Polaris Series 10 Ranger 425 2x4 User Manual

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WARNING

The engine exhaust from this

product contains chemicals known

to cause cancer, birth defects or

other reproductive harm.

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WELCOME

Thank you for purchasing a Polaris vehicle, and welcome to our world-wide family of Polaris enthusiasts. Polaris proudly produces an exciting line of recreational products, including snowmobiles, all-terrain vehicles, personal watercraft, utility vehicles, and Victory motorcycles.

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

Follow the instructions and recommendations in this Owner’s Manual for safe and enjoyable operation of your vehicle. Your Owner’s Manual contains instructions for minor maintenance, but major repairs are covered in the Polaris Service Manual and should be performed by a Factory Certified MSD (Master Service Dealer) Technician.

Your Polaris RANGER dealer knows your vehicle best and is interested in your complete satisfaction. Return to your dealership for all of your service needs during, and after, the warranty period.

Polaris also takes great pride in our PAA (Parts Apparel and Accessories) which are available on our online store www.purepolaris.com. Have your accessories and clothing delivered right to your door!

Polaris and Polaris The Way Out are registered trademarks of Polaris Industries Inc.

THIS VEHICLE IS NOT A TOY AND CAN BE

HAZARDOUS TO OPERATE. This vehicle handles differently from other vehicles including motorcycles and cars. A collision or rollover can occur quickly, even during routine maneuvers such as turning and driving on hills or over obstacles, if you fail to take proper precautions.

SEVERE INJURY OR DEATH can result if you do not follow these instructions:

n Read this manual and all labels carefully and follow the operating

procedures described.

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

vehicle.

n Minimum age recommendation for passengers is five years old.

Passengers 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.

n Never permit a guest to operate this vehicle unless the guest has

read this manual and all product labels.

n To reduce tipover risk, be especially careful when encountering

obstacles and slopes, when braking on hills or during turns.

n Always fasten your seat belts securely around you.

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

as severe injury or death may occur. Always avoid paved surfaces.

n Helmets are recommended whenever driving this vehicle in an

aggressive manner. Eye protection i s recommended at all times.

n Never consume alcohol or drugs before or while operating this

vehicle.

n Never operate at excessive speeds. Always travel at a speed which

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

n Never attempt wheelies, jumps or other stunts.

n Always inspect your vehicle each time you use it to make sure it is

in safe operating condition. Always follow the inspection and maintenance procedures and schedules described in t his m anual.

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

floorboards of the vehicle during operation.

n Always go slowly and be extra careful when operating on

unfamiliar terrain. Always be alert to changing terrain conditions when operating this vehicle.

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

n Always follow proper procedures for turning as described in this

manual. Practice turning at low speeds before attempting to turn at faster speeds. Do not turn at excessive speed.

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

it has been involved in an accident.

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

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

n Always follow proper procedures for climbing hills as described in

this manual. Check the t errain carefully before you start up any 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 any hill at high speed.

n Always follow proper procedures for going down hills and for

braking on hills as described in this manual. Check the terrain carefully before you start down any hill. Never go down a hill at high speed. Avoid going down a hill at an angle which would cause the vehicle to lean sharply to one side. Go straight down the hill where possible.

n Always follow proper procedures for crossing the side of a hill as

described in this manual. Avoid hills with excessively slippery or loose surfaces. Never attempt to turn the vehicle around on any hill until you have mastered the turning technique described in this manual on level ground. Avoid crossing the side of a steep hill if possible.

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

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

n Always be careful of skidding or sliding. On slippery surfaces,

such as ice, go slowly and be very cautious in order to reduce the chance of skidding or sliding out of control.

n Never operate vehicle in fast flowing water or in water deeper than

that specified in this manual. Remember that 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.

n Always be sure there are no obstacles or people behind you when

you operate in reverse. When it is safe to proceed in reverse, go slowly. Avoid turning at sharp angles in reverse.

n Always use the size and type tires specified in this manual.

Always maintain proper tire pressure as described on page 101.

n Never modify this vehicle t hrough improper installation or use of

accessories.

n Never exceed the stated load capacity for this vehicle. Cargo

should be properly distributed and securely attached. R educe speed and follow instructions in this manual for carrying cargo or pulling a trailer. Allow greater distance for braking.

n Always wear the seat belts whenever the vehicle is operated. This

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

n Always keep arms and legs inside of cab frame while the vehicle is

in motion.

n Always apply the parking brake before getting out of the vehicle.

The parking brake is located on the left side of the center console. Activate by pulling up on the lever. Release by pressing the button on the end of the handle and lowering the lever.

n Always activate the foot pedal brake before releasing the park

brake.

n Always shut off the engine before refueling. Make sure the area is

well ventilated and free of any source of flame or sparks. Gasoline is very flammable. S ee page 50 for refueling i nstructions.

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

Additional Important Information...

Due to our concern for the safety of our customers and the general public, Polaris hereby strongly recommends and requests that consumers not have installed on a Polaris RANGER any equipment which is intended to increase t he 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 RANGER substantially increase the risk of bodily injury. Please be aware that these modifications may create a substantial safety hazard.

Polaris hereby informs you that the warranty on your RANGER is terminated if any such equipment has been added to the vehicle or any modifications have been made to the vehicle which increase its speed or power.

We also advise you to strictly follow the recommended maintenance program outlined in this manual. This preventive maintenance program is designed to ensure that all critical components on the vehicle are thoroughly inspected by your dealer at various mileage intervals.

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.

Be certain any accessories added to this vehicle have been approved by Polaris.

Familiarize yourself with their function and affect on the vehicle.

TABLE OF CONTENTS

Vehicle Identification Numbers 10.............

Safety 1 1 - 45................................

Operator Safety 11................................

Decals and Locations 40...........................

Features and Controls 46.....................

Features 46......................................

Controls 51.......................................

Operation 57 - 64.............................

Before You Ride 57...............................

Vehicle Break-In Period 58.........................

Starting the Engine 59.............................

Driving 62........................................

Stopping the Engine 63............................

Fuel 64..........................................

Noise Emission 65...........................

TABLE OF CONTENTS

Maintenance and Lubrication 67 - 110..........

Periodic Maintenance Schedule 67..................

Lubrication Recommendations 70...................

Oil Recommendations 74..........................

Cooling System 81................................

PVT 85..........................................

Filter Service 87..................................

Spark Plugs 89...................................

Spark Arrestor 91.................................

Adjustments 93...................................

Tires 101.........................................

Lights 103........................................

Cleaning and Storage 105..........................

Battery 108.......................................

Specifications 111.................................

Trouble Shooting 113..............................

Warranty 115.....................................

VEHICLE IDENTIFICATION NUMBERS

Important: Record these numbers from your vehicle in the spaces provided.

1. Frame VIN:

2. Vehicle Model Number:

3. Engine Serial Number (Right front side of engine crankcase)

Remove the spare key and store in a safe place.

The vehicle frame and engine serial numbers are important for model identification when registering your vehicle, obtaining insurance or whenever replacement parts are required. In the event your vehicle were stolen these numbers are essential to the recovery and identification of your vehicle.

Dealer Imprint

SAFETY

Operator Safety

The following two pages identify signal words and symbols that appear in this manual. 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 RANGER or in this manual, alerts you to the potential for personal injury.

WARNING

Indicates a potential hazard that could result in serious injury or death.

CAUTION

Indicates a potential hazard that may result in minor personal injury or damage to the machine.

CAUTION

Indicates a situation that may result in damage to the machine.

NOTE

“NOTE:” will alert you to important information or instructions.

SAFETY

Operator Safety

WARNING

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.

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

All Polaris RANGERs are designed and tested 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. DO NOT MODIFY YOUR MACHINE. The RANGER may become aerodynamically unstable at speeds higher than those for which it is designed. Loss of control m ay occur at higher speeds. Modifications may also create a safety hazard and lead to bodily injury.

The warranty on your entire machine is terminated if any equipment has been added, or any modifications have been made, to increase the speed or power of the RANGER.

Operator Safety

WARNING

15_ Maximum

POTENTIAL HAZARD Operating on excessively steep hills. WHAT CAN HAPPEN The vehicle can overturn more easily on extremely steep hills

than on level surfaces or small hills. HOW TO AVOID THE Never operate the RANGER on hills too steep for the vehicle

or for your abilities. Practice on smaller hills before attempting large hills. Never operate vehicle on hills steeper than 15_.

HAZARD

SAFETY

Operator Safety

WARNING

POTENTIAL HAZARD Climbing hills improperly. WHAT CAN HAPPEN Could cause loss of control or cause vehicle to overturn. HOW TO AVOID THE HAZARD Always check the terrain carefully before you start up any hill. Never climb hills with excessively slippery or loose surfaces. Never open the throttle suddenly. The vehicle could go out of

control. Never go over the top of any hill at high speed. An obstacle, a

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

WARNING

POTENTIAL HAZARD Going down a hill improperly. WHAT CAN HAPPEN Could cause loss of control or cause vehicle to overturn. HOW TO AVOID THE HAZARD Always check the terrain carefully before you start down any hill. Never go down a hill at high speed. Avoid going down a hill at an angle which would cause the

vehicle to lean sharply to one side. Go straight down the hill where possible.

Operator Safety

WARNING

POTENTIAL HAZARD

Improperly crossing hills or turning on hills.

WHAT CAN HAPPEN

Could cause loss of control or cause vehicle to overturn.

HOW TO AVOID THE HAZARD

Be very careful when turning on any hill. Avoid crossing the side of a steep hill if possible. When crossing the side of a Avoid hills with excessively slippery or loose surfaces.

hill:

WARNING

SAFETY

POTENTIAL Improperly operating over obstacles. WHAT CAN HAPPEN Could cause loss of control or a collision. Could cause vehicle

to overturn. HOW TO AVOID THE Before operating in a new area, check for obstacles. Use extreme caution when operating over large obstacles, such

as large rocks or fallen trees.

HAZARD

SAFETY

Operator Safety

WARNING

POTENTIAL HAZARD Stalling, rolling backwards while climbing a hill. WHAT CAN HAPPEN Could result in vehicle overturning. HOW TO AVOID THE HAZARD Maintain steady speed when climbing a hill. Ifyouloseallforwardspeed: Apply the brakes. Lock parking brake after you are stopped. If you begin rolling Never apply engine power. Apply the brake gradually. When fully stopped, lock parking brake. In the event of an accident, have a qualified service dealer check

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

backwards:

Operator Safety

SAFETY

WARNING

Never carry passengers in the box. If the weight distribution on the box is located toward the rear of

the box and the release lever is pulled, the box will want to dump on its own. Never operate the dump lever without checking the position of the load. This will prevent unexpected dumping of the cargo box.

SAFETY

Operator Safety

WARNING

POTENTIAL HAZARD Operating this vehicle on paved surfaces. WHAT CAN HAPPEN 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.

HOW TO AVOID THE Avoid operating the vehicle on pavement whenever

possible. If you must operate on a paved surface, go slowly and do not make sudden turns or stops.

HAZARD

WARNING

Safe operation of this vehicle requires good judgement and physical skills. Persons with cognitive or physical disabilities who operate this vehicle have an increased risk of overturns and loss of control which could result in serious injury or death.

WARNING

POTENTIAL HAZARD Operating this vehicle without proper instruction. WHAT CAN HAPPEN 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.

HOW TO AVOID THE Read and understand the Owner’s Manual and all warning and

instruction labels on the vehicle.

HAZARD

Operator Safety

WARNING

POTENTIAL HAZARD Operating this vehicle on public streets, roads or

highways. WHAT CAN You can collide 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 is illegal to operate vehicles of this type

on public streets, roads and highways.

HAPPEN

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 Never consume alcohol or drugs before or while driving this

vehicle.

HAZARD

SAFETY

Operator Safety

WARNING

POTENTIAL HAZARD Operating this vehicle at excessive speeds. WHAT CAN HAPPEN Increases your chances of losing control of the vehicle,

which can result in an accident. HOW TO AVOID THE Always travel at a speed which is proper for the terrain,

visibility and operating conditions; and your experience.

HAZARD

WARNING

POTENTIAL HAZARD Attempting jumps and other stunts. WHAT CAN HAPPEN Increases the chance of an accident, including an overturn. HOW TO AVOID THE HAZARD Never attempt stunts such as jumps. Don’t try to show off.

SAFETY

Operator Safety

WARNING

POTENTIAL HAZARD Failure to inspect the vehicle before operating. Failure to properly maintain the vehicle. WHAT CAN HAPPEN Increases the possibility of an accident or equipment damage. HOW TO AVOID THE HAZARD Always inspect your RANGER eachtimeyouuseittomakesureit

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

schedules described in the Owner’s Manual.

WARNING

POTENTIAL Failure to use extra care when operating this vehicle on unfamiliar

terrain. WHAT CAN You can come upon hidden rocks, bumps, or holes, without enough

time to react. Could result in the vehicle overturning or going out of control. HOW TO AVOID THE Go slowly and be extra careful when operating on unfamiliar

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

vehicle.

HAZARD

HAPPEN

HAZARD

SAFETY

Operator Safety

WARNING

POTENTIAL HAZARD Failure to use extra care when operating on excessively

rough, slippery or loose terrain. WHAT CAN Could cause loss of traction or vehicle control, which could

result in an accident, including an overturn. HOW TO AVOID THE Do not operate on excessively rough, slippery or loose

terrain until you have learned and practiced the skills necessary to control the vehicle on such terrain.

Always be especially cautious on these kinds of terrain.

HAPPEN

HAZARD

SAFETY

Operator Safety

WARNING

POTENTIAL HAZARD Skidding or sliding. WHAT CAN HAPPEN You may lose control of the vehicle. You may also regain traction unexpectedly, which may cause the

vehicle to overturn. HOW TO AVOID THE On slippery surfaces, such as ice, go slowly and be very

cautious in order to reduce the chance of skidding or sliding out of control.

HAZARD

WARNING

POTENTIAL Operating on frozen lakes and rivers. WHAT CAN HAPPEN Serious injury or death can result if the vehicle and/or the

operator break through the ice. HOW TO AVOID THE Never operate your RANGER on a frozen body of water before

you are sure the ice is thick enough and sound enough to support the machine and its operator, as well as the force that is created by a moving vehicle.

HAZARD

SAFETY

Operator Safety

WARNING

POTENTIAL HAZARD Operating this vehicle through deep or fast flowing water. WHAT CAN HAPPEN Tires may float, causing loss of traction and loss of control,

which could lead to an accident. HOW TO AVOID THE Never operate this vehicle in fast flowing water or in water

deeper than that specified in your Owner’s Manual. See page 31.

Remember that wet brakes may have reduced stopping ability. Test your brakes after leaving water. If necessary, apply them several times to let friction dry out the pads.

HAZARD

WARNING

POTENTIAL Operating this vehicle with improper tires, or with improper

or uneven tire pressure. WHAT CAN Use of improper tires on this vehicle, or operation of this

vehicle with improper or uneven tire pressure, may cause loss of control, and increases the risk of an accident.

HOW TO AVOID THE Always use the size and type tires specified in the Owner’s

Manual for this vehicle. See page 113. Always maintain proper tire pressure as described in the

Owner’s Manual. See page 40.

HAZARD

HAPPEN

HAZARD

SAFETY

Operator Safety

WARNING

POTENTIAL HAZARD Improperly operating in reverse. WHAT CAN HAPPEN You could hit an obstacle or person behind you, resulting in

serious injury. HOW TO AVOID THE Before you select reverse gear, make sure there are no

obstacles or people behind you. When it is safe to proceed, go slowly. Always avoid backing down hill.

HAZARD

WARNING

POTENTIAL HAZARD Overloading this vehicle or carrying or towing cargo improperly. WHAT CAN HAPPEN Could cause changes in vehicle handling which could lead to an

accident. HOW TO AVOID THE Never exceed the stated load capacity for this vehicle. Cargo should be properly distributed and securely attached. Reduce speed when carrying cargo or pulling a trailer. Allow

greater distance for braking. Always follow the instructions in the Owner’s Manual for carrying

cargo or pulling a trailer. See page 36.

HAZARD

SAFETY

Operator Safety

WARNING

POTENTIAL HAZARD Failure to follow the age recommendations for this vehicle. WHAT CAN HAPPEN Use of this vehicle by a child can lead to serious injury or death

of the child or others. 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.

HOW TO AVOID THE No one without a valid driver’s license should operate a Polaris

RANGER.

HAZARD

WARNING

In the event of an accident have a qualified service dealer check the complete machine including, but not limited to, brakes, throttle, and steering for possible damage.

WARNING

POTENTIAL HAZARD Operating this vehicle with improper modifications. WHAT CAN HAPPEN Improper installation of accessories or modification of this vehicle

may cause changes in handling which in some situations could lead to an accident.

HOW TO AVOID THE Never modify this vehicle through improper installation or use of

accessories. All parts and accessories added to this vehicle should be genuine Polaris Sales Inc. or equivalent components designed for use on this vehicle; and should be installed and used according to instructions. If you have questions, consult an authorized Polaris dealer.

HAZARD

SAFETY

Operator Safety

Driving On Slippery Surfaces

Whenever driving on slippery surfaces such as wet trails or loose gravel, or during cold freezing weather, special attention must be paid to prevent vehicle turnover. Always:

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. Driving with AWD (All Wheel Drive) engaged can assist in controlling the vehicle in slippery areas.

CAUTION

Engaging AWD while the wheels are spinning can cause severe damage to the drive train.

Before operating your vehicle on a frozen body of water be sure that the ice is thick enough to support the machine and its operator, as well as the force that is created by a moving vehicle. Severe injury or death can result if the vehicle and/or its operator break through the ice.

WARNING

Failure to exercise care when operating on slippery surfaces can be dangerous.

Loss of tire traction and vehicle control can result in an accident, including an overturn.

D Never apply brakes during a skid. Complete loss of control can

result.

D Do not operate on excessively slippery surfaces if possible. D Always reduce speed and use additional caution.

SAFETY

Operator Safety

Operating on Hills

WARNINGWARNINGWARNING

Improperly crossing hills or turning on hills can be dangerous! Loss of vehicle control or overturning of the vehicle could occur.

D Avoid crossing the side of a steep hill if possible. D Use extreme care when operating your RANGER in hilly terrain.

Whenever descending a hill always:

1. Drive directly downhill.

2. Slow down.

3. Apply the brakes lightly to aid in slowing.

WARNING

Loss of vehicle control due to excessive speed can occur. Loss of control may result in serious injury or death.

Whenever traveling uphill always travel straight uphill and:

1. Avoid steep hills.

2. Keep both feet on the floor.

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

SAFETY

Operator Safety

Operating on Hills

WARNING

Braking and handling are greatly affected whenever operating in hilly terrain.

Loss of vehicle control or overturning of the vehicle could occur.

D Avoid climbing steep hills (15_ maximum). D Use extreme care when operating your vehicle in hilly terrain.

WARNING

Avoid climbing steep hills. Loss of vehicle control or overturning of vehicle could occur. D Use extreme care when operatingyour RANGER in hillyterrain.

WARNING

Improperly crossing hills or turning on hills could cause loss of control or cause the vehicle to overturn.

If at all possible, avoid crossing the side of a steep hill. Avoid hills with excessively slippery or loose surfaces.

SAFETY

Operator Safety

Operating on Hills

WARNING

Going down a hill improperly could cause loss of control or cause the vehicle to overturn.

Always check the terrain carefully before you start down any hill. Never go down a hill at high speed. Avoid going down a hill at an angle which would cause the

vehicle to lean sharply to one side. Go straight down the hill where possible.

WARNING

Climbing hills improperly can cause loss of control or cause vehicle to overturn.

Always check the terrain carefully before you start up any hill. Never climb hills with excessively slippery or loose surfaces. Never open the throttle suddenly. The vehicle could go out of

control. Never go over the top of any hill at high speed. An obstacle, a

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

Operator Safety

Crossing Streams

SAFETY

Your Polaris RANGER can operate through water up to depths reaching the floorboards. Before fording streams always:

1. Determine water depths and current.

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

3. Proceed slowly, avoiding rocks and obstacles if possible.

4. After crossing, dry the brakes by applying light pressure to the lever until braking action is normal.

Should your vehicle become immersed, it will be necessary to take it to your dealer as soon as possible. Do not start the engine! Immersion of the vehicle can cause major damage if not correctly repaired.

SAFETY

Operator Safety

Crossing Streams

WARNING

Never try to cross any deep or fast flowing streams. The large tires can cause the vehicle to float resulting in loss of

control. D Determine stream depth and speed before crossing.

NOTE: After running the vehicle in water, it is critical your machine is serviced as outlined in the maintenance chart beginning on page 67. The following areas need special attention: engine oil, transmission oil, front and rear gearcases, and all grease fittings.

If your vehicle is immersed, take it to your dealer before operating. If this is impossible, service your machine as outlined on page 86 and take the machine to your dealer at your first opportunity.

SAFETY

Operator Safety

Trail Obstacles

Keep Alert!

Look ahead and learn to read the trail as you drive. Stay on the right side of the trail, if possible, and be constantly alert for hazards such as logs, rocks and low hanging branches.

WARNING

Hidden or unseen hazards on the trail can be dangerous. Personal injury or the vehicle overturning can occur from unseen

obstacles. D Keep alert and constantly look for obstacles on the trail.

SAFETY

Operator Safety

Backing Up

1. When backing up, always avoid backing downhill.

2. Back slowly.

3. When in reverse, apply the brakes lightly for stopping.

4. Avoid turning at sharp angles in reverse.

5. Never open the throttle suddenly while backing.

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

WARNING

Backing your RANGER can be dangerous! You could hit an obstacle or person behind you; or the vehicle could tip over on a steep incline.

D Always back slowly, avoiding excessive speed. D Avoid backing on steep inclines.

Operator Safety

ParkingOnAnIncline

SAFETY

Whenever the Vehicle is Parked

1. Place the transmission in gear.

2. Set the parking brake.

3. Avoid parking on an incline. If it is necessary to park on an incline, always block the rear wheels on the down hill side.

WARNING

Always check to be sure that the parking brake has been disengaged before operating the vehicle. An accident could result if the parking brake is left on while the vehicle is operated.

Always block the downhill side of the wheels if leaving the vehicle on a hill or park the vehicle in a side hill position.

SAFETY

Operator Safety

Carrying Loads

The RANGER has been designed to carry or tow a certain amount of load. Always read and understand the load distribution warnings listed on the warning labels. Never exceed the following weights.

Maximum Capacities

(Level Ground)

RANGER 2X4 1350 lbs. (614 kg) 850 lbs. (386 kg) RANGER 4X4 1500 lbs. (681 kg) 1000 lbs. (454 kg) RANGER 6X6 1500 lbs. (681 kg) 1000 lbs. (454 kg)

Cargo Box

Load Distribution

1. Always load the cargo box placing the load as far forward as possible.

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

3. Slow down and drive in low gear.

4. The cargo box dump latch must be securely latched before loading and operating. Unintentional box tilting will result if weight is placed in the rear of the box and the latch is not secured.

WARNING

Never operate this vehicle with the cargo box in the raised position. The cargo box could close unexpectedly while driving, severely injuring the driver. The rear tires will catch the rear of the box, damaging the vehicle and creating hazardous driving conditions.

Do not overload the vehicle.

SAFETY

Operator Safety

Dumping the Cargo Box

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

2. Set the parking brake.

3. Dismount the vehicle.

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

5. Stand clear and pull up on the cargo box release mechanism lever (1). Lift the front of the cargo box to dump.

WARNING

If the weight distribution on the box is located toward the rear of the box and the release lever is pulled forward, the box will want to dump on its own. Never operate the dump lever without checking the position of the load. This will prevent unexpected dumping of the cargo box.

WARNING

Never carry passengers in the box.

WARNING

In the event of an accident have a qualified service dealer check the complete machine including, but not limited to, brakes, throttle, and steering for possible damage.

SAFETY

Operator Safety

Towing Loads

Maximum Towing Capacities (Level Ground)

RANGER

2X4

RANGER

4X4

RANGER

6X6

Total Towed

Load Weight

(level ground)

1400 lbs.

(636 kg)

1500 lbs.

(681 kg)

1500 lbs.

(681 kg)

Total Towed

Load Weight

(15° grade)

800 lbs. (364 kg)

850 lbs. (386 kg)

Total Hitch

Vertical

Weight

150 lbs

(68.1 kg)

150 lbs

(68.1 kg)

150 lbs

(68.1 kg)

Towing

Speed

10 mph

(16 kph)

or less

10 mph

(16 kph)

or less

10 mph

(16 kph)

or less

Do not tow in high gear. Drive belt life will be affected. Maximum grade while trailer towing - 15°; do not tow any trailer on a

grade steeper than 15°.

WARNING

Never carry a passenger in a trailer 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. Remember that towing a trailer increases braking distance.

Do not tow more than the recommended weight. 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 and have an accident.

SAFETY

Operator Safety

Parking the RANGER

1. Stop the vehicle on a level surface.

2. When the engine has s topped, apply the parking brake to help prevent the vehicle from rolling.

WARNING

Be sure to apply the parking brake before leaving the vehicle. If the vehicle should move, it might be damaged or cause injury.

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

NOTE: When parking inside a garage or other structure, be sure the structure is well ventilated and the vehicle is not close to any source of flame or sparks. This includes any appliance with a pilot light.

WARNING

Gasoline is extremely flammable and can be explosive under certain conditions.

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 SEATBELT for maximum protection.

7079425

S Moving parts hazard under belt-clutch guard. To

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

S Do not modify engine or clutch. Doing so can

cause partfailure, possibleimbalance, and excessive engine RPM which can result in serious injury or death.

NO STEP

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

WARNING

SEE OWNER’S MANUAL FOR PROPER TIRE INFLATION FOR DIFFERENT VEHICLE APPLICAT IONS.

TIRE PRESSURE (PSI):

FRONT MIN. ___ MAX. ___ REAR MIN. ____ MAX. ____

MAXIMUM WEIGHT CAPACITY

(Gross Vehicle Weight)

INCLUDING MACHINE, PASSENGER

AND CARGO IS _____ LBS.

7078689

Safety Decals and Locations

SAFETY

D Operation of this vehicle without

the filter element will severely damage the engine.

D Clean air filter often, more

frequent cleaning required in dusty conditions

D Operation of this vehicle without

engine breather filter(s) can cause engine damage. Consult owner’s manual for details.

ATTENTION

adjustments are required depending on temperature and altitude. See your Owner’s Manual.

D Specific

carburetor jetting and

Factory setting:

40_ to 80_ F. at 0-3000 feet

(5_ to 27_ C. at 0-900 meters).

7079902

SAFETY

Safety Decals and Locations

MANUFACTURED BY: POLARIS IND INC.

DATE:

VIN:

THIS VEHICLE IS A GENERAL PURPOSE OFF-ROAD

UTILITY VEHICLE AND IS NOT INTENDED FOR USE ON PUBLIC ROADS.

CE VÉHICULE USAGE GENERAL VEHICULE UTILITAIRE POUR SERVICE HORS ROUTE QUI NEST PAS DESTINE A ETRE UTILISE SUR LES CHEMINS PUBLICS.

PRINTED IN U.S.A.

7078472

(Under Hood)

Remove flammable containers from box before refueling.

(inside/front of box - text is printed below)

Fuel / Passenger Warning Decal Text

Remove flammable containers from box before refueling. S Passengers can be thrown off. This can cause serious injury or

death.

S Never carry passengers in cargo box. Maximum2x4BoxLoad850lbs.

Maximum4x4BoxLoad1000 lbs. Maximum6x6BoxLoad1000 lbs.

Safety Decals and Locations

SAFETY

Safety Decals and Locations

SAFETY

Safety Decals and Locations

WARNING

Improper vehicle use can result in SEVERE INJURY or DEATH.

NEVER:

S Operate on public roads. A collision can occur with another ve-

hicle.

S Carry more than two passengers, or passengers under age five. S Use ALCOHOL or DRUGS before or while operating this vehicle. S Operate at speeds too fast for your skills or the conditions. S Operate this vehicle on HILLS steeper than 15 degrees. To prevent

flipover on hilly terrain, use throttle and brakes gradually.

ALWA YS:

S A void paved surfaces which may adversely affect handling and con-

trol.

S Use proper RIDING TECHNIQUES to avoid vehicle overturns on

hills and rough terrain and in turns.

S Wear eye protection. REVERSE operation can be dangerous, even at low speeds. Steering

becomes difficult. To prevent flipover, avoid sharp turns. The park/emergency brake lever will supply increased braking, but

should be used as an emergency or parking brake only.

READ OWNER’S MANUAL. FOLLOW ALL INSTRUCTIONS

AND WARNINGS. IF OWNER’S MANUAL IS MISSING,

CONTACT A POLARIS DEALER FOR A REPLACEMENT.

THIS GENERAL PURPOSE OFF-ROAD UTILITY VEHICLE DOES

NOT MEET FEDERAL MOTOR VEHICLE SAFETY ST ANDARDS

FOR ON ROAD VEHICLES.

FEATURES AND CONTROLS

Features

1. Cab Frame

2. Cab Frame Hand Hold

3. Dashboard

4. Steering Wheel

5. Seat

6. Cargo Box

7. Seat Belts

8. Gas Tank Cap / Gas Gauge

9. Battery (under seat)

5, 9

Features

FEATURES AND CONTROLS

10. Headlights

11. Radiator

12. Front B umper/Brush Guard

13. Hood Hold Down Strap

1313

FEATURES AND CONTROLS

Features

14. Oil Tank

15. Battery (Under Seat)

16. Tail Lights

17. Tail Gate

18. Tailgate Latch Release

19. Airbox (under cargo box)

20. Muffler (Spark Arrester)

21. Rear Caliper

22. Trailer Hitch Receiver

23. Engine Oil Plug

FEATURES AND CONTROLS

Features

Auxiliary Lighting /Electrical Accessory Terminals

The 12-volt receptacle has spade connections on the back that may be used for accessory power such as an auxiliary light or other optional light or accessory.

To locate these connections, lift t he hood and look behind the dash board.

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, observe the precautions on page

36.

Seat Belts

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

WARNING

Seat belts reduce injury. Always were your seat belt. Minimum age recommendation for passengers is five years old. Passengers under five years of age require special restraints which are not available with this vehicle.

To wear the seat belt properly, follow this procedure:

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

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

3. Release the strap, it will self tighten. NOTE: The center belt must be tightened manually by pulling on the strap.

To unfasten the belt, press on t he squared red button in the center of t he buckle.

FEATURES AND CONTROLS

Features

Seat Removal

To remove the seat, pull up on the front of the seat and slide it toward the front of the vehicle.

Install the seat by sliding the tabs into the rear of the seat base and then push down firmly on the front of the seat until the pins are fully seated into the grommets.

Fuel Cap

The fuel tank filler cap (1) is located on the right side by the passengers seat. It has a built in fuel gauge which indicates the amount of fuel in the tank. Use either leaded or unleaded gasoline with a minimum pump octane number of 87 R+ M/2 octane.

Fuel Gauge

The fuel gauge, located on the gas tank cap, indicates the amount of fuel in the fuel tank.

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

Controls

FEATURES AND CONTROLS

24. Choke Knob

25. Ignition Switch

26. Hour Meter

27. Indicator Lights

28. 12V Accessory Plug

29. Fog/High Beam Light Switch

30. AWD (All Wheel Drive) Switch (if equipped)

31. Shift Lever

32. Differential Lock Lever

FEATURES AND CONTROLS

Controls

Transmission Gear Selector Operation

The transmission gear selector (1) is located on the console to the right of the steering wheel and has four positions (2): high, low, neutral and reverse

NOTE: Low is the primary driving range for this vehicle. High 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 to shift gears with engine speed above idle or while the vehicle is moving.

Always place the transmission in gear with the parking brake locked whenever the vehicle is left unattended.

Maintaining shift linkage adjustment is important to assure proper transmission function. Should you experience any shifting problem see your dealer.

CAUTION

Do not attempt to shift the transmission while the vehicle is moving or damage to the transmission could result.

Always place the transmission in gear with the parking brake applied and turn the vehicle off whenever the vehicle is left unattended.

FEATURES AND CONTROLS

Controls

Brake Pedal

The brake pedal (5) is the left pedal on the foot board. Depress the brake pedal to slow or stop the vehicle.

Throttle Pedal

The throttle pedal (6) is the right pedal on the floor board. 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. In addition, there must be adequate throttle pedal play. Refer to page 93 for throttle pedal adjustment procedure.

Indicator Lights

There are indicator lights (3) on the dash panel which indicate the following:

1. High

2. Low

3. Neutral

4. Reverse

5. High Temperature Light

N R

FEATURES AND CONTROLS

Controls

Ignition Switch

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

OFF ON

START

Engine off. All electrical circuits off except Acc. 12V. All electrical equipment can be used.

Electric starter is engaged by holding ignition switch key in this position. Upon release, the key will return to the ON position.

CAUTION

Do not operate the starter continuously for more than 5 seconds, or the starter will overheat and the battery power will drop temporarily. Wait at least 5 seconds between each operation of the starter to let it cool and the batter power recover.

Do not turn the ignition switch key to the START position with the engine running, or damage to the starter can result.

Light Switch Lever

Turn on headlights and taillights by flipping the light switch lever up, with the ignition switch key in the ON position.The lights go off when the lever is pushed down.

AWD Rocker Switch

Vehicles equipped with AWD can be operated in either 2WD or AWD. The AWD is operated by a rocker switch located on the console. Flipping the lever up will engage the AWD.

FEATURES AND CONTROLS

Controls

All Wheel Drive (AWD)

All Wheel Drive

The Polaris RANGER 4X4 and 6X6 are equipped with a unique, Polaris exclusive, All Wheel Drive (AWD) system, which is activated by a switch on the dash (1). When the switch is off the RANGER is in two-wheel drive at all times. When the switch is on the RANGER is in AWD, and 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.

The AWD button position indicates when the vehicle is in AWD. There is no limit to the length of time the vehicle may remain in AWD.

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

CAUTION

If the rear wheels are spinning, release the throttle before turning the AWD switch on. If AWD is engaged while the wheels are spinning, severe drive shaft and clutch damage could result.

FEATURES AND CONTROLS

Controls

Parking Brake L ever

The parking brake (1) is located below the dash in the center of the vehicle. It will help hold the vehicle from rolling while parked.

To apply the parking brake, push down on t he pedal with your foot.

To release, Pull the release handle (2) located below the dash. Spring pressure helps return the lever to the released position.

Make sure the parking brake lever is functioning properly before each operation.

Differential Lock

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

To lock the differential, pull the differential lever (3) down.

CAUTION

Damage to the differential can occur if it is engaged when the vehicle is traveling at high speeds or while the rear wheels are spinning.

OPERATION

Before You Ride

Daily Pre -operation Inspection

Inspect your vehicle each time before operating to ensure it is in proper working order. If proper inspection is not done, serious injury or death could result.

WARNING

If a proper inspection is not performed serious injury or death can result.

Always inspect your RANGER before operating following the checklist carefully.

Before operating your vehicle, inspect all operating controls and parts.

Item/Inspection Procedure

1. Tires - check condition and pressures

2. Fuel and oil tanks - fill both tanks to their proper levels

3. All brakes - check operation, adjustment and fluid level (includes emergency/parking brake)

4. Throttle - check for free operation and closing

5. Headlight/Taillight/Brakelight - check operation of all indicator lights and switches

6. Engine ignition switch - check for proper function

7. Wheels - check for tightness of wheel nuts and axle nuts; check that axle nuts are secured by cotter pins

8. Air cleaner element - check for dirt; clean or replace

9. Steering - check for free operation noting any unusual looseness in any area

10. Loose parts - visually inspect vehicle for any damaged or loose nuts/bolts or fasteners

1 1. Operator and passenger should be properly dressed.

12. Engine coolant - check for proper level in the overflow bottle.

13. Check condition and operation of the dump box/bed latch mechanism.

OPERATION

Vehicle Break-In Period

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

CAUTION

Use only Polaris Premium 4 All Season synthetic oil, or API certified “SH” oil. Never substitute or mix oil brands. Serious engine damage and voiding of warranty can result.

1. Fill fuel tank with either unleaded or leaded fuel which has a minimum pump octane number of 87= (R+ M)/2.

2. Check oil reservoir level indicated on dipstick. Add oil if necessary.

3. Drive slowly at first. Select an area which is open and will give you room to familiarize yourself with vehicle operation and handling.

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

ADD 8 OZ. NORMAL FULL

Maintain Oil Level In Normal Range

CAUTION

Operating at full throttle or high speeds for extended periods during the first three hours of use can cause excessive heat resulting in damage to close fitted engine parts.

5. Perform regular checks on fluid levels, controls and all important areas on the vehicle as outlined earlier on the daily pre-operation inspection checklist found on page 57.

6. Pull only light loads.

7. Break in oil and filter. Change at 25 hours.

OPERATION

Starting the Engine

Procedure for Starting a Cold Engine

WARNING

Do not start or operate this vehicle with sticking or improperly operating throttle pedal. A stuck or improperly operating throttle could cause an accident resulting in severe injury or death.

Always contact your dealer for service repairs whenever throttle problems arise.

Failure to check or maintain proper operation of the throttle system can result in the throttle pedal sticking during driving and cause an accident.

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

1. Place the transmission in neutral.

2. Lock the parking brake.

3. Sit in the vehicle in the driver’s seat and fasten your seat belt.

4. Pull the choke lever all the way out.

5. Turn the ignition key to START.

6. If engine does not start, release ignition switch and wait five seconds; then turn the ignition switch to start for another five seconds. Repeat this procedure until engine starts.

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

OPERATION

Starting the Engine

After the Engine Starts

1. If the engine slows or stops, push the choke knob in half way.

2. Vary the engine RPM slightly with the throttle to aid in warm up until the engine idles smoothly. Then push the choke all the way in.

CAUTION

Proper engine warm up is essential each time before driving to avoid engine damage.

WARNING

Carbon monoxide exhaust gas is poisonous! Always start the vehicle outdoors. Never run the engine in an enclosed area.

WARNING

The engine exhaust from this

product contains chemicals known to cause cancer, birth defects or other reproductive harm.

OPERATION

Starting the Engine

Starting a Warm Engine

Warm engines do not normally require the use of the choke. Overuse of the choke can cause the spark plug to become wet fouled.

1. Place the transmission in neutral and move the vehicle to a level surface.

2. Lock the parking brake

3. Sit in the vehicle in the driver’s seat with the seatbelt fastened.

4. Turn the ignition key to START.

5. If the engine has cooled to a point where it does not readily start, intermittent use of the choke knob pulled half way out is permitted.

6. If the engine is over-choked by mistake when warm, depress the throttle lever fully while cranking to aid in starting.

7. Release the throttle lever immediately after the engine starts. If the engine does not start and all conditions are favorable, change the spark plug.

OPERATION

Driving the RANGER

1. Sit in the driver’s seat with the seatbelt fastened.

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

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

4. Release the parking brake.

5. Keeping both hands on the steering wheel, slowly depress the throttle with your right foot and begin driving. Vehicle speed is controlled by the amount of throttle opening and PVT shifting is done automatically.

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

WARNING

When carrying cargo or towing a trailer, remember that load weight will increase braking distances. Failure to allow for increased braking distance may result in accident and injury.

Braking

NOTE: Practice starting and stopping (using the brakes) until you are 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.

1. Release the throttle pedal completely

2. Press on the brake pedal evenly and firmly.

OPERATION

Stopping the Engine

1. Release the throttle pedal completely.

2. Put the gear shift lever into (N) Neutral.

3. Apply the parking brake to help prevent the vehicle from rolling.

CAUTION

Low is the primary gear for operating this vehicle. High is intended for use on hard packed surfaces with light loads. Premature belt wear is the result of operating in a gear that is unsuitable for the terrain.

WARNING

Be sure to apply the parking brake before leaving the vehicle. If the vehicle moves, it might be damaged or cause injury.

OPERATION

Fuel

WARNING

Gasoline is highly flammable and explosive under certain conditions.

D Always exercise extreme caution whenever handling gasoline. D Always refuel with the engine stopped and outdoors or in a well

ventilated area.

D Do not smoke or allow open flames or sparks in or near the

area where refueling is performed or where gasoline is stored.

D Do not over fill the tank. Do not fill the tank neck. D If you should get gasoline on your skin or clothing, immediately

wash it off with soap and water and change clothing.

D Never start the engine or let it run in an enclosed area. Gaso-

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

n Never use gasohol with an octane rating lower than the minimum

octane rating specified for this product.

n Never use gasohol containing more than 10% ethanol (grain

alcohol).

n Never use gasohol containing more than 5% methanol (wood

alcohol). Gasoline containing methanol must also be blended with cosolvents and corrosion inhibitors.

n Never use gasohol for extended periods and never store this vehicle

with gasohol in the fuel system.

n Gasoline containing alcohol can cause paint damage. Be extra

careful not to spill gasohol during refueling.

Gasoline and Alcohol Blends

Blends of gasoline and alcohol called “gasohol” can be used on an occasional basis, however continued use is not recommended. Switch back immediately to gasoline which does not contain alcohol if you experience any operating irregularities. Any deterioration of fuel system components or degradation of performance resulting from the use of gasohol will not be covered by Polaris’ Warranty.

NOISE EMISSION CONTROL SYSTEM

REGULATION

TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED! U.S. Federal law prohibits the following acts or the causing thereof: (1) The removal or rendering inoperative by any person other than for

purposes of maintenance, repair, or replacement of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use or

(2) the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person.

“AMONG THOSE ACTS PRESUMED TO CONSTITUTE TAMPERING ARE THE ACTS LISTED BELOW.”

1. Removal or alteration or the puncturing of the muffler or any engine component which conducts removal of engine exhaust gases.

2. Removal or alteration or the puncturing of any part of the engine air induction system.

3. Replacement of any vehicle parts with parts not in compliance with federal regulations.

4. Lack of proper maintenance.

CAUTION

Exhaust system components are very hot during and after use of the vehicle and will cause burns if they come in contact with skin.

S Do not touch hot exhaust system components. Serious burns can

result.

S Be especially careful when traveling through tall grass. The poten-

tial for fire exists.

USFS Approved Spark Arrestor

The muffler on this vehicle was tested and approved in accordance with the USF S Forest S ervice Standard 5100-1A.

-NOTES-

MAINTENANCE AND LUBRICATION

Periodic Maintenance Schedule

Careful periodic m aintenance will help keep your vehicle i n the safest, most reliable condition. Inspection, adjustment and lubrication intervals of important components are explained in the following chart:

Maintenance intervals are based upon average operating conditions. Vehicles subjected to severe use, such as operation in wet or dusty areas, should be inspected and serviced more frequently. If you are not familiar with safe service and adjustment procedures, have a qualified dealer perform these operations.

Inspect, clean, lubricate, adjust or replace parts as necessary.

CAUTION

Due to the nature of adjustments indicated by a J,itis recommended that service be performed by an authorized Polaris dealer. Do not attempt to perform this work unless you are familiar with mechanical repair.

" More often under severe use, such as dirty or wet conditions L Emission Control System Service (California)

NOTE: Inspection may reveal the need for replacement parts. Always use genuine Polaris parts available from your Polaris dealer.

Item Hours Remarks Brake System Pre-op-

eration

Tires Pre-op-

eration

Wheels Pre-op-

eration

Frame nuts, bolts, fasteners

Parking Brake Pre-op-

Coolant/Level Inspection

Headlamp Inspection Daily Check operation daily; apply Polaris

Pre-operation

eration Daily Replace engine coolant every two

Pre-operation inspection item

Inspect daily, pre-operation inspection item

Pre-operation inspection item

Check lever adjustment daily; adjust

years

dielectric grease to connector when replaced

MAINTENANCE AND LUBRICATION

Periodic Maintenance Schedule

Item Hours Remarks Tail lamp inspection Daily Check operation daily; apply Polaris

dielectric grease to socket when replaced

"LAirFilter-MainEle-

ment

" Transmission Oil

Level Battery 25 hrs Check Terminals/clean/check fluid

J Brake pad wear 25 hrs Inspect periodically

"LEngine breather filter 25 hrs Inspect--replace annually and as

" General Lubrication 25 hrs Lubricate all fittings, pivots, cables,

Engine Cylinder Head and Cylinder Base Fasteners

"LEngine Oil - Level/

Change (4-Cycle)

"LOil Filter 100 hrs Replace with oil change

Weekly Inspect-Replace if necessary

25 hrs Check level; change annually

level

needed

etc.

25 hrs Re-torque required at first service

only

100 hrs Check Level Daily; Break in Service

at 25 hours. Change oil more often in cold weather use.

L Engine breather

hose

J Carburetor Float

Bowl

J Throttle Cable 50 hrs Inspect--adjust, lubricate, replace if

L Choke (Enricher)

Cable Shift linkage 50 hrs Inspect, adjust

J Drive belt 50 hrs Inspect--adjust, replace if necessary J Steering 50 hrs Inspect daily, lubricate

100 hrs Inspect

50 hrs Drain bowl periodically and prior to

storage

necessary; pre-operation inspection item

50 hrs Inspect--adjust, lubricate, replace if

necessary

MAINTENANCE AND LUBRICATION

Periodic Maintenance Schedule

Item Hours Remarks

" Front Suspension 50 hrs Inspect--lubricate, tighten fasteners " Rear Suspension 50 hrs Inspect, tighten fasteners

Coolant strength/ pressure test system

Engine Mounts 100 hrs Inspect

JLValve Clearance 100 hrs Inspect/Adjust

L Spark Plug 100 hrs Inspect--replace if necessary

JLIgnition Timing 100 hrs Inspect and adjust as needed

J Front Hub Bearings 100 hrs Check at 100 hours and replace as

JLFuel System 100

J Fuel Filter 100 hrs Replace annually

Cooling System hoses

Spark arrestor 100 hrs Clean out

" Front Gearcase Oil 100 hrs Check monthly and change annually J Clutches (drive and

driven)

J Brake fluid 200 hrs Change every two years J Front wheel bearings 300 hrs Inspect; replace if necessary L Idle Speed As Re-

Engine side cover As re-

J Toe adjustment As re-

Headlight Aim As re-

100 hrs Inspect strength seasonally; pressure

test system annually

required Check for leaks at fuel cap, lines, fuel

hours

100 hrs Inspect

100 hrs Inspect, clean

quired

valve, filter, pump and carburetor. Replace lines every two years.

Adjust

Drain moisture out after driving in water

Periodic inspection, adjust when parts are replaced

Adjust if necessary

" More often under severe use, such as dirty or wet conditions L Emission Control System Service (California - 4-Cycle)

MAINTENANCE AND LUBRICATION

Lubrication Recommendations

Item Lube Rec. Method Frequency*

1. Engine Oil Polaris Premium 4 Synthetic 0W40

2. Brake Fluid DOT 3 Only Maintain level be-

3. Transmission Oil Polaris Premium Synthetic chain case lube

4. Gearcase Oil,

Front

Gearcase Oil, Middle

5. Prop Shaft

U-joints

6. Front Propshaft

Yoke

7. Front Drive Axle

(U Joint)

8. Ball Joint Grease** Locate fitting on

Premium Hub Lube

GL5 80-90 weight general lube

Grease+ Locate Fittings and

Grease+ Locate fittings and

Grease+ Locate grease fit-

Add to proper level on dipstick. See page 77.

tween fill lines. See page 95.

Maintain level at the bottom of the fill plug threads. See page 78.

Fill to bottom thread of filler hole. Make sure machine is on level surface.

grease

grease -- 3 pumps maximum

ting and grease with grease gun.

back side of struts and grease with grease gun.

Check level daily.

As required; change every 200 hours

Change at 100 hours

Change annually

50 hours

MAINTENANCE AND LUBRICATION

Lubrication Recommendations

4. Front Gearcase

4. Middle Gearcase

Fill plug

5. Prop Shafts

MAINTENANCE AND LUBRICATION

Lubrication Recommendations

9. Swing Arm

Bushings

10.Rear angle

drives

11. Front A Arm

Pivot Shaft

* More often under severe use, such as wet or dusty conditions. **Polaris Premium all Season Grease or grease conforming to NLGI No. 2, such as Conoco Superlube M or Mobilegrease Special. + Grease every 50 hours, or after submerging in water or before long periods of storage or after pressure washing. Always use Polaris Premium U-Joint Lube for maximum service of these driveline components (PN 2871515 3 oz.)(PN 2871551 14 oz.). ∆ When suspension action becomes stiff or after washing. NOTE: Hours are based on 10 mph average.

Grease** Locate fittings on swing arm and

grease with grease gun.

GL5 80-90 weight gear lube

Grease**∆ Locate fitting on pivot shaft and

Fill to bottom thread of filler hole. Make certain machine is on a level surface.

grease with grease gun.

25 hours

50 hours

MAINTENANCE AND LUBRICATION

Lubrication Recommendations

11.

MAINTENANCE AND LUBRICATION

Engine Oil

Check the Oil

The oil tank is located under the seat. To check the oil:

1. Set machine on a level surface.

2. Start the engine and let it idle for 20-30 seconds.

3. Stop the engine, and remove the seat as describedonpage50to access the dipstick (1).

4. Remove dipstick and wipe dry with a clean cloth.

5. Screw in the dipstick completely, remove it and read the oil level. NOTE: The dipstick m ust be screwed in to keep the angle and depth of stick consistent.

6. Remove dipstick and check to see that the oil level is between the full and add marks. Add oil as indicated by the level on the dipstick. Do not overfill.

ADD 8 OZ. NORMAL FULL

Maintain Oil Level In Normal Range

CAUTION

Use only Polaris Premium 4 All Season synthetic oil, or API certified “SH” oil. Never substitute or mix oil brands. Serious engine damage and voiding of warranty can result.

WARNING

Vehicle operation with insufficient, deteriorated, or contaminated engine oil will cause accelerated wear and may result in engine seizure, accident, and injury.

MAINTENANCE AND LUBRICATION

Engine Oil

Oil and Filter Change

In order for the engine to function properly, maintain the engine oil at the proper level, and change the oil and oil filter in accordance with the Periodic Maintenance Schedule. Not only do dirt and metal particles collect in the oil, but the oil itself loses its lubricative quality if used too long.

The recommended oil change interval is 100 hours or every six months, whichever comes first. Suggested break in oil change is at 25 hours or one month, whichever comes first. Severe use operation requires more frequent service. Severe use includes continuous duty in dusty or wet conditions, and cold weather operation. NOTE: Severe use cold weather operation is all operating below 10° F, and operating between 10° F and 30°F when most trips are slow speed and less than 5 miles. Be sure to change the oil filter whenever changing oil (Polaris PN 3084963).

1. Place vehicle on a level surface.

2. Clean area around drain plug at the bottom of the oil tank.

3. Run engine for two to three minutes until warm. Shut engine off.

4. Place a drain pan beneath the oil tank and remove the drain plug.

CAUTION

Oil may be hot. Do not allow hot oil to come into contact with skin as serious burns may result.

5. Allow oil to drain completely.

6. Install a new sealing washer (PN 5850135) on oil drain plug. NOTE: The sealing surfaces on the drain plug and the oil tank should be clean and free of burrs, nicks or scratches.

7. Reinstall drain plug and torque to 14-17 ft. lbs. (1.93-2.35 kg/m)

MAINTENANCE AND LUBRICATION

Engine Oil

Oil and Filter Change (cont.)

8. Disconnect the lower oil delivery hose. Remove the fitting (C) from the oil tank. Clean the fitting screen. Reinstall the fitting screen, torquing to 14-17 ft. lbs. Reattach oil line. Torque banjo fitting (D) to 14-17 ft. lbs.

9. Place shop towels beneath oil filter.

Using an oil filter wrench, turn filter (1) counterclockwise to remove.

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

11. Lubricate O-Ring on new filter with a film of new engine oil. Check to make sure the O-Ring is in good condition. Also make sure the O-ring from the old filter is not still on the engine.

12. Install new filter (1) and tighten by hand 1/2 to 3/4 turn after gasket contact.

13. Approximately 1 cup of engine oil will remain in the crankcase. To drain, remove drain plug found on lower right side of crankcase. NOTE: The sealing surfaces on the drain plug and crankcase should be clean and free of burrs, nicks or scratches.

MAINTENANCE AND LUBRICATION

Engine Oil

Oil and Filter Change

14. Reinstall drain plug.

15. Remove dipstick (2) and add 2 quarts (1.9 l) of P olaris Premium 4 synthetic oil. Reinstall dipstick. NOTE: If sump is not drained, add about 1 3/4 quarts initially.

16. Pl ace gear selector in neutral and set parking brake.

17. St art engine and let it idle for one to two minutes. Stop engine and inspect for leaks.

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

19. Dispose of used filter and oil properly.

20. Reinstall panel.

4 Cycle Premium 4 Synthetic Lubricant

Polaris Premium 4 All Season Synthetic engine oil has been specially formulated for use in Polaris 4 cycle engines. It is a fully synthetic, high performance, multi-viscosity oil designed to provide the ultimate in lubrication performance and protection.

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. Its exceptional frictional properties result in more efficient operation, more power output and lower fuel consumption.

Although Polaris Premium 4 is the only oil recommended for use in this engine, use of any API certified “SH” oil is allowable. Oil may need to be changed more frequently if Polaris Premium 4 is not used. You will also need to follow the manufacturers recommendations for ambient temperature operation.

Fuel Filter

Your Polaris RANGER is equipped with an in-line fuel filter that should be replaced by your dealer after every 100 hours of operation.

Do not attempt to clean these filters.

MAINTENANCE AND LUBRICATION

Transmission Oil

The transmission lubricant level should be checked at 25 hours or monthly, whichever comes first. Transmission oil s hould be changed annually.

To check the transmission lubricant level you must first position the vehicle on a level surface. Remove fill plug (2) which is located on the right hand side of the machine and check the lubricant level. Lubricant should be kept at the bottom of the fill plug threads. The correct transmission lubricant to use is Polaris Premium Synthetic Gearcase Lubricant.

CAUTION

Be careful not to allow any dirt or foreign materials to enter the transmission case.

MAINTENANCE AND LUBRICATION

Front Gearcase

Gearcase Lubrication

The front gearcase fill plug (1) is located on the right side of the front gearcase. The drain plug (2) is located on the bottom side of the gearcase.

The front gearcase lubricant level should be checked every six months or 100 hours, whichever comes first. Front gearcase oil should be changed annually.

With the RANGER on a level surface, remove fill plug and check the lubricant level. Lubricant should be kept at the bottom thread of the fill plug hole. The correct gearcase lubricant to use is Polaris premium hub oil.

The oil should be changed according to the requirements in the maintenance chart. If the machine is used in wet conditions the oil should be checked more frequently. If the oil has a milky appearance it should be changed as soon as possible. Failure to properly m aintain this important area can result in premature wear or possible failure of the front grease components. Always use Polaris premium hub oil in the front gearcase.

Front Gearcase Oil Chan ging Procedure

1. Support the vehicle securely with a jackstand.

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

3. Remove fill plug (1).

4. Remove drain plug (2) and drain the oil. Catch and discard used oil properly.

5. Clean and reinstall the drain plug.

6. Add the recommended type of oil to the bottom thread of the fill plug hole.

7. Check for leaks.

Bottom view

MAINTENANCE AND LUBRICATION

Gearcases

Middle Gearcase Lubrication

The middle gearcase fill plug (1) is located on the right side of the middle gearcase. The drain plug (2) is located on the bottom side of the gearcase.

The middle gearcase lubricant level should be checked every six months or 100 hours, whichever comes first. Middle gearcase oil should be changed annually.

With the RANGER on a level surface, remove fill plug and check the lubricant level. Lubricant should be kept at the bottom thread of the fill plug hole. Always use GL5 80-90 weight general lube.

The oil should be changed according to the requirements in the maintenance chart. If the machine is used in wet conditions the oil should be checked more frequently. If the oil has a milky appearance it should be changed as soon as possible. Failure to properly maintain this important area can result in premature wear or possible failure of the grease components. Always use GL5 80-90 weight general lube in the middle gearcase.

To rear of vehicle

Bottom view

Middle Gearcase Oil Chan g in g Procedure

1. Support the vehicle securely with a jackstand.

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

3. Remove fill plug (1).

4. Remove drain plug (2) and drain the oil. Catch and discard used oil properly.

Bottom view

5. Clean and reinstall the drain plug.

6. Add the recommended type of oil to the bottom thread of the fill plug hole.

7. Check for leaks.

MAINTENANCE AND LUBRICATION

Engine Cooling System

How it Works

The overflow bottle is located in front of the right front tire of the machine. It must be maintained between the minimum and maximum levels indicated on the overflow bottle.

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

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

NOTE: Some coolant level drop on new machines 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.

MAINTENANCE AND LUBRICATION

Engine Cooling System

Coolant L evel Inspection

NOTE: Check the coolant level when the engine is cold (room or atmospheric temperature).

1. Situate the vehicle on level ground.

2. Check the coolant level by looking at the overflow bottle located in front of the right front wheel. The coolant level should be between the Minimum and Maximum marks.

3. If the amount of coolant is not within the operating range lift the hood, and locate the overflow bottle lid. Unscrew the lid from the overflow bottle and use a funnel to add coolant through the filler opening until the fluid level has reached the maximum mark. Install the cap.

NOTE: 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. NOTE: Polaris Premium 60/40 is already premixed and ready to use. Do not dilute with water. NOTE: Always follow the manufacturer’s mixing recommendations for the freeze protection required in your area.

NOTE: In an emergency you can add water alone to the overflow bottle, however it must be returned to the correct mixture ratio by the addition of antifreeze concentrate as soon as possible.

CAUTION

If coolant must be added often, or the overflow bottle completely runs dry, it is possible there is a leak in the system. Have the cooling system inspected by your Polaris RANGER dealer.

MAINTENANCE AND LUBRICATION

Engine Cooling System

Radiator Coolant Level Inspection

WARNING

Never remove the pressure cap when the engine is warm or hot. Escaping steam can cause severe burns. The engine must be cool before removing the pressure cap.

Lift the hood and locate the radiator cap(1) and visually inspect the level of coolant in the radiator..

NOTE: This procedure is only required if the cooling system has been drained for maintenance and/or repair. However, if the overflow bottle has run dry, the level in the radiator should be inspected and coolant added if necessary.

NOTE: Use of a non-standard pressure cap will not allow the recovery system to function properly. If the cap should need replacement contact your dealer for the correct replacement part.

Changing the Coolant

To insure that the coolant maintains its ability to protect the engine, it is recommended that the system be completely drained every two years and a fresh mixture of antifreeze and water be 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. NOTE: Polaris Premium 60/40 is already premixed and ready to use. Do not dilute with water. NOTE: Always follow the manufacturer’s mixing recommendations for the freeze protection required in your area.

Using a funnel, slowly add coolant as necessary.

MAINTENANCE AND LUBRICATION

Engine Cooling System

Radiator and Cooling Fan

Check and clean the screen and radiator fins for obstruction by insects or mud in accordance with the Periodic Maintenance Chart.

CAUTION

Using high-pressure water, as from a car wash facility, could damage the radiator fins and impair the radiator’s effectiveness.

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

Coolant absorbs excessive heat from the engine and transfers it to the air at the radiator. If the coolant level becomes low, the engine overheats and may suffer damage. Check the coolant level each day before operating the vehicle, and replenish coolant if the level is low. Change the coolant in accordance with the Periodic Maintenance Chart.

MAINTENANCE AND LUBRICATION

PVT System

WARNING

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

S Do not modify any component of the PVT system. Doing so

may reduce its strength so that a failure may occur at high speeds. This system has been precision balanced. Any modification will cause the system to be out of balance, creating vibration and additional loads on components.

S Routine maintenance is the responsibility of the owner. Al-

ways follow recommended maintenance procedures. See your dealer!

S This PVT system is intended for use on Polaris products only. S The PVT housing must be securely in place during operation.

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

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:

Shift t he transmission into neutral and apply full throttle for no longer than 10 seconds and repeat as necessary. This will expel the moisture and air-dry the belt and clutches. Allow the engine RPM to settle to idle speed and shift the transmission to the lowest available range and test for belt slippage. If the belt slips, repeat the process.

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

MAINTENANCE AND LUBRICATION

Vehicle Immersion

CAUTION

If your vehicle becomes immersed, take it to your dealer before starting the engine. Major engine damage can result if the machine is not thoroughly inspected.

If it is impossible to take it to a dealer before starting, follow the steps outlined below.

S Move the vehicle to dry land or at the

very least, to water below the floor.

S Disconnect the fuel pump wires. S Remove the spark plug. S Loosen the carburetor drain screw (1) S Turn the engine over several times

with electric start.

S Drythesparkplugandreinstallorre-

place with a new plug.

S Tighten the carburetor drain screw (1) . S Reinstall crankcase drain. S Reconnect the fuel pump wires. S Attempt to start the engine. If necessary repeat the “drying” proce-

dure.

S Take the machine to your dealer for

service as soon as possible whether you succeed in starting it or not.

If water has been ingested into the PVT follow the procedure on page 85 to dry out the PVT.

MAINTENANCE AND LUBRICATION

Air Filter Service

It is recommended that the air filter be replaced yearly. When operating in extremely dusty conditions replacement will be required more often.

1. Lift the box.

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

3. Remove the air filter. Do not attempt to clean the main element.

4. Install new air filter. NOTE: Apply a small amount of general purpose grease to the sealing edges of the filter before installing.

5. Check air box. If oil or water deposits are found, drain them into a suitable container. NOTE: Service more frequently if vehicle is operated in wet conditions or at high throttle openings for extended periods.

MAINTENANCE AND LUBRICATION

Breather Filter and Hoses

WARNING

Do not perform this operation immediately after the engine has been run. The exhaust system becomes very hot and can cause severe burns.

1. Lift box and locate the airbox (1).

2. Follow right hand breather line out of the side of the airbox and locate filter (2).

3. Inspect filter for debris. Blow through gently in direction of arrow on filter to check for clogging. Replace as needed.

4. Check hoses for cracks, deterioration, abrasion, or leaks. Replace as needed.

5. Reinstall filter and clamps with arrow pointing toward engine.

CAUTION

Operation of your vehicle without a breather filter can cause engine damage.

MAINTENANCE AND LUBRICATION

Spark Plugs

S Proper electrode gap i s .036″/.90mm. S Spark plug torque is 14 ft. lbs./19 Nm. S Use NGK BKR5ES spark plugs.

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.

1. Normal

The 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 carburetion adjustments.

2. Wet Fouled

The 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 are excessive oil, improper use of the choke, or incorrect carburetion adjustments.

MAINTENANCE AND LUBRICATION

Spark Plug Removal and Replacement

WARNING

The exhaust system or engine can cause serious burns. Always wait for the engine to cool before removing spark plugs.

The spark plug is removed by using the special wrench provided in the tool pouch. Remove the seat to access the engine compartment. Remove the spark plug cap and then the spark plug by rotating counterclockwise.

Reverse the procedure for spark plug installation. Torque to 14 ft. lbs. (19 Nm).

CAUTION

Always use the spark plugs recommended in this owner’s manual. Using the wrong plugs can cause engine damage.

Cylinder Head/Cylinder Base Fastener Torque

Have your dealer check the RANGER cylinder head and cylinder base fasteners for proper torque at the first service or after 25 hours.

MAINTENANCE AND LUBRICATION

Spark Arrestor

The exhaust pipe must be periodically purged of accumulated carbon as follows:

1. Remove the clean out plugs located on the bottom of the muffler as shown above.

2. Place the transmission in neutral and start the engine. Purge accumulated carbon from the system by momentarily revving the engine several times.

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

4. If particles are still suspected to be in the muffler, back the machine onto an incline so the rear of the machine is one foot higher than the front. Set the parking brake and block the wheels. Make sure the machine is in neutral and repeat steps 2 and 3. WARNING: SEE BELOW.

5. If particles are still suspected to be in the muffler, drive the machine onto the incline so the front of the machine is one foot higher than the rear. Set the parking brake and block the wheels. Make sure the machine is in neutral and repeat steps 2 and 3. WARNING: SEE BELOW.

6. Repeat steps 2 through 5 until no more particles are expelled when the engine is revved.

7. Stop the engine and allow the arrestor to cool.

8. Reinstall the arrestor plugs.

Clean Out Plug

MAINTENANCE AND LUBRICATION

Spark Arrestor

WARNING

D Because exhaust system temperatures can reach 1000°F, do not

perform this operation immediately after the engine has been run because the exhaust system becomes very hot.

D Because of the increased fire hazard, make sure that there are

no combustible materials in the area when purging the spark arrestor.

D Wear eye protection. D Do not stand behind or in front of the vehicle while purging the

carbon from the spark arrestor.

D Never run the engine in an enclosed area. The exhaust contains

poisonous carbon monoxide gas. D Do not go under the machine while it is inclined. Failure to heed these warnings could result in serious personal injury

or death.

MAINTENANCE AND LUBRICATION

Throttle Pedal

Throttle Freeplay

If the throttle pedal (1) has excessive play due to cable stretch or cable misadjustment, it will cause a delay in throttle response, especially at low engine speed. Also, the throttle may not open fully. If the throttle pedal has no play, the throttle may be hard to control, and the idle speed may be erratic. Check the throttle pedal play periodically in accordance with the Periodic Maintenance Chart and adjust the play if necessary.

Throttle Freeplay Inspection

1. Apply the parking brake (2).

2. Put the gear shift lever in the N (Neutral) position.

3. Start the engine, and warm it up thoroughly.

4. Measure the distance the throttle pedal moves before the engine

begins to pick up speed. Free play should be 1/16 - 1/8 inches.

Adjustment

1. Slide the bolts off inline cable adjuster sleeve. Loosen adjuster

locknut.

2. Turn adjuster until 1/16″ to 1/8″ freeplay is achieved pedal.

NOTE: While adjusting freeplay, it is important you flip the throttle lever back and forth.

3. Tighten locknut and slide boots over cable adjuster until they touch

at the mid point of adjuster.

Boot

Adjuster Sleeve

Locknut

Boot

MAINTENANCE AND LUBRICATION

Carburetor

The idle speed adjustment should be performed in accordance with the Periodic Maintenance Chart or whenever the idle speed is changed. The following procedure covers the idle speed adjustment:

Carburetor/Engine Idle RPM Adjustment

Recommended engine idle RP M i s 1200 +/- 200. If the engine idle speed is not satisfactory, and all other conditions are favorable, t he carburetor can be adjusted as follows:

1. Apply the parking brake.

2. Put the gear shift lever in the N (Neutral) position.

3. Warm up the engine by running the vehicle approximately five minutes.

4. Remove the the seat and locate theidlescrew.

5. Place the transmission in gear with the parking brake applied.

6. Adjust the carburetor idle screw in or out until the desired idle RPM is reached . Turning the screw in (clockwise) will raise RPM. Turning the screw out (counterclockwise) will lower RPM.

Idle Screw

MAINTENANCE AND LUBRICATION

Brakes

Front and Rear Brakes

The front and rear brakes are hydraulic disc type brakes activated by the brake pedal. See page 53.

The following checks are recommended to keep the brake system in good operating condition. How often they need checking depends upon the type of driving that has been done.

S Inspect the level of the brake fluid

before each operation. Change the brake fluid according to the Periodic Maintenance Chart. The brake fluid should also be changed if it becomes contaminated with dirt or water.

S To check the fluid level, the vehicle must be on level ground. In-

spect the brake fluid by looking at the reservoir (1) under the hood. The level should be between the upper (MAX) and lower (MIN) level lines.

S If the fluid level is lower than the lower level line, add brake fluid

to the upper (MAX) line. Apply the brake forcefully for a few seconds and check for fluid leakage around the fittings.

CAUTION

Change the fluid in the brake system completely if the fluid level is low or the type and brand of the fluid already in the reservoir are unknown.

Once a bottle of brake fluid is opened, use what is necessary and discard the rest. Do not store or use a partial bottle of brake fluid. Brake fluid is hygroscopic, meaning it rapidly absorbs moisture from the air. This causes the boiling temperature of the brake fluid to drop, which can lead to early brake fade and the possibility of serious injury.

Polaris does not recommend the use of a high pressure wash system to clean your RANGER. The best and safest way to clean your vehicle 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 labels are damaged, contact your a Polaris dealer for free replacement.

MAINTENANCE AND LUBRICATION

Brakes

Front and Rear Brakes

S Check brake system for fluid leaks. S Check brake for excessive travel or

spongy feel.

3/64″ (.1 cm)

WARNING

If the brake pedal has a soft “spongy” feeling” when it is applied,

there could be air in the brake lines or the brake may be defective. Do not operate the vehicle under these conditions. Have the brake system serviced by an authorized Polaris dealer immediately.

S Check friction pads for wear, damage and looseness. S Check security and surface condition of the disc. S Pads should be changed when worn to 3/64″ (.1 cm), or about the

thickness of a dime.

MAINTENANCE AND LUBRICATION

Brakes

Rear Brake

The rear brake is a hydraulic disc type brake which is activated by the same pedal which activates the front brake system. The rear brake system requires periodic checks of the pads for wear.

Wear Line

S Pads should be changed

when worn to 3/64″ (.1 cm) which is about the thickness of a dime.

S Inspect the brake disc

spline and pad wear surface for excessive wear.

3/64″ (.1 cm)

WARNING

Due to the nature of this type of vehicle and where it is operated, headlight and taillight lenses may become dirty. Frequent washing is necessary to maintain lighting quality. Poor lighting while operating can result in severe injury or death.

CAUTION

Do not service while lights are hot. Serious burns may result.

Brake Light Switch

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

To inspect the brake light, first turn the ignition switch to the ON position.

Depress the brake pedal. The brake light should go on after about 10mm (0.4 in.) of pedal travel.

If the light does not go on, check the bulb.

MAINTENANCE AND LUBRICATION

Brakes

Parking Brake In sp ectio n:

S Push the parking brake

down with your foot.

S After 8 to 12 clicks of le-

ver travel, the vehicle should not roll while parked.

S If the vehicle moves, ad-

justment is necessary

Adjustment:

S Place the vehicle in neutral

on a flat level surface.

S Carefully lift the rear of

the vehicle off the ground and stabilize on jack stands.

S Loosen the locknut on the rear caliper adjustment bolt. S Tighten the adjustment bolt until the rear tire will not rotate. S Back the adjustment bolt out 1/4 turn. S Tighten the jam nut while holding the adjustment nut in place. S Repeat this procedure on the other rear tire.

Polaris Series 10 Ranger 425 2x4 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual