Polaris TM 2X4, 500 4X4, 500 2X4 User Manual

WARNING

The engine exhaust from this

product contains chemicals known

to cause cancer, birth defects or

other reproductive harm.

WELCOME

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

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

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

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

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

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

Copyright 2005 Polaris Sales Inc. All information contained within this publication is based on the latest product information at the time of publication. Due to constant improvements in the design and quality of production components, some minor discrepancies may result between the actual vehicle and the information presented in this publication. Depictions and/or procedures in this publication are intended for reference use only. No liability can be accepted for omissions or inaccuracies. Any reprinting or reuse of the depictions and/or procedures contained within, whether whole or in part, is expressly prohibited.

Printed in U.S.A.

2006 RANGER 2X4/4X4/TM Owner’s Manual P/N 9920210

TABLE OF CONTENTS

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

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

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

OPERATION 32..............................

EMISSION CONTROL SYSTEMS 51............

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

POLARIS PRODUCTS 101.....................

SPECIFICATIONS 102........................

TROUBLESHOOTING 108.....................

WARRANTY 111..............................

MAINTENANCE LOG 120......................

INDEX 122...................................

VEHICLE IDENTIFICATION NUMBERS

Record your vehicle’s identification numbers and key number in the spaces provided. Remove the spare key and store it in a safe place. Your key can be duplicated only by mating a Polaris key blank with one of your existing keys, so if both keys are lost, the ignition switch must be replaced.

31XX

Vehicle Model Number: (behind left front wheel)

Frame VIN (1): (under hood)

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

Key Number (3):

SAFETY

Operator Safety

WARNING

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

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

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

Age Restrictions

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

Know Your Vehicle

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

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

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

SAFETY

Operator Safety

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

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

WARNING

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

CAUTION

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

CAUTION

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

NOTE:

A note will alert you to important information or instructions.

SAFETY

Operator Safety

WARNING

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

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

cedures described.

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

vehicle.

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

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

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

this manual and all product labels.

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

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

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

Always avoid paved surfaces.

S Helmets are recommended whenever driving this vehicle in an

aggressive manner. Eye protection is recommended at all times.

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

hicle.

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

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

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

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

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

floorboards of the vehicle during operation.

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

miliar terrain. Be alert to changing terrain.

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

SAFETY

Operator Safety

S Always follow proper procedures for turning as described in this

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

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

it has been involved in an accident.

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

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

S Always follow proper procedures for climbing hills as described in

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

S Always follow the proper procedures outlined in this manual for

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

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

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

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

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

S Never operate your vehicle in fast-flowing water or in water deeper

than that specified in this manual. Wet brakes may have reduced stopping ability. Test your brakes after leaving water. If necessary , apply them lightly several times to let friction dry out the pads.

S Always be sure there are no obstacles or people behind your vehicle

when operating in reverse. When it’s safe to proceed in reverse, move slowly. Avoid turning at sharp angles in reverse.

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

Always maintain proper tire pressure as specified on page 103.

SAFETY

Operator Safety

S Never modify this vehicle through improper installation or use of

accessories.

S Never exceed the stated load capacity for this vehicle. Cargo should

be properly distributed and securely attached. Reduce speed and follow the instructions in this manual for hauling cargo or pulling a trailer. Allow a greater distance for braking.

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

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

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

in motion.

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

Seepage31.

S Always activate the foot pedal brake before releasing the park brake. S Always turn off the engine before refueling. Make sure the refueling

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

S Always remove the ignition key when the vehicle is not in use to

prevent unauthorized use or accidental starting.

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

SAFETY

Operator Safety

WARNING

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

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

Do not make any modifications to your RANGER.

Equipment Modifications

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

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

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

to) mowers, blades, tires, sprayers, or large racks, may change the handling characteristics of the vehicle. Use only Polaris-approved accessories, and familiarize yourself with their function and effect on the vehicle.

Operator Safety

WARNING

POTENTIAL HAZARD Stalling, rolling backwards while

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

climbing a hill. Ifyouloseallforward Apply the brakes. Lock the parking brake after fully 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 vehicle for possible damage, including (but not limited to) brakes, throttle and steering.

HAPPEN

HAZARD

speed:

backwards:

SAFETY

Operator Safety

WARNING

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

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

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

HAPPEN

HAZARD

WARNING

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

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

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

HAPPEN

HAZARD

SAFETY

Operator Safety

WARNING

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

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

streets, roads and highways.

HAPPEN

HAZARD

WARNING

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

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

HAPPEN

HAZARD

SAFETY

Operator Safety

WARNING

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

operating conditions, and your experience.

HAPPEN

HAZARD

WARNING

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

HAPPEN

HAZARD

WARNING

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

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

HAPPEN

HAZARD

SAFETY

Operator Safety

WARNING

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

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

schedules described in the Owner’s Manual.

HAPPEN

HAZARD

WARNING

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

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

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

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

HAPPEN

HAZARD

SAFETY

Operator Safety

WARNING

POTENTIAL HAZARD Failure to follow the minimum age recommendations for this

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

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

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

HAPPEN

HAZARD

WARNING

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

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

Manual for this vehicle. See page 103. Always maintain proper tire pressure as described on the decal

and in the Owner’s Manual. See page 103.

HAPPEN

HAZARD

Operator Safety

WARNING

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

WARNING

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

CAUTION

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

SAFETY

Safety Decals and Locations

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

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

WARNING

S VEHICLE ROLLOVER could cause severe injury or death. The cab frame is not designed or intended to provide rollover protection.

S ALWAYS WEAR YOUR SEAT BELT for maximum protection.

Location 1

WARNING

S Moving parts hazar d 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 part failure, possible imbalance, and excessive engine RPM, which can result in serious injury or death.

7172676

NO STEP

7172563

Location 2

WARNING

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

TIRE PRESSURE (PSI): FRONT ___ REAR ___

MAXIMUM WEIGHT CAPACITY (Gross Vehicle Weight)

INCLUDING MACHINE, DRIVER AND CARGO IS _______ LBS.

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

Read Owner’s Manual for more detailed loading information.

Location 3

Safety Decals and Locations

SAFETY

WARNING

Remove flammable containers from box before refueling.

Location 4 (inside front of box)

WARNING

Passenger s c an be thrown off. This can cause serious inj ury or death.

Never carr y pas sengers in cargo box.

Maximum Box Load i s ___ lbs .

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.

Maximum 2X4 (TM) Box Load 750 lbs. (340 kg) Maximum 4X4 Box Load 1000 lbs. (454 kg)

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 PASDESTINE A ETRE UTILISE SUR LES CHEMINS PUBLICS.

7078472

Location 5 (under hood)

ATTENTION

S Operation of this vehicle without the

filter element will severely damage the engine.

S Clean air filter often, more frequent

cleaning required in dusty conditions

S Operation of this vehicle without en-

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

Location 6

S Specific carburetor jetting and adjust-

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

Factory setting:

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

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

CAUTION

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

Location 7

7172674

7079902

Safety Decals and Locations

Discretionary Warning Decal

SAFETY

Location 8

WARNING

7172675

Improper vehicle use can result in SEVERE INJURY or DEATH.

NEVER:

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

ALWAYS:

S A void paved surfaces, which may adversely affect handling and

control.

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 STANDARDS

FOR ON-ROAD VEHICLES.

SAFETY

Fuel Safety

WARNING

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

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

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

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

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

FEATURES AND CONTROLS

Some Polaris vehicles are equipped with special features such as the cab frame. Not all models come with all features. Refer to the specifications section beginning on page 102.

Component Locations

1. Cab Frame (if equipped)

2. Hip Bar

3. Console

4. Steering Wheel

5. Seat

6. Cargo Box

7. Seat Belts

8. Fuel Tank Cap / Fuel Gauge

9. Battery

FEATURES AND CONTROLS

Component Locations

10. Headlights

11. Radiator (if equipped)

12. Front Bumper/Brush Guard

13. Hood Hold Down Strap

FEATURES AND CONTROLS

Component Locations

14. Taillights

15. Tailgate

16. Tailgate Latch Release

17. Muffler (Spark Arrester)

18. CV Boot/Rear Caliper

19. Air Box

20. Receiver Hitch

FEATURES AND CONTROLS

Indicator Lights

The indicator lights on the console display:

1. High Gear

2. Low Gear (if equipped)

3. Neutral Gear

4. Reverse Gear

5. High Temperature

6. Brakes

Trailer Hitch Bracket

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

To avoid injury and property damage, always heed the warnings and towing capacities outlined on page 47.

Auxiliary Outlet (1)

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

Fuel Cap/Fuel Gauge (2)

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

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

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

FEATURES AND CONTROLS

Seat Removal

Pull up on the front of the seat and slide it toward the front of the vehicle.

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

Seat Belts

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

WARNING

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

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

To wear the seat belt properly, follow this procedure:

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

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

3. Release the strap, it will self tighten.

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

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

strap.

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