skin contact with electrolyte as
severe burns could result.

3. First connect and tighten the red (positive) cable.

4. Second connect and tighten the black (negative) cable.

5. Verify that cables are properly routed.

NOTE: When installing a new battery, make sure it’s fully charged

prior to its initial use. Using a new battery that has not been
fully charged can damage the battery and result in a shorter
life. It can also hinder vehicle performance.

Battery Storage

When the vehicle is placed in storage for three months or more, the
battery should be removed, stored out of the sun in a cool, dry place
and tested monthly. Before reusing, take the battery to your dealer for
testing and recharging.

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MAINTENANCE AND LUBRICATION

Cleaning and Storage

See page 99 for the part numbers of Polaris products.

Cleaning the RANGER

Keeping your RANGER clean will not only improve its appearance but
it can also extend the life of various components. With a few
precautions, your RANGER can be cleaned much like an automobile.

Washing the RANGER

The best and safest way to clean your RANGER is with a garden hose
and a pail of mild soap and water. Use a professional type washing
mitten, cleaning the upper body first and the lower parts last. Rinse
with water frequently and dry with a chamois to prevent water spots.

NOTE: If warning and safety labels are damaged, contact your a

Polaris dealer for free replacement.

CAUTION

High water pressure may damage vehicle components. Polaris
recommends washing the vehicle by hand or with a garden hose
using mild soap.

Certain products, including insect repellants and chemicals, will
damage plastic surfaces. Do not allow these types of products to
come into contact with the vehicle.

If a high pressure water system is used, exercise extreme caution to
avoid damaging wheel bearings, radiator, transmission seals, body
panels, brakes and warning l abels. Grease all zerk fittings immediately
after washing, and allow the vehicle to run for a while to evaporate any
water that may have entered the engine or exhaust system.

Waxing the RANGER

Your RANGER can be waxed with any non-abrasive automotive paste
wax. Avoid the use of harsh cleaners since they can scratch the body
finish.

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MAINTENANCE AND LUBRICATION

Cleaning and Storage

Storage Tips

CAUTION

Starting the engine during the storage period will disturb the
protective film created by fogging and damage could occur. Never
start the engine during the storage period.

Clean the Exterior

Make necessary repairs and then clean the vehicle thoroughly with
mild soap and warm water to remove all dirt and grime. Don’t use
harsh detergents or high pressure washers. Some detergents deteriorate
rubber parts. Use dish soap type cleaners only. High pressure washers
may force water past seals.

Stabilize the Fuel

Fill the fuel tank. Add Polaris Carbon Clean Fuel Treatment or Polaris
Fuel Stabilizer. Follow the instructions on the container for the
recommended amount. (Carbon clean will also reduce the possibility of
bacterial growth in the fuel system.) Allow 15-20 minutes of operation
for the stabilizer to disperse through the fuel in the tank.

Oil and Filter

Warm the engine and change the oil and filter.

Air Filter / Air Box / Breather Filter

Inspect and clean or replace the pre-cleaner and air filter. Clean the air
box and drain the sediment tube.

Fluid Levels

Inspect the following fluid levels and change if necessary: front and
rear gearcases; transmission and brake fluid (change every two years or
as required if fluid looks dark or contaminated).

Inspect and Lubricate

Inspect all cables and lubricate. Follow lubrication guidelines in the
Maintenance Section of t he service or owner’s manual to completely
grease and lubricate the entire vehicle with Polaris Premium All
Season Grease.

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MAINTENANCE AND LUBRICATION

Cleaning and Storage

Storage Tips

Fog the Engine

1. Treat the fuel system with Polaris Carbon Clean, following the
instructions on the can. Run the engine for several minutes so the
Carbon Clean reaches the injectors. Turn the engine off.

2. Remove the spark plugs and add 2-3 tablespoons of Premium 4
Synthetic 0W40 engine oil. To access the plug holes, use a section of
clear 1/4” hose and a small plastic squeeze bottle filled with the
pre-measure d amount of oil.

NOTE: Do this carefully! If you miss the plug holes, oil will drain from

the spark plug cavities into the hole at the front of the cylinder
head, and appear to be an oil leak.

3. Reinstall the spark plugs. Torque to specification. See page 70.

4. Apply dielectric grease to the inside of each spark plug cap and
reinstall the caps onto the plugs.

5. Turn the engine over several times. Oil will be forced in and around
the piston rings and ring lands, coating the cylinder with a protective
film of fresh oil.

6. If Polaris fuel system additive is not used, fuel tank, fuel lines, and
injectors should be completely drained of gasoline.

Battery Maintenance

Remove the battery and recharge it fully. Store the battery in a cool,
dry place.

Engine Anti-Freeze

Test engine coolant strength and change if necessary. Coolant should
be replaced every two years.

Storage Area/Covers

Be sure the storage area is well ventilated, and cover the machine with a
genuine Polaris cover.

NOTE: Do not use plastic or coated materials. They do not allow

enough ventilation to prevent condensation, and may promote
corrosion and oxidation.

97