Polaris Series 10 Ranger 425 2x4 User Manual

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.

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