Polaris RANGER XP 700 EFI User Manual

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WARNING

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 Victory 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 s afe 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!

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

TABLE OF CONTENTS

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

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

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

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

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

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

POLARIS P RODUCTS 99......................

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

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

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

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

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

VEHICLE IDENTIFICATION NUMBERS

Record your vehicle’s i dentification 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.

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):

31XX

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, the safety of others, and the protection of our environment. Read and understand your owner’s manual, which includes valuable information about all aspects of your vehicle, including safe operating procedures.

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

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

SAFETY

Operator Safety

The following signal words and symbols appear throughout this manual and on your 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.

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 t urns.

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 i n

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.

SAFETY

Operator Safety

S Always follow proper procedures for turning as described in this

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

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.

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 legs 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.

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.

SAFETY

Operator Safety

WARNING

POTENTIAL HAZARD Stalling, rolling backwards while

climbing a hill WHAT CAN

HAPPEN Vehicle overturn HOW TO AVOID THE

HAZARD

Maintain a steady speed when climbing a hill.

Ifyouloseallforward

speed: Apply the brakes. Engage the park brake after fully stopped. If you begin rolling

backwards: 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.

SAFETY

Operator Safety

WARNING

POTENTIAL HAZARD Operating this vehicle on paved surfaces WHAT CAN

HAPPEN Loss of control HOW TO AVOID THE

HAZARD

This vehicle’s tires are designed for off-road use only, not for use on pavement. Paved surfaces may seriously affect handling and control of the vehicle, and may cause the vehicle to go out of control.

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

WARNING

POTENTIAL HAZARD Operating this vehicle without proper instruction WHAT CAN

HAPPEN Loss of control, accident HOW TO AVOID THE

HAZARD

The risk of an accident is greatly increased if the operator does not know how to operate the vehicle properly in different situations and on different types of terrain.

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

SAFETY

Operator Safety

WARNING

POTENTIAL HAZARD Operating this vehicle on public streets, roads or highways WHAT CAN

HAPPEN Collision with another vehicle HOW TO AVOID THE

HAZARD

Never operate this vehicle on any public street, road or highway , including dirt or gravel.

In many states it’s illegal to operate vehicles of this type on public streets, roads and highways.

WARNING

POTENTIAL HAZARD Operating this vehicle after consuming alcohol or drugs WHAT CAN

HAPPEN Could seriously affect your judgment. Could cause you to react more slowly. Could affect your balance and perception. Could result in an accident. HOW TO AVOID THE

HAZARD

Driving a RANGER requires your full attention. DO NOT drink alcohol or use drugs or medications before or while driving. They will reduce your alertness and slow your reaction time. In most states and provinces, it’s prohibited by law to drive while intoxicated or under the influence of drugs.

SAFETY

Operator Safety

WARNING

POTENTIAL HAZARD Operating this vehicle at excessive speeds WHAT CAN

HAPPEN Loss of control, accident HOW TO AVOID THE

HAZARD

Always travel at a speed proper for the terrain, visibility and operating conditions, and your experience.

WARNING

POTENTIAL HAZARD Attempting jumps and other stunts WHAT CAN

HAPPEN Loss of control, accident and/or vehicle overturn HOW TO AVOID THE

HAZARD

Never attempt jumps and other stunts. Avoid exhibition driving.

WARNING

POTENTIAL HAZARD Operating on frozen bodies of water. WHAT CAN

HAPPEN Severe injury or death can result if the vehicle and/or the operator

fall through the ice. HOW TO AVOID THE

HAZARD

Never operate the RANGER on a frozen body of water.

SAFETY

Operator Safety

WARNING

POTENTIAL HAZARD Failure to inspect the vehicle before operating Failure to properly maintain the vehicle WHAT CAN

HAPPEN Accident, equipment damage HOW TO AVOID THE

HAZARD

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

Always follow the inspection and maintenance procedures and schedules described in the Owner’s Manual.

WARNING

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

unfamiliar terrain WHAT CAN

HAPPEN Loss of control, vehicle overturn HOW TO AVOID THE

HAZARD

Travel slowly and use extra caution when operating on unfamiliar terrain.

Always be alert to changing terrain conditions when operating the vehicle. You may come upon hidden rocks, bumps, or holes suddenly , without enough time to react.

SAFETY

Operator Safety

WARNING

POTENTIAL HAZARD Failure to follow the minimum age recommendations for this

vehicle WHAT CAN

HAPPEN Serious injury or death (the child or others) HOW TO AVOID THE

HAZARD

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.

WARNING

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

uneven tire pressure WHAT CAN

HAPPEN Loss of control, accident and/or overturn HOW TO AVOID THE

HAZARD

Always use the size and type of tires specified in the Owner’s Manual for this vehicle. See page 19.

Always maintain proper tire pressure as described on the decal and in the Owner’s Manual. See page 19.

SAFETY

Operator Safety

WARNING

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

WARNING

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

CAUTION

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

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.

WARNING

S Moving par ts hazard under belt-clutch guard. To

prevent serious in jur y, do not op er ate 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

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.

SAFETY

Safety Decals and Locations

Location 5 (under hood)

Location 6

Location 7

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.

7172921

SAFETY

Safety Decals and Locations

Discretionary Warn ing Decal

SAFETY

Fuel Safety

WARNING

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

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

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

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

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

FEATURES AND CONTRO LS

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. 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)

FEATURES AND CONTRO LS

Component Locations

12. Headlights

13. Radiator (if equipped)

14. Front Bumper/Brush Guard

15. Hood Hold Down Strap

FEATURES AND CONTRO LS

Component Locations

16. Taillights

17. Tailgate

18. Tailgate Latch Release

19. Muffler (Spark Arrester)

20. CV Boot/Rear Caliper

21. Air Box

22. Receiver Hitch

FEATURES AND CONTRO LS

Indicator Lights

1. High Gear

2. Low Gear

3. Neutral Gear

4. Reverse Gear

5. High Temperature

6. Park Brake

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.

FEATURES AND CONTRO LS

Fuel Cap/Fuel Gauge

The fuel tank filler cap (8) is 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 t he 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.

FEATURES AND CONTRO LS

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 l ow 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.

FEATURES AND CONTRO LS

Console

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

FEATURES AND CONTRO LS

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.

To change gears, stop the vehicle, and with the engine idling, move the lever to the desired gear. Do not attempt t o 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.

FEATURES AND CONTRO LS

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.

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)

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

A: High Beam B: Low Beam C: Off

AWD/Differential Lock Switch (3)

The AWD/Differential S witch has three positions: D: AWD

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

Press t he top of the rocker switch to engage AWD. 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.

AWD

FEATURES AND CONTRO LS

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.

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 effi cient 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.

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

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 s econds. Release the key when the engine starts.

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

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

CAUTION

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

OPERATION

Stopping the Engine

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

2. Turn the engine off.

3. Engage the park brake.

WARNING

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

Braking

1. Release the throttle pedal completely.

2. Press on the brake pedal evenly and firmly.

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

familiar with the controls.

NOTE: When the throttle pedal is released completely and the

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.

OPERATION

Driving Safely

Driving Procedures

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 t hrottle 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.

OPERATION

Driving Safely

Driving On Slippery Surfaces

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

1. Slow down when entering slippery areas.

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

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

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

CAUTION

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

WARNING

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

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

on slippery surfaces.

OPERATION

Driving Safely

Driving Uphill

Whenever traveling uphill, follow these precautions:

1. Always travel straight uphill.

2. Avoid steep hills (15_ maximum).

3. Keep both feet on the floor.

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

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.

15_ Maximum

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.

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.

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.

OPERATION

Driving Safely

Driving Over Obstacles

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

WARNING

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

OPERATION

Driving Safely

Driving in Reverse

Follow these guidelines when operating in reverse:

1. Back slowly.

2. Apply the brakes lightly for stopping.

3. Avoid turning at sharp angles.

4. Always avoid backing downhill.

5. Never open t he 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.

OPERATION

Driving Safely

ParkingonanIncline

Avoid parking on an incline i f 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.

OPERATION

Driving Safely

Hauling Cargo

WARNING

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

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

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

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

Always operate the vehicle with extreme care when hauling or towing loads.

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

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

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

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

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

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

OPERATION

Driving Safely

Hauling Cargo

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)

Cargo Box

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

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

WARNING

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

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

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.

WARNING

If the weight distribution on the box is located toward the rear of the box when the release lever is pulled forward, the box may dump unexpectedly and cause serious injury to the operator or bystanders.

Never operate the dump lever without ensuring that the load is positioned evenly or at the front of the box.

OPERATION

Driving Safely

Towing Loads

WARNING

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

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

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

Total Towed

Load Weight

(level ground)

Total Towed

Load Weight

(15° grade)

Total Hitch

Vertical

Weight

Maximum

Towing

Speed

RANGER

4x4 XP

1500 lbs.

(681 kg)

850 lbs.

(386 kg)

150 lbs.

(68.1 kg)

10 mph

(16 kph)

RANGER

6X6 EFI

1750 lbs.

(794 kg)

1000 lbs.

(454 kg)

150 lbs.

(68.1 kg)

10 mph

(16 kph)

Belt Life

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

OPERATION

Driving Safely

Parking the 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.

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 l ow 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

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.

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 to 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.

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. Vi olations 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.

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 m aintenance 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 l oad 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.

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.

MAINTENANCE AND LUBRICATION

Periodic Maintenance Chart

Perform all services at whichever maintenance interval is reached first.

Item Maintenance Interval

(whichever comes first)

Remarks

Hours Calendar Miles

(Km)

Steering -- Pre-Ride --

Make adjustments as need-

Front suspension -- Pre-Ride --

ed. See Pre-Ride Checklist on page 34.

Rear suspension -- Pre-Ride --

onpage3

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

Air box sediment tube

-- Daily -- Drain deposits when visible

Coolant (if applicable)

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

Headlamp/tail lamp

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

Air filter, main element

-- Weekly -- Inspect; replace as needed

" J

Brake pad wear 10 H Monthly -- Inspect periodically

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

Front gearcase oil (if equipped)

25 H Monthly -- Inspect level; change yearly

Middle gearcase oil (if equipped)

25 H Monthly -- Inspect level; change yearly

Rear gearcase oil (if equipped)

25 H Monthly -- Inspect level; change yearly

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

" 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.

MAINTENANCE AND LUBRICATION

Periodic Maintenance Chart

Item Maintenance Interval

(whichever comes first)

Remarks

Hours Calendar Miles

(Km)

Engine breather filter (if equipped)

25 H Monthly -- Inspect; replace if necessary

Engine oil change (break-in)

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

change at one month

General lubrication

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

cables, etc.

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

Steering 50 H 6M -- Lubricate

Front suspension 50 H 6M -- Lubricate

Rear suspension 50 H 6M -- Lubricate

Throttle Cable/ ETC Switch

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

replace if necessary

Throttle body air intake ducts/ flange

50 H 6M -- Inspect ducts for proper

sealing/air leaks

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

needed

Cooling system (if applicable)

50 H 6M -- Inspect coolant strength

seasonally; pressure test system yearly

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

change at 25 hours/one month

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

" 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.

MAINTENANCE AND LUBRICATION

Periodic Maintenance Chart

Item Maintenance Interval

(whichever comes first)

Remarks

Hours Calendar Miles

(Km)

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

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

Fuel filter 100 H 12 M -- Replace yearly

Radiator (if applicable)

100 H 12 M -- Inspect; clean external

surfaces

Cooling hoses (if applicable)

100 H 12 M -- Inspect for leaks

Engine mounts 100 H 12 M -- Inspect

Exhaust muffler/ pipe

100 H 12 M -- Inspect

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

Ignition Timing 100 H 12 M -- Inspect

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

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

Clutches (drive and driven)

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

parts

Front wheel bearings

100 H 12 M -- Inspect; replace as needed

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

Spark arrestor 300 H 36 M -- Clean out

Idle speed -- Adjust as needed

Toe adjustment -- Inspect periodically; adjust

when parts are replaced

" J

Auxiliary brake (if equipped)

-- Inspect daily; adjust as needed

Headlight aim -- Adjust as 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.

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

Synthetic 0W40

Add to proper level on dipstick.

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

page 82.

Main Gearcase Oil (Transmission)

Premium AGL Synthetic Gearcase Lube

See page 64.

Front Gearcase Oil Premium Demand

Drive Hub Fluid

See page 66.

Middle Gearcase Oil (6X6 only)

Premium ATV Angle Drive Fluid

See page 67.

Rear Gearcase Oil Premium ATV Angle

Drive Fluid

See page 68.

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

Front Prop Shaft Yoke FGrease Locate fittings and grease

(3 pumps maximum)

(2) Ball Joint

"LGrease

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

(3) Swing Arm Bushings

LGrease

Locate fittings on swing arm and grease with grease gun.

MAINTENANCE AND LUBRICATION

Lubrication Recommendations

(1)

(3)

6X6

4X4 6X6

6X6

(2)

4X4 6X6

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 Synth etic 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. It 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 i n 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. F ollow 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.

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 S eason Synthetic engine oil.

Oil Check

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

1. Position t he 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.

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.

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

SAFE

ADD 8 OZ

MAINTENANCE AND LUBRICATION

Engine Oil

Oil and Filter Change

CAUTION

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

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

1. Position t he vehicle on a level surface.

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

3. Clean the area around the drain plug.

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

5. Allow the oil to drain completely.

6. Reinstall the sealing washer on the drain plug.

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

clean and free of burrs, nicks or scratches.

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

8. Place shop towels beneath t he oil filter. Using an oil filter wrench, turn the filter counterclockwise to remove.

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

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

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

MAINTENANCE AND LUBRICATION

Engine Oil

Oil and Filter Change

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

13. Shift the transmission to neutral.

14. 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

Torque

Drain Plug

Torque

Main Gearcase (Transmission)

Premium AGL

Synthetic Gearcase

Lube

15.2 oz. (450 ml)

14 ft. lbs.

(19.4 Nm)

14 ft. lbs.

(19.4 Nm)

Front Gearcase Premium Demand

Drive Hub Fluid

5oz.

(150 ml)

8-10 ft. lbs.

(11-13.6 Nm)

1 1 ft. lbs.

(15 Nm)

Middle Gearcase

(6X6)

Premium ATV Angle

Drive Fluid

6.75 oz. (200 ml)

14 ft. lbs.

(19.4 Nm)

14 ft. lbs.

(19.4 Nm)

Rear Gearcase

(4X4)

Premium ATV Angle

Drive Fluid

18 oz.

(532 ml)

40-50 ft. lbs.

(54-68 Nm)

30-45 in. lbs.

(3-5 Nm)

Rear Gearcase

(6X6)

Premium ATV Angle

Drive Fluid

10 oz.

(300 ml)

14 ft. lbs.

(19.4 Nm)

14 ft. lbs.

(19.4 Nm)

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 t he 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.

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

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

5. Reinstall the drain plug. Torque to specification.

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

7. Reinstall the fill plug. Torque to specification.

8. Check for leaks.

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 lubricants, capacities and torque specifications. See page 99 for the part numbers of Polaris products.

Oil Check

1. Position t he 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.

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 lubricants, 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 t he 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.

6X6

4X4

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 lubricants, 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 i s 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 t he 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.

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.

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

.035″ (.9 mm)

18 ft. lbs.

(24 Nm)

18 ft. lbs.

(24 Nm)

RANGER

6X6 EFI

.035″ (.9 mm)

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.

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.

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 i s 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.

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

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

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

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.

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.

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

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.

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 it out before operating.

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

2. Allow the water to drain.

3. Tighten the screws.

4. Apply the brakes. Start the engine.

5. Engage the park brake.

6. Shift the transmission to neutral.

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

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

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

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

MAINTENANCE AND LUBRICATION

Filter Systems

Air Filter

Always change the air filter at t he 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.

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.

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.

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.

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).

MAINTENANCE AND LUBRICATION

Throttle System

Throttle Freeplay Adjustment

1. Slide t he 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. Ti ghten the locknut and slide the boots over the cable adjuster until they touch at the midpoint of adjuster.

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.

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 t he 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.

WARNING

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

MAINTENANCE 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 In sp ectio n

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 t he vehicle on a level surface.

2. Shift the transmission to neutral.

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

3/64″ (1 mm)

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 t he 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. l bs. (40 Nm).

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.

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.

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.

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.

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

110 ft. lbs. (150 Nm)

1/8I (3 mm)

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 In stallatio 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.

MAINTENANCE AND LUBRICATION

Lights

When servicing a halogen l amp, 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.

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 i ntense 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.

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.

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

maintenance.

MAINTENANCE AND LUBRICATION

Vehicle Immersion

CAUTION

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

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

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

2. Dry any water present in the air box.

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.

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.

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 t o a battery.

WARNING

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

Battery Removal

1. Open the hood.

2. 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.

MAINTENANCE AND LUBRICATION

Battery

Battery Installation

1. Set t he 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.

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.

Wash in g t he 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 labels. 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 th e 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.

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 recomme nded amount. (Carbon clean will also reduce the possibility of bacteria l 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-clea ner 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 the service or owner’s manual to completely grease and lubricate the entire vehicle with Polaris Premium All Season Grease.

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-mea sure 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 specifica tion. 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.

Polaris RANGER XP 700 EFI User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual